HENROB

GALM15 PRESENTATION
Henrob Self-Piece Riveting (SPR)
An Overview and How To Optimize Its Use
August 2015
HENROB – WHAT WE DO
Innovative Joining Solutions
Ø  Our sole focus is the engineering and manufacturing of
Self-Pierce Riveting Systems and Self-Piercing Rivets (SPR)
Ø  Acquired by Atlas Copco in September 2014
Courtesy of Ford Motor Company
HENROB - APPLICATIONS
Current BIW SPR “Poster Child” – 2015 F150
Courtesy of Ford Motor Company
Ø  2,200 to 2,600 SPRs per vehicle
Ø  239 different material combinations joined by SPRs
Ø  62 material specifications (gauge/alloy/temper)
Ø  Henrob direct involvement started in 2010
Courtesy of Ford Motor Company
WHAT IS HENROB SPR
“No hole” automated riveting
4
HENROB – IN BIW
Joining Capabilities
2T Joint
Steel to steel
Aluminum to aluminum
Multiple Layer
Aluminum alloys up to 10 mm
Mild steel alloys up to 6 mm
Dissimilar Metals
Aluminum to steel to aluminum
Dissimilar Materials
Plastic / aluminum
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HENROB – IN BIW / CIW
Recent Henrob SPR Developments
T-Rivet Geometry
3T Aluminum with Adhesive
3mm + 3mm + 2.7mm
T-Rivet Geometry
3T Aluminum with Adhesive
0.9mm + 3mm + 3.2mm
Self-Piercing Stud (SPS)
M6 in 2.3 mm Aluminum
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WHAT'S CRITICAL TO SPR - JOINT
Parameters
Rivet Body Geometry Rivet Inser7on Direc7on Rivet Inser7on Direc7on WHAT'S CRITICAL TO SPR - JOINT
General Design Rule
Preferred - Thin to Thick
Non-Preferred - Thick to Thin
Bottom sheet is >33% of the total stack
•  Better strength consistency
•  Easier rivet rationalization
•  Less chance of rivet tail
breakthrough
Bottom sheet is <33% of the total stack
•  Lower strength consistency
•  Difficult rivet rationalization
•  Increased chance of rivet tail
breakthrough
WHAT'S CRITICAL TO SPR - JOINT
Joint Development Testing
Riveted “coupons” are made using the
application materials to test joint strength and
integrity.
WHAT'S CRITICAL TO SPR - EQUIPMENT
Required Process Inputs
Servo Rivet Se*er Ø  Access to joint(s).
Mount Ø  Directional process
Ø  Type of riveting tool
Ø  Robot mounted
Ø  Pedestal mounted
Ø  Manual
Ø  Type of feed system
Rivet Spool Ø  Tape or loose
Feed System Ø  Throughput requirements
Ø  Jobs per hour (JPH)
Ø  Grouping of joints
Ø  Clearance around fixture tooling
C-­‐Frame Die Post BIW TRENDS
Material Make-up of SPR Joints
15 - 18 years ago
5 - 8 years ago
5 - 7 years from now
AL Sheet AL Sheet AL Sheet AL Cas=ng AL Cas=ng AL Cas=ng AL Extrusion AL Extrusion AL Extrusion HSS Steel HSS Steel PHS Steel PHS Steel Mg Cas=ng Composites 11
OPTIMIZING THE USE OF SPR
Ø 
Minimize the number of unique joints
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Material types and gauges
Insertion direction
With and without adhesive
Loading conditions
Ø 
Early testing and validation is key to success
Ø 
Establish realistic SPR standards
•  Head height
•  Interlock
•  Bottom thinning (tmin)
Ø 
Manufacturing strategy needs to aligned with product
development and design
OPTIMIZING THE USE OF SPR
Ø 
Reduce learning curve utilizing vendors with
previous experience
Ø 
Utilize vendor resources at every level of product
design cycle through launch
Ø 
Early engagement with is critical !