Brochure Eckold Clinching

Eckold Clinching
The joining technique
of the future
Clinching technology
Product program
Drives
Quality monitoring
References
for sheet metal and profiles
Eckold Clinching
is where the future
of joining technology begins.
Starting with this catalogue the method known as “press joining“ will now be
referred to as clinching.
Eckold clinching is the innovative and proven technique for joining metal sheets and
profiles. The permanent joints are created by cold forming alone, without the use of
additional or ancillary parts. The most significant feature of this technique, which is
established in the DIN 8593 standard, is that the joint is formed from the material of
the metal parts to be clinched. Not only that, the parts to be clinched can be of the
same or differing sheet thickness and be made from the same or different materials.
The requirements of joints are so diverse that Eckold takes the individual requirements of the user into account. Eckold offers an unsurpassed diversity of joint types
in order to allow the ideal clinch to be made for the respective application.
Eckold clinching has proven its worth both in use in automatic production lines or
with robots and with portable tooling. Clinching of oil-impregnated or painted
panels or stainless steels and its ability to cope with fluctuations in sheet thickness
are only a few of the advantages that have helped Eckold establish a prominent
position in the market. In addition, Eckold offers a joining technique with which
metal panels of aluminium alloys or non-malleable materials such as spring steels can
be joined to malleable materials.
Furthermore, Eckold clinching has special advantages with respect to the environment. No toxic welding vapours or emissions, no noise pollution and low energy
consumption present the user with improved working conditions.
In comparison with conventional joining techniques, the Eckold clinching offers a
saving of up to 55% for investment costs and 25% for operating costs.
Technologically, Eckold has remained true to its reputation as a trend-setter.
Not only did Eckold introduce the clinching technique to industry 25 years ago,
the company more recently set a new milestone with the economical clinching of
stainless steels, thus continuing progress for joining technology of the future.
2
The basis of our success
is our extensive
product range...
... starting with a widely varied tool
programme through to a comprehensive
range of standard machines and complete
production systems:
Portable
Tools
CONECO 45/60
easily portable, mobile,
electric, electrohydraulic,
hydraulic
or pneumatic
driven tools
Modular
MZD 60/6
C-frame range
mobile tool with
modular construction
adjustable fixed
C-frame for mobile or
stop and large jaw
stationary use
capacity
3
Multipoint tooling
Multipoint tooling
for use in presses
Stationary
machines
DFG 500/80 E
universal machines,
large throath,
electrically driven
Special installation
Automatic
production
systems
4
The Benefits
of Eckold Clinching.
Eckold Clinching stands out from other joining techniques
as a result of the following benefits:
• no thermal effects on the clinch area
• no toxic gases or vapours arising
• no preservative afterwork
• no additional or ancillary parts
• no pre-treatment of surface
• technique compensates for fluctuations in sheet thickness
• also suitable for joining coated sheets
• electricity or compressed air are the only energy sources
required
• suitable for joining sheets of different materials
and thicknesses
• non-destructive quality assurance possible
Examples
Engine bonnet – motor car
Casing for laboratory or domestic appliances
Window opener – car door
Flow safety device – gas heating appliance
5
An unsurpassed range of variations
for individual problems.
The principle of Eckold Clinching: diagram showing how a clinching element is created,
taking R-DF as an example
Punch
Stempel
Clinching
element
Fügeelement
Panel, punch-side
Blech,
stempelseitig
Blech,
Panel,
matrizendie-side
seitig
Die
Matrize
The wide range of variations and the tool concept allows you to choose the right
R
type of joint for your purposes.
CLINCHING
R-DF
S-DF
H-DF
Cutting of sheet
neither sheet
cut
both sheets
cut
one sheet
cut
one sheet with
prepunched round hole
Geometry of
clinching element
round
rectangular
rectangular
round
Benefits /
particular applications
Possible tool
design
- circular, closed element
= visually better
- high-strenght
clinching element
- symmetry of shear
tension holding forces
- particularly
beneficial when
clinching sheets with
different forming behaviour
(e.g. steel/aluminium or
steel/sandwich)
- high holding forces
- high economy tools
- anti-twist element
- also suitable for
clinching more than
two sheets
- beneficial when
clinching sheets
with different
forming behaviour
(e.g. steel/aluminium)
8 mm
10 mm
Possible individual sheet thicknesses [mm]
Possible overall sheet thickness [mm]
0.5 – 1.5
1.0 – 3.0
0.5 – 2.0
1.0 – 4.0
1.0 – 3.0
2.0 – 6.0
- circular element with
flush finish on die side
= visually better
- symmetry of shear tension
holding forces
- for clinching pairs of
materials with
difficult to form material
on die side (spring steel)
- clinching of sheets with
different
thicknesses
(e.g. 1.0 mm in 4.0 mm)
S punch width
2 mm 3 mm 4 mm Tw
3 mm
4 mm
Tw
0.5 – 1.25
1.0 – 2.50
0.5 – 1.25
1.0 – 2.50
0.5 – 1.25
1.0 – 2.50
0.5 – 1.25
1.0 – 2.50
punch side: 0.7 – 3.0
to be checked in each case
Punch width
6 mm
- high economy tools
- anti-twist element
- high holding forces
- element ist closed
on punch side
Anvil diameter
depending on pre-punched
hole diameter
5 mm
6 mm
Die-side element
diameter
[Tw = twin element]
CONFIX clinch
0.5 – 1.5 0.5 – 2.5 0.5 – 1.5
1.0 – 3.0 1.0 – 5.0 1.0 – 3.0
Tool life
The tool life quantities of the clinching tools can be in the order of 200.000 to 250.000
quantities:
clinching operations. Customers confirm from tests and typical actual cases
that far greater tool life quantities have been achieved, dependant on the material,
the thickness and the quality.
6
Effect of load
direction on the
holding force of
different joints
4000
St12 / St14 / sheet thickness a0 = 1.0 mm
cross tension
shear tension, longitudinal
Holding force [N]
shear tension, transverse
3000
2000
1000
R-DF
Holding forces
of R-DF
elements
H-DF
R-DF
Sheet material Sheet thickness Sheet thickness Tensile strength
punch side
die side
Rm
CONFIX
Holding force
Shear
Cross
tension tension
[N]
[N]
[mm]
[mm]
[N/mm2]
1.00
1.00
1.00
1.00
325
228
3000
2620
1700
1200
1.50
0.70
1.50
0.70
300-350
250
1950
920
1860
540
R-DF 8 element
St 12/St 14
AIMg3 W19
R-DF 6 element
St 12/St 14
AIMg3 F 24
Holding forces
of S-DF
elements
Holding forces
of H-DF
elements
Sheet material
St 1203
1.00
1.00
303
2100
1900
–
AIMg3 F22
1.00
1.00
256
1240
960
–
Sheet material
St 12 / St 14
Holding forces
of CONFIX
clinches
Holding force
Sheet thickness Sheet thickness Tensile strength
punch side
die side
Rm
Shear tension Shear tension Cross tension
transverse longitudinal
[mm]
[mm]
[N/mm2]
[N]
[N]
[N]
Sheet thickness Sheet thickness Tensile strength
Holding force
Rm
die side
Shear tension Shear tension Cross tension
punch side
transverse longitudinal
[N/mm2]
[N]
[mm]
[mm]
[N]
[N]
1.00
1.00
300-380
3150
2300
1300
Sheet material Sheet material Sheet thickness Sheet thickness Tensile strength
Holding force
punch side
die side
punch side
die side
punch side Shear tension Cross tension
[mm]
[N/mm2]
[N]
[N]
[mm]
St 1203
St 1203
St 1203
Federstahl
1.00
1.50
1.00
0.50
335
–
3000
4450
1300
4400
7
Many Benefits
at low cost.
Economic
viability
and costs
Cost comparisons of customers and independent bodies have shown that Eckold
clinching is significantly more cost-effective than other joining techniques.
Depending on the joining task, the overall costs for the manufacture of a clinched
component are approximately 55% of the costs for spot welding, for example.
This takes account of both investment costs and operating costs.
[%]
Clinching
Investment costs in [%]
Operating costs in [%]
Spot welding
Investment costs in [%]
Operating costs in [%]
100
55.8
29.5
Clinching costs
75
31.1
50
16.8
41.3
25
55.8
14.7
22.9
44.2
43.5
14.7
22.4
26.1
25.5
22.4
14.7
0
Sheet steel
uncoated
Sheet aluminium
Sheet steel
Sheet steel
zinc thickness 10 µm zinc thickness 20 µm
Comparison based on 1 industrial robot for setting a joining element
Why Eckold
clinching?
• Various stainless steels can be joined economically
• Optional versions (R-DF, S-DF, H-DF and CONFIX) for the ideal joint to solve
individual problems
• Sheets of aluminium alloys or non-formable materials such as spring steels
can be joined with a formable material by means of the CONFIX variation
• Joining elements with the greatest holding forces
• Compensates for fluctuations in sheet thickness
• Joining of oil-impregnated sheets possible
8
Ecology
and Health
If you have ever experienced the smell of the toxic gases that
arise during welding or the noise of punch riveting or had
to physically carry the additional weight of protective clothing
or additional materials, you will appreciate the benefits of
Eckold clinching. This takes account of the user’s health in
many respects. Besides the significantly lower physical stresses,
Eckold clinching is distinguished by low energy consumption
and no industrial effluents whatsoever are generated.
All in all, the Eckold technique is a clean and user friendly
process.
A manual method and a computer-aided online monitoring
system can be used for quality control of Eckold clinching.
The quality of the clinch element can be examined manually
by means of the bottom thickness or width. 100% control is
provided by the computer-aided online monitoring system.
This can be used to achieve unbroken quality control in automatic plants for mass production. Production becomes more
efficient and cost effective because down time and rejection
rates are reduced through early detection of load errors.
Clinching force
Quality
control
Envelope curve top
Envelope curve bottom
Tool travel
9
Power sources
for every application.
Hydraulic, air over oil, electric and electrohydraulic drive units
from the Eckold company are available to drive Eckold clinching machines. Below are three standard units which, depending on the application, can be supplemented with special
units that are also available in stationary versions.
Drives
HAT 525
portable
hydraulic unit
HA 510
Antriebsarten
mobile
elektrisch
hydraulic unit
hydraulisch
pneumohydraulisch
10
Eckold
is available for you worldwide.
Increasing in importance alongside the standard products are
special tools, project organisation and design of special tools,
machines and installations.
Thanks to our years of experience, including the solving of
particularly complex customer requirements, we are well
equipped to move into this area. In close collaboration with you,
our customer, we plan, design and produce for any location
you wish.
Our involvement does not stop at that either - the subsequent
training of operating staff, the maintenance of machines and the
worldwide service are a natural step for us.
To cope with this demand - all over the world - we have
established a widely distributed network of representatives.
Eckold production plants are of course certified to ISO 9001:2000
as well as VDA 6.4:2005.
Further information is available on
our CD-ROM and in our Clinching
manual, which we would be pleased to
send you.
Weitere Informationen finden Sie
auf unserer CD-ROM und in unserem
Leitfaden Clinchtechnik, welche wir
Ihnen gerne zusenden.
11
The Eckold Group
• Eckold GmbH & Co. KG
D-37444 St. Andreasberg
Germany
Tel.: ++ 49 (55 82) 8 02-0
Fax: ++ 49 (55 82) 8 02-3 00
Net: www.eckold.com
eMail: [email protected]
• Eckold-Biegetechnik GmbH & Co. KG
D-37444 St. Andreasberg
Germany
Tel.: ++ 49 (55 82) 8 02-1 11
Fax: ++ 49 (55 82) 8 02-2 50
eMail: [email protected]
• Eckold AG
Rheinstraße
CH-7203 Trimmis
Switzerland
Tel.: ++ 41 (81) 3 54 12 70
Fax: ++ 41 (81) 3 54 12 01
Net: www.eckold.com
eMail: [email protected]
• Eckold Limited
15 Lifford Way
Binley Industrial Estate
GB-Coventry CV3 2RN
Great Britain
Tel.: ++ 44 (24) 76 45 55 80
Fax: ++ 44 (24) 76 45 69 31
eMail: [email protected]
• Eckold France
16, Rue de la Noue Guimante
Z.I. de la Courtillière
F-77400 St. Thibault-des-Vignes
France
Tel.: ++ 33 (1) 64 30 92 47
Fax: ++ 33 (1) 64 30 81 92
Net: www.eckold.fr
eMail: [email protected]
• Eckold & Vavrouch spol. s.r.o.
Jilemnickeho 8
CZ-61400 Brno
Czech Republic
Tel.: ++ 420 (5) 45 24 18 36
Fax: ++ 420 (5) 45 24 18 36
Net: www.eckold.cz
eMail: [email protected]
• Eckold Japan Co. Ltd.
2-14-2 Maihara-higashi
274-0824 Funabashi-shi, Chiba pref.
Japan
Tel.: ++ 81 (47) 4 70 24 00
Fax: ++ 81 (47) 4 70 24 02
Net: www.eckold.co.jp
eMail: [email protected]
Printed in Germany 002/09.08/4/500/D/Kohlmann
Technische Änderungen vorbehalten/Technical modifications kept under reserve.