This paper shows an overview of different analyses regarding current challenges at self-pierce riveting with solid rivets as well as semi-tubular rivets of lightweight materials like aluminum die casting, carbon fiber reinforced plastic and 7xxx series aluminum alloy. The joining process analyses will demonstrate the cause and the development as well as the influence on joint quality of individual joining process-induced defects. In addition, methods are described how these imperfections can be avoided or reduced.

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Der Fachbeitrag beschreibt Zusammenhänge zwischen verschiedenen – in einer Automobilproduktion relevanten – Randbedingungen und dem Fügeergebnis beim Halbhohlstanznieten in Form von mathematischen Modellen. Diese Modelle sowie neue Ansätze bei der Fügewerkzeuggestaltung bilden die Grundlage für die dargelegten Konzepte zur Weiterentwicklung der mechanischen Fügetechnik hin zu cyber-physischen Systemen, die mit anderen Prozessen in der Automobilproduktion vernetzt sind.   This article describes in mathematical models how various boundary conditions in an automotive production system and the joining result for self-pierce riveting are related. These models and new approaches in the joining tool design are the basis for the described concepts for developing mechanical joining techniques to enable cyber-physical systems linked to other processes in automobile production.

Mechanical joining techniques like clinching are standard joining techniques for processing aluminum and steel alloys in the automotive car body manufacturing. When using conventional methods, joints will have a high quality after a finally tool check on a specific joining press system. However, if the press system during manufacturing will changed, it can occur that joints get other quality values e.g. smaller interlock. The reason for that has multiple influences,this paper considers especially the press-sided ones. With optical measurements of press deformation and punch speed during real joining processes, new 3D-halfsymmetric simulation models were built up, which take into account of press-side behavior such as joining velocity and angular as well as lateral misalignment of the joining tools during clinching process. Sensitivity analyses identifies significant influencing variables. On the base of this, equations of quality changes can be determined. Finally, this allows better prediction of the modification about joint quality after a press change from system A to B or C during manufacturing.