Stud welding within sheet metal working tools

authored by: B. A. Behrens, D. Gruß, A. Jenicek
Abstract: Sheet metal parts often have to be connected by fasteners. Within conventional process chains for the production of sheet metal parts, fasteners like bolts are mostly welded individually after the forming process and outside the working tool. This spatial separation of production steps requires complex handling operations and has negative impact upon the positioning accuracy of the fasteners. Every executable manufacturing step inside the sheet metal working tool shortens the process chain significantly. Furthermore, using a combined process the precision of position and orientation of fasteners improves. The challenges of integrating the welding process into the sheet metal working tool are some appropriate feeding technique, handling the emissions and associated pollutions of the tool as well as creating a dependable monitoring-system for the welding-process. Within the scope of a research project, a reliable technology for the integration of capacitor discharge (CD) stud welding with tip ignition was developed and tested. It complements existing solutions for integrated resistance welding processes. Due to its high-speed capability, low insertion of energy and only needed one-sided accessibility, this technique is particularly suitable for the integration in sheet metal working tools. A newly developed exhaustion-system is installed and tested for the first time by the CD arc stud welding process. The new technology produced top quality welding results along with high process stability and robustness in long-term tests.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Institut für integrierte Produktion Hannover (IPH)
GSI Helmholtz Centre for Heavy Ion Research
Type: Article
Journal: Production Engineering
Volume: 5
Pages: 283-292
No. of pages: 10
ISSN: 0944-6524
Publication date: 01.04.2011
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanical Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.1007/s11740-011-0304-3 (Access: Unknown)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{00f440e0a23b4e0f9be194bd1dd7c4a8,
title = "Stud welding within sheet metal working tools",
abstract = "Sheet metal parts often have to be connected by fasteners. Within conventional process chains for the production of sheet metal parts, fasteners like bolts are mostly welded individually after the forming process and outside the working tool. This spatial separation of production steps requires complex handling operations and has negative impact upon the positioning accuracy of the fasteners. Every executable manufacturing step inside the sheet metal working tool shortens the process chain significantly. Furthermore, using a combined process the precision of position and orientation of fasteners improves. The challenges of integrating the welding process into the sheet metal working tool are some appropriate feeding technique, handling the emissions and associated pollutions of the tool as well as creating a dependable monitoring-system for the welding-process. Within the scope of a research project, a reliable technology for the integration of capacitor discharge (CD) stud welding with tip ignition was developed and tested. It complements existing solutions for integrated resistance welding processes. Due to its high-speed capability, low insertion of energy and only needed one-sided accessibility, this technique is particularly suitable for the integration in sheet metal working tools. A newly developed exhaustion-system is installed and tested for the first time by the CD arc stud welding process. The new technology produced top quality welding results along with high process stability and robustness in long-term tests.",
keywords = "Capacitor discharge arc stud welding with tip ignition, Process integration, Progressive die, Sheet metal forming, Transfer tool",
author = "Behrens, {B. A.} and D. Gru{\ss} and A. Jenicek",
note = "Funding information: Acknowledgments The documented deliverables are developed in the research project Integration and control of welding of standard parts in metal-composite tools (AiF-Nr. 14.938 N). This project has been funded by the German Federation of Industrial Research Associations {\textquoteleft}{\textquoteleft}Otto von Guericke{\textquoteright}{\textquoteright} e.V. (AiF) and has been supervised by the European Research Association for Sheet Metal Working e.V. (EFB) with financial resources of the Federal Ministry of Economics and Technology (BMWi) for the period of June 2007 to May 2009. The final documentation is published as EFB research report no. 300. The authors thank all funders and partners.",
year = "2011",
month = apr,
day = "1",
doi = "10.1007/s11740-011-0304-3",
language = "English",
volume = "5",
pages = "283--292",
journal = "Production Engineering",
issn = "0944-6524",
publisher = "Springer Verlag",
number = "3",
}