FORD FLTM BA 114-01-2013 CLINCHING SCHEDULE DEVELOPMENT ACCEPTANCE TEST FOR ALUMINUM AND LOW CARBON STEEL SHEET.pdf

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1、 FORD LABORATORY TEST METHOD BA 114-01 Date Action Revisions Rev.1 2013 12 11 Revised See Summary of Revisions A. Freis, NA 2013 05 10 Released J. Kim, A. Freis, A. Campbell, FNA Controlled document at www.MATS Copyright 2013, Ford Global Technologies, LLC Page 1 of 17 CLINCHING SCHEDULE DEVELOPMENT

2、 ACCEPTANCE TEST FOR ALUMINUM AND LOW CARBON STEEL SHEET Application This procedure defines the clinching acceptance test for clinch schedule development for aluminum and low carbon steel sheet. All such sheet material must pass minimum performance testing. Consult the appropriate Engineering Materi

3、al Specification for material exceptions. Testing confirms that the correct punch and die combination were used to satisfactorily join given gauges of sheet metal together. Cross sections of the clinch joint must be evaluated to ensure a robust joint. After the correct tooling has been identified, l

4、ap shear and coach peel samples are fabricated. Initial testing requires a sample size of 30 each for the strength tests. Samples are pulled on a tensile test machine. Apparatus Required Clinch Tooling This test shall be conducted on an appropriate hydraulic or servo driven single point press-type c

5、linch pedestal system and, in general, complying with the Clinching Manufacturing requirements for size and type of machine required. It shall have preclamp and punch force capacities to meet the requirement of the range of material gauges to be tested. Gage Calipers Dial Metric Caliper Gage Kroepli

6、n Laengenmesstechnik Model #D2X001, 0-20 mm measuring range, 0.01 mm increments, S/N DA36K032 or Mitutoyo 209-531, Digimatic Caliper Gage, 0-40 mm measuring range or equivalent. Figure 1: Gage Caliper Caliper gages are used to measure cap thickness (to calibrate the gage, open and gently close re-ze

7、ro). The lowest measured value at the center of the clinch is the cap thickness. A gage R Stat Regression Fitted Line Plot Cap Thickness (mm) for the response (Y) and Cap Thickness Setting (mm) for the predictor (X). Check the linear box for Type of regression model, then pick options and enter conf

8、idence interval of 95.0 and check the display prediction bands box. Next enter the title of the graph and then pick Ok and Ok. (This analysis does not apply to hydraulic or air over oil tooling because the machine is set manually by adjusting either the shut height or oil and air pressure.) 1.41.31.

9、21.11.01.51.41.31.21.11.00.9Cap Thickness Setting (mm)Cap Thickness(mm)S 0.0262141R-Sq 97.4%R-Sq(adj) 97.2%Regression95% PIRegression AnalysisCap Thickness (mm) = - 0.02200 + 1.011 Cap Thickness Setting (mm)Figure 15: Regression Analysis of Cap Thickness vs. Servo Setting Typical Regression Analysis

10、: Cap Thickness (mm) versus Cap Thickness Setting Graph Equation for Cap Thickness (mm) for example above = -0.02200 + 1.011 Cap Thickness Setting (mm) Example Analysis of Variance Source DF SS MS F P Regression 1 0.331240 0.331240 482.03 0.000 Error 13 0.008933 0.000687 Total 14 0.340173 To determi

11、ne the correlation between Cap Thickness (mm) vs. Cap Thickness Setting (mm) using Minitab 15, pick Stat Basic Statistics Correlation, then pick Cap Thickness Setting (mm) and Cap Thickness (mm) from the variables list, then pick OK. Pearson correlation of Cap Thickness Setting (mm) and Cap Thicknes

12、s (mm) = 0.987 A strong (greater than 0.75 in absolute value) correlation value is important to show the existence of a relationship between the nominal cap thickness of the clinch and the equipment setting used to set the clinch. This gives an indication of the repeatability of the clinching equipm

13、ent for a given clinch schedule. This correlation test must be done for each clinch schedule. Note: This regression equation can be used by plant personnel to estimate an adjustment to the clinch controls to achieve desired nominal cap thickness in production. FORD LABORATORY TEST METHOD BA 114-01 C

14、opyright 2013, Ford Global Technologies, LLC Page 15 of17 ADAPTING CLINCH SCHEDULES TO PRODUCTION TOOLING Tooling Certification After all clinch schedules used to build an assembly have been certified with this FLTM process, they are then to be used to certify production tooling. Initial set-up of t

15、he tooling requires a performance test to verify that each clinch gun is functioning correctly. After the tooling is calibrated, data is gathered from production tooling and analyzed to certify individual clinch guns. Laboratory equipment used to develop clinch schedules has different physical prope

16、rties than production tooling. Production C-frames may be larger and have deeper throats and flex compared to laboratory developmental tools. New tooling has more internal friction to overcome and adjustments to the process variable may be required to set the fasteners to the desired clinch cap thic

17、kness. Tooling should be monitored during the break in cycle and adjustments be made as required. The process variable settings identified for each clinch schedule should be used as a setup or initial starting point for the clinch process. After matching the correct clinch schedule to the appropriat

18、e work station, load process settings into the controls of the clinching tools. Then using coupons made from production sheet metal, build five lap-shear test samples for each schedule on each workstation. Mark each sample with station number and order of build. Record the clinch cap thickness setti

19、ng for each coupon and log them into a data sheet. Then pull the samples in a tensile test machine and record the peak load (kN) corresponding to its cap thickness in the data sheet. Care must be taken to match data to the appropriate test coupon. The following flow chart should be followed for tool

20、 certification for each unit. FORD LABORATORY TEST METHOD BA 114-01 Copyright 2013, Ford Global Technologies, LLC Page 16 of17 Flow Chart for Clinch Tooling Certification Yes No Yes Equipment Supplier Integrator KIT Ship KIT to plant Trial parts available Test on 5 parts confirm X-dimension and visu

21、ally inspect No Coupon material must be production representative 6000 series aluminum should be less than 6 months from Continuous Annealed Solution Heat-treat date Coupons should resemble material characteristic of final part Ship to Plant Clinch 6 coupons Confirm X-dimensions; make 2 cross sectio

22、ns (inline & transverse to confirm tool alignment) & 5 lap shear samples to compare to lab clinch schedule Make 5 clinches (all can be on same coupon) confirm X-dimension meets schedule and visually inspect each clinch for cracks Test on 5 parts confirm X-dimension and visually inspect Test on 5 par

23、ts confirm X-dimension and visually inspect Make 5 clinches (all can be on same coupon) confirm X-dimension meets schedule and visually inspect each clinch for cracks Make 5 clinches (all can be on same coupon) confirm X-dimension meets schedule and visually inspect each clinch for cracks Make 5 cli

24、nches (all can be on same coupon) confirm X-dimension meets schedule and visually inspect each clinch for cracks No Tooling Certification is complete FORD LABORATORY TEST METHOD BA 114-01 Copyright 2013, Ford Global Technologies, LLC Page 17 of17 Plant Certification Tooling must be recertified after

25、 disassemble at the vendors and reassembly in the production plant. After the guns are recalibrated coupons can be used to adjust the tooling. Production Process Monitoring (data gathered from production parts) The process certification is a repeat of the clinch gun certification process using produ

26、ction parts. Each operation is now broken down into individual clinch locations. This is done to identify any tooling issues and or robot programming errors. After the clinch schedules are adjusted and the clinch location and gun assignments identified, parts can be assembled. Before building parts,

27、 verify that the robot paths are programmed correctly. When programming robot paths, care must be taken to make sure the clinch gun anvil (die) just touches the bottom sheet. When gaps are present between the anvil and bottom sheet and the gun cycles, the nose of the gun pushes the sheet metal down

28、to the die. The part will be permanently fixed out of position when clinched. When programming the exit path from the gun, the part and anvil must separate in a line perpendicular to the sheet surface to avoid damage to the clinch button. The clinch controller should be used to collect the data, gra

29、ph and analyze the production part recorded data to control and monitor the production clinch process. SUMMARY OF REVISIONS 2013 12 11 Added Figure 3, for Misaligned TOX Cross Section and renumbered photos. Replaced BTM Clinch Button with TOX Clinch SKB Button, Figure 5. Added alignment to flow chart.