A method is provided for manufacturing a catalytic converter housing arrangement with at least one sensor carrier for an exhaust system of a vehicle. The method includes the steps of: a) providing at least one sensor carrier sheet metal blank (42); b) forming at least one sensor mounting opening (48) in the sensor carrier sheet metal blank (42) by flow drilling such that a length (L) of the opening is greater than a thickness (D) of the material of the sensor carrier sheet metal blank (42) before step b) is carried out; and c) preparing an internal thread in the at least one sensor mounting opening (48) for providing a sensor carrier.

A method of reducing the cycle time required for flow-drill screw operations by providing a dimple on a part that is engaged by a flow-drill screw. A tip of the flow-drill screw engages a contact band at a location spaced from the tip of the distal end of the flow-drill screw and base portion of the dimple. Friction between the flow-drill screw tip and dimple creates a heat concentration area and results in displaced material forming a threaded sleeve. The flow-drill screw is secured by the threads of the threaded sleeve to secure the top part to the bottom part.

A method and an assembly use two copper sheets, which are connected to each other by a screw connection. The screw connection is performed by a screw that is screwed directly into the copper sheets without screw holes having been provided. Therefore the production tolerances for preset screw holes can be dispensed with.

A method of installing a flow drill screw (FDS) into a substrate includes engaging the FDS with an automatic tool, operating the tool at a first setting to drive the FDS into the substrate by causing flow of the substrate to permit the FDS to penetrate the substrate, and switching the automatic tool from the first setting to a second setting in response to a controller analyzing axial acceleration data of the FDS. The first setting is configured to rotate the FDS at a first rotational speed and to apply a first axial feed force. The first setting is further configured to cause flow of the substrate to permit the FDS to penetrate the substrate. The second setting is configured to rotate the FDS at a second rotational speed and to apply a second axial feed force. The second rotational speed is less than the first rotational speed.

A method and device are provided for simplifying a flow-drill screwing process. Based on work performed during the process, a process variable E is formed. This variable is compared to analogously formed comparison values in order to be able to determine the proper or faulty running of the process.

A method of installing a flow drill screw (FDS) into a substrate includes engaging the FDS with an automatic tool, operating the tool at a first setting to drive the FDS into the substrate by causing flow of the substrate to permit the FDS to penetrate the substrate, and switching the automatic tool from the first setting to a second setting in response to a controller analyzing axial acceleration data of the FDS. The first setting is configured to rotate the FDS at a first rotational speed and to apply a first axial feed force. The first setting is further configured to cause flow of the substrate to permit the FDS to penetrate the substrate. The second setting is configured to rotate the FDS at a second rotational speed and to apply a second axial feed force. The second rotational speed is less than the first rotational speed.

A method and a device are provided for simplifying a flow-hole screw process, in which the difference between a process parameter and its smoothed value is employed as a criterion for changing said process parameter or another process parameter in order in particular to be able to determine the changeover point between hole forming and thread forming.

A workpiece processing method includes preparing a workpiece having a plate portion that includes a base material and a first coating layer. The base material has a first surface and a second surface opposite to the first surface in a direction along a thickness of the base material. The first coating layer is provided on the second surface of the base material. The first coating layer in a first region of the plate portion is removed. A burring tool is moved in a first direction from the first surface toward the second surface in a rotating state to burr the plate portion so as to form a through hole and a flange in the first region of the plate portion after removing the first coating layer in the first region.

A method of installing a flow drill screw (FDS) into a substrate includes engaging the FDS with an automatic tool and operating the tool at a first setting to drive the FDS into the substrate. The first setting rotates the FDS at a first rotational speed and applies a first axial feed force. The first setting causes flow of the substrate to permit the FDS to penetrate the substrate. The method includes detecting, via a sensor, axial position data of the FDS while operating the automatic tool and calculating, via a controller, volatility of the axial position data. The method includes switching the automatic tool from the first setting to a second setting in response to the volatility. The second setting rotates the FDS at a second rotational speed and applies a second axial feed force to the FDS. The second rotational speed is less than the first rotational speed.

The invention relates to a method for connecting at least two elements by a connecting element. The method comprises the steps of: providing a first element, a second element and the connecting element; placing the connecting element on a surface of the first element; in a first time period, rotating the connecting element at a first rotational speed and exerting a first axial force on the connecting element in the direction of the surface of the first element; and in a second time period, rotating the connecting element at a second rotational speed and exerting a second axial force on the connecting element in the direction of the surface of the first element.