PUNCH RIVET AND METHOD FOR PRODUCING A PUNCH-RIVETED JOINT

Abstract

A punch rivet for joining two workpieces, has a head and a shank. The shank is a hollow shank with a shank internal diameter (D3), a shank external diameter (D1) and a shank end face. On the shank end face is a ring cutting edge with the diameter (D4) that is smaller than the shank external diameter (D1) but greater than the shank internal diameter (D3). The ring cutting edge is radially spaced both from the shank external diameter (D1) and from the shank internal diameter (D3) by at least 20% of the radial shank wall thickness (M5). And the ratio D3/D1 of shank internal diameter D3 to shank external diameter D1 is smaller than 0.6.

Claims

1. A punch rivet for joining two workpieces, the punch rivet comprising: a head; a hollow shank extending axially from the head with a shank internal diameter (D3), a shank external diameter (D1), a radial shank wall thickness (M5), an axial shank end face distal from the head, and a ring cutting edge located on the shank end face, and the ring cutting edge defines a cutting edge diameter (D4) which is smaller than the shank external diameter (D1) and greater than the shank internal diameter (D3), and the ring cutting edge is radially spaced by at least 20% of the radial shank wall thickness (M5) both from the shank external diameter (D1) and from the shank internal diameter (D3), and wherein the ring cutting edge defines a cutting ring surface width (M3) which is smaller than 10% of the radial shank wall thickness (M5); and a ratio (D3/D1) of shank internal diameter (D3) to shank external diameter (D1) is smaller than 0.6.

2. The punch rivet according to claim 1, wherein the ring cutting edge merges into the shank internal diameter (D3) by a profile which defines a cutting radius (R2) and a ratio (R2/D1) of cutting radius (R2) to shank external diameter (D1) is smaller than 0.3.

3. The punch rivet according to claim 2, wherein the profile with the cutting radius (R2) adjoins the ring cutting edge and merges tangentially into the shank internal diameter (D3), and a ratio (M2/D1) of cutting portion height (M2) to shank external diameter (D1) is smaller than or equal to 0.25.

4. The punch rivet according to claim 2, wherein the profile with the cutting radius (R2) adjoins the ring cutting edge and merges tangentially into an inner conical surface axially between the profile and the shank internal diameter (D3).

5. The punch rivet according to claim 4, wherein the inner conical surface defines an opening angle (α2) which is smaller than 50°.

6. The punch rivet according to claim 2, wherein the profile which defines a cutting radius (R2) is adjacent to the shank internal diameter (D3) and merges tangentially into an inner conical surface axially between the profile and the ring cutting edge.

7. The punch rivet according to claim 6, wherein the inner conical surface defines an opening angle (α2) which is greater than 55°.

8. The punch rivet according to claim 2, wherein the profile which defines the cutting radius (R2) is located axially between a first inner conical surface adjoining the ring cutting edge and a second inner conical surface adjoining the shank internal diameter.

9. The punch rivet according to claim 1, wherein the shank external diameter (D1) merges into an external circumference of the head by a second profile, which defines an underhead radius (R1), and a head cone, and the ratio (R1/D1) of the underhead radius (R1) to the shank external diameter (D1) is smaller than 0.13.

10. The punch rivet according to claim 1, wherein the ring cutting edge merges into the shank external diameter (D1) by a shank external bevel which defines at least one of a bevel angle (α.sub.1) smaller than 40° with reference to a radial plane and an axial external bevel height (M4) smaller than or equal to 0.3 mm.

11. A method for producing a punch-riveted joint between a first workpiece and a second workpiece, the second workpiece made of a high-strength material with a strength of at least 600 MPa and a thickness where joined of at least 0.5 mm, wherein the method comprises the steps of: arranging the workpieces so that one of either the first workpiece or the second workpiece is an upper workpiece; providing a punch rivet comprising: a head; a hollow shank extending axially from the head with a shank internal diameter (D3), a shank external diameter (D1), a radial shank wall thickness (M5), an axial shank end face distal from the head, and a ring cutting edge located on the shank end face, and the ring cutting edge defines a cutting edge diameter (D4) which is smaller than the shank external diameter (D1) and greater than the shank internal diameter (D3), and the ring cutting edge is radially spaced by at least 20% of the radial shank wall thickness (M5) both from the shank external diameter (D1) and from the shank internal diameter (D3), and wherein the ring cutting edge defines a cutting ring surface width (M3) which is smaller than 10% of the radial shank wall thickness (M5); and a ratio (D3/D1) of shank internal diameter (D3) to shank external diameter (D1) is smaller than 0.6; and carrying out a punch riveting operation, wherein the upper workpiece is pierced.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Exemplary embodiments of the invention are shown in the drawing and are explained in more detail in the following description, in which drawings:

[0056] FIG. 1 shows a longitudinal sectional view through an embodiment of a punch rivet according to the invention.

[0057] FIG. 2 shows a view of a detail II of FIG. 1.

[0058] FIG. 3 shows a longitudinal sectional view through a further embodiment of a punch rivet according to the invention.

[0059] FIG. 4 shows a longitudinal sectional view of a further embodiment of a punch rivet according to the invention.

[0060] FIG. 5 shows a longitudinal sectional view through a further embodiment of a punch rivet according to the invention.

[0061] FIG. 6 shows a schematic representation of a punch riveting device.

[0062] FIG. 7 shows a schematic representation of a punch-riveted joint produced according to the invention.

[0063] FIG. 8 shows a schematic representation of a further punch-riveted joint produced according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0064] A punch riveting device is given the general reference of 10 in FIG. 6.

[0065] The punch riveting device 10 serves for the purpose of joining a first workpiece 12 and a second workpiece 14 together. The workpieces 12, 14 can be in particular sheets, such as are used in vehicle body construction. The thickness of the workpieces 12, 14 can be within the range of between, for example, 0.5 mm and 4 mm, in particular within the range of between 1 mm and 2.5 mm. The materials of the workpieces 12, 14 must meet the usual requirements for materials that can be cold formed. These materials are frequently alloyed metals such as steel, aluminium and magnesium. However, it is also possible to produce one of the workpieces 12, 14, in particular the upper workpiece, from a plastics material.

[0066] The punch riveting device 10 comprises a die 16, onto which the workpieces 12, 14 are placed directly one on top of the other. Hold-down clamps which are pressed onto the workpiece arrangement at a certain hold-down force 20 serve for fixing the workpieces. A punch 22, which is movable along a longitudinal axis 26 toward the die 16 at a predetermined punch riveting force 24, is arranged between the hold-down clamps 18. The punch 22 serves for the purpose of driving a punch rivet 30 into the workpiece arrangement 12, 14. The punch rivet 30 is realized as a semi-hollow punch rivet, with a head 32 and a hollow shank 34 which extends from said head in the axial direction and on the end face of which a cutting edge 36 is realized.

[0067] When the punch 22 moves down, the shank 34 initially pierces the upper workpiece 14 on the punch side such that a so-called punch slug is cut out from said upper workpiece. As the punching operation progresses, the free shank end 34 is driven into the workpiece 14 on the die side. A cavity 38, which in a manner known per se enables the shank 34 to expand radially as the punch riveting operation progresses such that the free end of the shank 34, when viewed in the axial direction, penetrates behind material of the workpiece 14 on the die side, is realized in the die 16. As a rule, the punch rivet 30 is driven into the workpiece arrangement 12, 14 by such an amount until the head closes off in a flush manner with the surface of the workpiece 12 on the punch side.

[0068] Different types of punch rivets 30 are available as a rule for the joining of workpieces produced from the most varied materials.

[0069] FIGS. 1 and 2 show an embodiment of a punch rivet 30 according to the invention which is suitable, in particular, in conjunction with workpieces 12, 14 produced from high-strength materials. In this case, the workpiece 14 on the die side can comprise a strength, for example, of greater than 400 MPa, preferably however of not more than 1200 MPa. The workpiece on the punch side can comprise high-strength materials with strengths of up to 1000 MPa or more than 1000 MPa or more than 1200 MPa.

[0070] The punch rivet 30 itself is also produced from a high-strength material, for example with a rivet hardness of greater than 1500 MPa, in particular greater than 1700 MPa.

[0071] The punch rivet 30 is realized so as to be rotationally symmetrical about the longitudinal axis 26 and comprises a head 32 and a shank 34. The shank 34 is divided into a shank portion 40 which connects to the head 32 and a cutting portion 42. The shank portion 40 is realized in a hollow cylindrical manner and comprises a shank external diameter D1 and a shank internal diameter D3. The cutting portion 42 comprises a cutting portion height M2.

[0072] The head 32 comprises a flat head top surface 44 and a cylindrical head external surface 46. The head top surface 44 comprises a head external diameter D2. The head external surface 46 comprises a head external surface height M1. Inside the shank 34, the head 32 comprises a head bottom surface 48 which, in the present case, is realized obtusely tapered or roundedly reduced and merges into the shank internal diameter D3 by means of a head internal radius R3. On the external circumference, the shank external diameter D1 merges into the bottom surface of the head external surface 46 by means of an underhead radius R1. In this case, the underhead radius R1 is arranged such that it merges tangentially into both the shank external diameter D1 and into a conical surface 49 which is arranged at a head cone angle α.sub.0 with respect to the head top surface 44. The head 32 comprises a head height H which extends from the head top surface 44 to the head bottom surface 48.

[0073] The shank 30 comprises in the region of the shank portion 40 a shank thickness M5 which is equal to half of the difference between the shank external diameter D1 and the shank internal diameter D3. In the axial projection, the shank 34 additionally comprises a ring surface which is defined on the external circumference by the shank external diameter D1 and on the inside circumference by the shank internal diameter D3.

[0074] A ring cutting edge 50, which is realized as a planar cutting ring surface and extends in the radial direction (see FIG. 2), is realized on the end face of the shank 32, more precisely of the cutting portion 42. The internal diameter of the cutting ring surface is shown at D4. In addition, the cutting ring surface comprises a radial width M3. In the axial projection, the ring cutting edge 50 consequently lies somewhat outside the middle shank diameter which is formed by the average between the shank external diameter D1 and the shank internal diameter D3.

[0075] The external circumference of the cutting ring surface merges into the shank external diameter D1 by means of a shank external bevel 52. The shank external bevel 52 assumes an angle α.sub.1 with a radial plane. In addition, the shank external bevel 52 merges into the shank external diameter D1 by means of a transition radius which is not designated in any more detail. The external bevel height is shown in FIG. 2 at M4.

[0076] The internal circumference of the cutting ring surface merges into the shank internal diameter D3 by means of a cutting radius R2. In this case, the cutting radius R2 merges tangentially into the shank internal diameter D3 and ends by realizing an opening angle in the cutting ring surface. The radius R2 extends more precisely from the shank internal diameter D3 toward the cutting ring surface in such a manner that the inside surface of the shank produces an opening angle α.sub.2 of approximately 100°. The opening angle α.sub.2, in the case of said embodiment, should be greater than 80° and is preferably smaller than 135°.

[0077] The above-mentioned dimensions of the punch rivet 30 are provided in the following table 1. On the one hand, preferred value ranges are given for the respective values and in addition an example of a particularly preferred embodiment, as is shown in FIG. 2. In addition, the table 1 gives preferred ratios of said dimensions from which it can be seen how a punch rivet according to the invention can be dimensioned for application examples.

TABLE-US-00001 TABLE 1 Desig- Value nation range Example Ratios Shank external D1 ≧5.2 mm 5.40 mm diameter Head external D2 ≦8.0 mm 7.75 mm D2/D1 < diameter 1.45 Shank internal D3 ≦3.2 mm 2.90 mm D3/D1 < 0.6 diameter Ring cutting D4 4.60 mm D4 > (D1 − edge diameter D3)/2 Head external M1 ≦0.70 mm 0.50 mm surface height Cutting portion M2 ≦1.90 mm 1.35 mm M2/D1 > height 0.25 Cutting ring M3 >0 AND 0.05 mm 0.02 < M3/ surface width ≦0.10 mm M5 < 0.08 External bevel M4 ≦0.3 mm 0.20 mm M4/D1 < height 0.05 Shank thickness M5 ≧1.1 mm 1.25 mm Rivet length M6 variable 5.5 mm Cutting cone M7 — — height Head cone angle α.sub.0  >20° 27.5° Bevel angle α.sub.1 ≦40° 30° ± 10° Opening angle α.sub.2 ≧55°  100° Head height H ≦1.5 mm 1.00 mm Underhead radius R1 ≦0.8 mm 0.5 mm R1/D1 < 0.13 Cutting radius R2 <2 mm 1.50 mm R2/D1 < 0.3 Head internal R3 0.35 mm radius

[0078] In addition, it is obvious that the punch rivet 30 can be realized in different lengths, in this connection in each case the length of the shank portion 40 varying. In contrast, the cutting portion 42 preferably remains unchanged with all the embodiments with different lengths.

[0079] FIG. 1 shows the axial overall length of the punch rivet 30 at M6.

[0080] As a result of the ratio of D2/D1<1.45 the punch rivet 30 can be realized with a relatively large shank external diameter, as a result of which the stability is increased during the punch riveting operation. As a result of the ratio D3/D1<0.6 the shank 34 can be realized with a relative large ring surface in the axial projection.

[0081] As a result of the ratio of D4<(D1−D3)/2 it can be ensured that the shank has a tendency rather to move radially outward during a punching operation and as a consequence supports the cold forming for the purpose of the undercut in the workpiece on the side of the die.

[0082] The result of the ratio of M2/D1>0.25 can be that a relatively large volume can be received in the interior of the shank during the punching operation. Accordingly, it is possible for the shank to receive at least extensively a punch slug severed out of the workpiece on the die side. This prevents the punch slug being pressed down axially by the shank, which would result either in the punch rivet being compressed or in a fracture in the workpiece on the side of the die.

[0083] As a result of the ratio between the cutting ring surface width M3 and the shank thickness M5 it can be ensured that a good punching effect can be achieved with a high degree of stability. This also applies to the ratio between the external bevel height and the shank external diameter (M4/D1<0.05).

[0084] The result of the ratio of R2/D1≦0.3 or <0.3 is that the transition from the ring cutting edge to the shank internal diameter can be realized somewhat more obtusely such that in spite of the relatively large radial shank thickness an expanding operation is supported in order to realize a sufficient undercut in a produced punch-riveted joint.

[0085] FIGS. 3 and 5 show further embodiments of punch rivets which correspond in general to the punch rivet 30 of FIGS. 1 and 2 as regards design and method of operation. Identical elements are consequently characterized by identical references. Essentially the differences are explained below.

[0086] In the case of the punch rivet 30′ of FIG. 3, the ring cutting edge merges into the shank internal diameter by means of a profile which comprises a cutting radius R″ which adjoins the ring cutting edge and which merges tangentially into a conical surface 60 which adjoins the shank internal diameter. The conical surface 60 comprises in this case an opening angle α2′ which is smaller than 50°, in the present case is equal to 30°.

[0087] Said embodiment combines a relatively obtuse portion in the region of the ring cutting edge to the conical surface 60 which is defined by the cutting radius R2′ which, for example, can be 1.5 mm. The conical surface, which defines a relatively small opening angle α2′, is provided in contrast at the transition from the cutting radius R2′ to the shank internal diameter. The conical surface 60 extends in the case of said embodiment over a cutting cone height M7. In the case of said embodiment and in the case of subsequent embodiments, the cutting cone height M7 can generally be within a range of greater than 0.2 mm and smaller than or equal to 1.4 mm. In the case of the embodiment in FIG. 3, the cutting cone height M7 can be in particular within a range of between 0.9 mm and 1.2 mm.

[0088] FIG. 4 shows a further embodiment of a punch rivet 30″ where the ring cutting edge merges into the shank internal diameter by means of a profile which comprises a cutting radius R2″ which adjoins the shank internal diameter and which merges tangentially into a conical surface 60″ which adjoins the ring cutting edge.

[0089] The conical surface 60″ defines an opening angle of 60° in this connection.

[0090] In this connection, another relatively large opening angle is obtained which can support the shank portion expanding. In addition, said conical region merges into the shank internal diameter by means of a relatively small cutting radius R2″, R2″ for example being able to be 1.5 mm. The value of the cutting cone height M7″ can be, for example, smaller than 0.9 mm and greater than 0.2 mm in the case of said embodiment.

[0091] FIG. 5 shows a further embodiment of a punch rivet 30′″ which is generally similar to the punch rivet 30″ in FIG. 4 as regards design. In this connection, however, the conical surface 60′″ comprises an opening angle α2′″ which is greater than 60°, in the present case 85°. The cutting radius R2′″, in this connection, however, is just as large as in the case of the punch rivet 30″ of FIG. 4. In the case of the embodiment in FIG. 5, the cutting cone height M7′″ can be relatively small, in particular smaller than 0.4 mm. Where applicable, another further conical portion with a very small opening angle of <30° can be provided between the portion with the radius R2′″ and the shank internal diameter (not identified in any more detail in FIG. 5).

[0092] FIG. 7 and FIG. 8 show in each case further embodiments of punch rivets 30.sup.IV, 30.sup.V, which can correspond to any arbitrary one of the above-designated embodiments. In both cases, a finished punch-riveted joint is shown in each case.

[0093] It must be recognized that in both cases a relatively high residual bottom thickness 62 is able to be achieved.

[0094] Although exemplary embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.