........................................................................................................................................................

TOX -Clinching Technology®

1

TOX®-Clinching Technology........................................................................................................................................................

The TOX®-Clinch Joint:
a buttonlike connection, tojoin sheet metal together.

2

tox-pressotechnik.com

........................................................................................................................................................

The highly efficient joining process
Assembly automation, multi-material stack ups,
fastening costs and energy savings – the challenges
for sheet metal forming are multifaceted. Automotive
and appliance manufacturers as well as general metal
processors must rely on innovative joining proceduresto assemble modern products using new materials
and manufacturing processes from a technical andeconomical point of view.

Why does a TOX®-Joint hold?
In the TOX®-Clinching process a punch displaces
material into a die. Through plastic deformation andreverse flow of the material the joint forms an undercut
to generate the holding force.
Residual bottom thickness= Control dimension X

Neck area

The cold joining process TOX®-Clinching is a highly
effective solution for this purpose. During clinching orpress joining, the sheet metals to be joined are connected force- and positive-locking with each other in a continuous forming process. A wide range of materials canbe joined with this press-forming process, all without
damaging the surface.
In hybrid joining, clinch points locate and relieve theadhesive bond during and after hardening – the specific properties of both techniques complement each other optimally. This means that the combination of bothjoining technologies results in innovative joining options.

Ring channel

Undercut

Creation of a TOX®-Clinching Joint

Penetration

Compression

Emergence of contour

Lateral spreading

Finished TOX®-Joint

3

Advantages of the TOX®-Clinching Technology........................................................................................................................................................

Versatile and full of options
Flexibility
With the clinching process, sheet metals of different
qualities, surfaces and thicknesses can also be joinedwith adhesive or other intermediate layers.

The TOX®-Clinching Technology offers numerous technical advantages:

Different materials
The TOX®-Clinching Technology can be used fornumerous material combinations. Whether it is steel,aluminum, copper, brass or stainless steel – allmaterials can also be joined in combination. Continuous development and experience with a large number
of applications have resulted in long tool life.

 Joining of similar or dissimilar materials
 Joining without heat: no distortion of the workpiece Ideal for hybrid connections or auxilary parts
 No additional materials required Automatic and precise monitoring anddocumentation of the process Strong connections
 No contamination of the workpiece No damage to the coating or surface

Excellent Electrical conductivity
The clinching process provides the best electricalconductivity compared to other mechanical joining
processes. This makes clinching ideally suited toelectrical assemblies and devices.

Point sizes:
Diameter 2 – 26 mm

Advantages:

Sheet metal thicknesses

0.1 mm
0.1 mm

up to

12 mm
12 mm

Common sizes

Clinching is possible

with different materials

4

with different surface finishes

tox-pressotechnik.com

with different thickness

with multiple layers

........................................................................................................................................................

Lighting assembly

Washing machine housing

Automotive part

Airbag crashbox

Washing machine drum

Electric motor housing

Heating elements

Back-up fuse box

Automotive seat component

5Technical Advantages........................................................................................................................................................

Strong and durable
High static strength
Clinch connections achieve high static retaining forces of up to 70 % of a weld point. They also have apositive strain hardening, maintain the surface coating
and are generally also more economical. Additionally
mixed-material joining can be realized.

TOX®-Clinching Joint Corrosion test
Holding strength with different materials
and conditions

1.000-h salt spray test
1.000-h alternating climate
without aging

9 kN
8 kN

Corrosion-free joining technology
The corrosion test proves: Because the surface
coating is not damaged during the round joint process
the anti-corrosive properties of the joined sheet metals(e. g. galvanization) are maintained. The surface is notdamaged by any cutting process – the coating flows
with the material and remains intact.

Shear force Fs

7 kN
6 kN
5 kN
4 kN
3 kN
2 kN
1 kN
0 kN

Consistent dynamic strength
In comparison to spot welding, the clinching process
does not have the negative properties of the notch
effect. This allows the joint strength to remain constantover various load cycles.

Flat steel
DC04 single
sheet thickness 0.8 mm,
steam
degreased

Flat steel
DC04 single
sheet thickness 0.8 mm,
adhesive film

Flat steel DC04
single sheet
thickness
0.8 mm,flanged seamadhesive paste

Dynamic strength
Strength of clinch, punch rivet and spot welding connections under oscillating
shear strength load (endurance fatigue test).
10000

Number of load cycles
100000

Aluminum
EN AW-5182
steam
degreased

F

F

1000000

Force amplitude Fa

100 kN

Material:
Flat steel ZStE 420
Single sheet thickness 1 mm
Joining technologies:

10 kN

 linching TOX®-Round-JointC
d = 8 mmMR
 iveting with semi-tubular
rivets 5.3 x 5.0 mm
S pot welding
d = 5 mm

1 kN

L

F Fatigue strength:
12 kN
13 kN
6 kN
D

6

tox-pressotechnik.com

Source: FOSTA P283

Economical Advantages........................................................................................................................................................

Cost saving and emission-freeExcellent cost savings
Directly compared to spot welding, TOX®-Clinching isapproximately 40 % cheaper with regard to investment,
operating and tool costs. This is ensured by thefollowing technical advantages:

Comparison of costs per joint

100 % Reduced investment due to long service life of the
TOX®-Tools
 Low ongoing operating costs, as no procurementof additional materials or elements Rational production due to the high degree ofautomation
 Energy savings, as no heat needs to be generated
 No post-processing required Continuous quality control provides verifiable
quality

75 %

50 %

25 %

0

Cost savings compound with multi-point applications.

Spot welding

Emission-free and energy-efficient
As clinching is a cold forming process, there are positiveenvironmental aspects including:Investment costs
Operating costs
Tool costs

TOX®-Joining No poisonous vapors or gases
 No harmful effects for the operating personnel
 Low noise despite short cycle times
 No consumption of coolants, oils or gases
 No disposal of chemicals or waste

Expected Number of joints until tool change (Punch and Die)The actual tool life will be determined after joining-tests of the particular application.

Stainless Steel1.4016

Steel

Alumnium andAl-alloys

Copper andCu-alloys

Total sheet thickness > 3,00 mm
Total sheet thickness ≤ 3,00 mm
Total sheet thickness ≤ 2,00 mm

Tensile strength 500 - 1000 MPa
Tensile strength 200 - 500 MPa

with silicon, extruded profiles
generalplaintinned0100.000

200.000

300.000

400.000

500.000

900.000

1.000.000

7Process Competence........................................................................................................................................................

The perfect joint for every application
TOX® PRESSOTECHNIK provides you with the best technological solutions and complete systems from one
source, the respective design will be tailored to your specific joining tasks. An important step here is the selectionof the clinch point shape:

TOX®-Round-Joint
The classic: A round punch presses the materials
to be joined into the die. The result is anaesthetically pleasing round button, which joins
clearly without any burrs or sharp edges the sheet
metals. The protective layer, e. g. paint, flows anddoes not get damaged.

TOX®-SKB
The special die consists of solid and movablesegments. The solid segments center the material
and the punch. The movable elements allow
flow of the material in the joint – especially withsheet metal of different thickness or when using
adhesives between the sheet layers.

TOX®-MICROpoint
The miniature TOX®-Round-Joint is our answer
to component miniaturization. With a diameterof 2 mm, it is ideal for sheet metal thicknesses of
0.1 – 0.5 mm and for slim flanges. For this reason,
it is also optimally suited as an eClinch-Point.

8

tox-pressotechnik.com

........................................................................................................................................................

TOX®-TWINpoint
This double cavity die provides protection
against rotation and increases the joint strengthcompared to the single joint. It is ideal for small
flanges and limited installation space. WheneClinching, it also makes sure the design
requirements are met.

TOX®-Flat-Joint
If the protrusion on die side presents a problem:with the TOX®-Flat Joint, the protrusion of theclinching joint on die side is pressed flat
again in a second round using a flat die. A
minimum protrusion height of only a few tenthsof a millimeter remains.

TOX®-Vario-Joint
The TOX®-Joint for difficult combinations: Joiningof sheet metal with large differences inthickness, joining of high strength or non
ductile materials with ductile materials or joiningof non metallic materials.
The sheet metal is driven through the pre-punchedmaterial for this purpose. The process requires
low joining forces and can also be applied in
multi-point tools.

9Process Competence........................................................................................................................................................

TOX®- e Clinching
Very low contact resistance makes TOX®-eClinchingideally suited for electrical components and is anefficient alternative to solder, welded and screwed
connections.
Long-term stable energy transfer
The secret of the good conductivity of the TOX®-eClinching-Point is the joint zone. During the clinchingprocess, in addition to the positive locking and force
locking, there is a also an adhesive bond: The joined
sheets flow together, resulting in an excellent
conductive structure.
Know-how for maximum conductivity
For maximum conductivity some design rules must
be taken into account for eClinching. If a piece partwill be mechanically stressed, the TOX®-eTWINpoint
is our recommendation, because it can withstandtorque. The TOX®-eMICROpoint is suitable for joining
small components, because it delivers good adhesivebond on a small diameter.

Areas with the highest adhesive bondvery high (neck area)
high (bottom)
goodMaterial mix
TOX®-eClinching joins aluminum with copper, acommon combination in battery modules, without
creating an isolating intermetallic phase. Soft coatings,
like for example tin coatings on copper, are also formed
without damage. eClinching is also perfect for joining
heat-sensitive battery cells. The process nearly doubles
the effective contact surface, which increases the
conductivity of the TOX®-Point significantly.

Advantages
 Force locking, positive locking and adhesivebond in on step Very robust connections
 No pretreatment required Joining process without heat Very low contact resistance Extensive documentation of relevant data10

tox-pressotechnik.com

........................................................................................................................................................

Proven process quality
Continuous quality monitoring
A significant advantage of the TOX®-Round Joint is
the simple quality control even in series production. By
continuously measuring the residual bottom thickness(the control dimension “X”), each joint can be checked.
An additional analysis can be carried out using crosssections (cut through the point). The shear and pullstrength can be determined via tensile tests.
Preliminary tests in the TOX®-Technical Center
Prior to collaboration, we will work on the most effective
solution for you in our labor. Here we will perform
preliminary joining tests on your samples, which wetest and analyze afterwards. We will also determine allparameters for your application, e. g. the required press
force and suitable tools, and we will establish which
system can be used for your joining application.
Final check of the machine parameters
Before we deliver a system, we check the real process
results. We will create a cross section and analyze thejoining process and the retention forces of the joint.
Everything will be documented in a detailed test report.
The initial set-up of the system is based on these
determined values and parameters.

Advantages
 Demonstrated joining quality in pre-tests
and during series production
 Measurement and documentation of theshear and tensile strengths
 Documentation of the joining quality
 Production of pre-production parts

8 mm
With a cross section of the clinching joint, the exact
formation can be examined under a microscope foranalysis. If necessary, optimizations can be made.

11

System Competence........................................................................................................................................................

Equipment for TOX®-Clinching
TOX® PRESSOTECHNIK with its decades of experience
provides you with competent know-how for clinchingsystems.
To achieve the best results for joining, systems arecomposed of proven components. Customer-specific requirements are fulfilled down to the last detail. All
system components are matched to each other thanks
to the modular principle.
1

Tools 1
Durable tools are necessary: punches and dies thatare precisely adapted to materials, thickness andjoining force.
Frame 2The high forces occurring during inserting are absorbed
by a low deflection frame.
TOX®-Drives 3
The forces required for clinching are created byelectromechanical servo drives or pneumohydraulicPowerpackages.

Control and process monitoring Ranging from external impulse to complete PLC
controls built to the highest safetey standards
 Software to control all processes
 Monitoring of process curves
Safety devices
Safety door, light curtain, safety controls etc.
Sensors
Sensors for automatic control of the process
and sequence parameters: Pressure, force-position
measurement and position sensors.
Accessories
We provide numerous accessories for example thespraying systems for lubricating the tools and materials
or the ToolCheck, which constantly checks that the die
is not damaged. We also have strippers, compensating
slides and many more options.

12

tox-pressotechnik.com

2

........................................................................................................................................................

System designs
Different basic designs are possible for clinchingsystems. Systems can be designed as tong − stationaryor mobile − or as a press.

3

Crucial factors for choosing one system over anotherinclude the potential integration into production lines,
optimum feed-in, the desired working speed and thesize of the components.
Robot tong
The tongs are controlled by a robot. It moves precisely
to the positions at the sheet metal parts to be joined.
Design as arobot tong

Machine tong
For integration in machines and devices. Ideally driven
via a central TOX®-Powerpackage X-KT system.
Hand-held tong
Flexible and easy to handle: Hand-held tongs are ideal
for small series production.
MachineMachines can be constructed as fully automatic, semiautomatic or purely manual workstations.
TOX® PRESSOTECHNIK is certified to build safety
rated work stations.

Designs

Machine tongHand-held tong

Machine13Components........................................................................................................................................................

TOX®-Clinching Tools
In the clinching process, the tool set plays the mostimportant role. The suitable tool set is determined in
the TOX®-Technical Center for each clinching process,guaranteeing the required retention forces.
A tool set always consists of a punch and a die. All tools
are produced from highest quality materials on precision
machining centers – with suitable special coatings
depending on the individual application.
Every tool set comes with its own tool passportwith individual information for your production andmaintenance department. Our objective is to ensure
reliable, safe and long-lasting production for you.

TOX®-ToolCheck

TOX®-Spraying System

The optional accessory TOX®ToolCheck can check thecondition of the die during theprocess, which ensures thatjoining always occurs with anintact die. Defects are detected
immediately.

The workpiece surface and / ortools can be sprayed with a
special liquid before the joining
process. Then the joining andstripping forces of the tools are
reduced and the forming of thematerial is made easier.

14

tox-pressotechnik.com

........................................................................................................................................................

Flexible control-software for the integrated production
Flexible Multi-Technology Control
One system – many possibilities! Our multi-technology
control operates and monitors all functions. It is driveindependent and can be used for any technology. Whena robot changes its tong, the system recognizes theparameters and can continue working immediately. This
yields the highest degree of flexibility.

TOX®-Multi-Technology-Control
TOX®-Clinching

Riveting
Insertionof functional
elements

Additionally, the intuitive TOX®-HMI software allows
easy installation and operation of the system. It is clearlystructured and internationally understandable.
Integrated Production
Using numerous interfaces it is easy to connect the
TOX®-Equipment to a company network. The systemcomponents communicate with each other via fieldbus.
The data collected there enables continuous monitoringand improvement of the processes. Feedback fromthe production process can be used to optimize thetechnology parameters (e. g. residual bottom thickness).
Unnecessary maintenance work and downtime can be
avoided thanks to predictive maintenance.

Advantages
 One control for different application technologies
 Import of process parameters from customer
network
 Auto-configuration of system components
 Condition Monitoring: Storage of operating hours,
maintenance counter, tool information etc.
 Preventive Maintenance avoids downtime
 Dynamic process monitoring Numerous interfaces for connecting periphery units(e. g. measurement sensors, feeding systems etc.)
 Network communication via OPC UA / MQTT

TOX®-HMI
Control andProcess unit

Customer
Network

15

Components........................................................................................................................................................

Process monitoring devices
Clinch monitoring was specifically developed for
the TOX®-Clinching Technology. The monitoring
systems CEP 400 and CEP 400 T allow the completemonitoring and documentation of the essential
quality parameters of the process. Force sensors
measure the press force during the joining
process and a travel measuring system monitors
compliance with the control dimension “X”.

C-Frames and column presses
The forces that occur during clinching processes areabsorbed by C-Frames or the columns of a columnpress. The designs takes into account interfering
contours, total weight, piece part accessibility, working
conditions and occupational safety.

Tong frame

Press frame

C-Frames
Torsion-resistant frames are used for tongs andpresses. We respond to the specific requirementswith standard frames or individual designs.
Column presses
Column presses are particularly useful for multi-point
clinching tools. They can be manufactured in various
sizes, but all have the same precision and good
handling.

16

tox-pressotechnik.com

Column press

........................................................................................................................................................

TOX®-Drives
High forces are needed for clinching to press thepunch into the material. These forces are generated
by electromechanical servo drives or pneumohydraulicPowerpackages.
TOX®-Powerpackage
The strong pneumohydraulic drive, which is alreadyused in thousands of machines all over the world. It isavailable with press forces 2 – 2000 kN.
TOX®-ElectricDrive
Modular electromechanical servo drive systems withpress forces up to 1000 kN.

Additional components
Information about additional components like controls,piece part holders, safety devices and accessories
can be found on our website tox-pressotechnik.com.

17

Individual Solutions for our Customers........................................................................................................................................................
TOX® PRESSOTECHNIK designs process flows more
economically – with special systems, intelligent assembly
systems and fully automatic feeds with integrated
additional functions. We possess long-standing
experience and comprehensive know-how in thedevelopment and design of these systems.
We look to create highly efficient systems to match ourcustomer’s designated work flow. We are committed
to finding the best solution for optimizing the
manufacturing processes according to our customer’s
requirements.
For this reason, our machines are the product of close
cooperation between our customers and our project
managers. Our service team will also be on handquickly and reliably at all times following delivery.

Identify demand
An extensive consultation forms the basis of eachconcept for us – for special machines as well as
production systems. We use our experience andhigh level of expertise to identify the basic needs,
determine the required components, and sketchout an initial layout. In our lab we can produce
samples with original materials, components andelements in parallel.

Development process
The specific system concept is forwarded to ourdesign department, which creates the machinelayout and generates detailed drawings for
production. We produce or procure the mechanicalcomponents according to the design and assemble
the system. There after the electrical components
are installed and the controller is configured.

Commissioning
Once complete, a trial run of the system isperformed. Once everything meets customer
expectations, the customer approves the system.
Following delivery, set-up and installation of thesystem, commissioning is performed by our
qualified personnel.

After-sales service
We train the operating personnel extensively –either at our premises or on site using the delivered
system. Often, we also support initial production
and provide advice and assistance. When everything is running smoothly, we are happy to perform
regular maintenance tasks on request.

18

tox-pressotechnik.com

........................................................................................................................................................

19

Application examples........................................................................................................................................................
TOX®-Robot tongs
for joining body parts inthe automotive industry.

TOX®-Press
joins housings forelectric motors.

TOX®-Handheld tong
for manual clinching.

20

tox-pressotechnik.com

........................................................................................................................................................

Multi-point tool with 120 punches anddies, which is used for joining sheet metal
in an automated production.

TOX®-Press
joins heating
elements for cars.

TOX®-Press
joins lighting parts.

21

Application examples........................................................................................................................................................
Special tongwith 2 multipoint tools.

TOX®-Pressfor eClinching of fuse parts.

TOX®-Press
joins seat rails for cars.

22

tox-pressotechnik.com

........................................................................................................................................................
TOX®-Pressfor clinching fuses to bus bars.

TOX®-Pressfor appliances. It clinches
refrigerator housing parts.

TOX®-FinePressfor joining electric parts
with a TOX®-MICROpointof 2 mm diameter.

23

........................................................................................................................................................

TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstrasse 488250 Weingarten / Germany
Find your local contact partner at:
tox-pressotechnik.com
309977 / 80.202111.en Subject to technical modifications.

24

tox-pressotechnik.com