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Riveting Technologies

1Riveting Technologies........................................................................................................................................................

Riveting – one of the oldest
joining technologies – evenreliably joins dissimilar materials

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A simple joining technology
In many industries including automotive, aerospace andappliances joining of metal components is achieved
using riveting technologies. Riveting is a proven,professional joining technology, permanently joining
two workpieces together. As opposed to screws, rivets
have the advantage of not needing a thread. Comparedto thermal joining, they also join non-weldable materials,
thus making them ideal joining elements for lightweight
designs and hybrid components. Fast cycling andhigh production rates make riveting an attractive andreasonably priced joining process.
In serial production, riveting processes without
pre-drilled holes are typically used. This means the
riveting elements punch through and deformthemselves into the materials to join them in one work
step. These joints are characterized by high strengthand one or both sides flush surfaces.

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Riveting Technologies........................................................................................................................................................

The styles of rivets
An important part of mechanical joining technology isriveting. It is based on the principle of a positive locking
and / or frictional connection. The rivet itself is inserted
into the parts to be joined where the rivet and / or joinedpart material are formed. In some instances, punchingprocesses accompany the actual forming process.

Self-Pierce Rivet
The self-pierce rivet (SPR) is a unidirectional elementthat functions as a punch through the top layer(s) of
material. It has the most available applications.
 Higher joint strengths
 Air tight on the die side
 Ideal for high strength materials

Full-Pierce Rivet
The full-pierce rivet (FPR) is suited to joining highstrength, low elongation punch side materials toformable die side materials. It is also good for multi-layer applications.
 One rivet length for multiple material stack-ups
 Can be designed to be flush on both sides
 Ideal for joining lightweight and mixed materials

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Rivet Comparison........................................................................................................................................................
RivetsSelf-Pierce Rivet (SPR)

Full-Pierce Rivet (FPR)

Ø = 3.3 – 3.4 mm
Rivet length 3.5 – 5.0 mm

Ø = 4.0 mm
Rivet length 3.3 – 8.1 mm

Ø = 5.15 – 5.5 mm
Rivet length 4.0– 9.0 mm

Ø = 5.0 mm
Rivet length 3.9 – 8.1 mm

Material strength< 1600 MPa< 1500 MPa

Multirange capacity(different joining tasks)

lowvery goodMultijoint capacity

possiblepossible

Typical number of sheets

2–3

2–4

Flush surfaces

punch side

possible on one sideand two sides

Pull strength (typical)

up to 2500 N

up to 2100 N

Shear strength (typical)

up to 4300 N

up to 3300 N

Minimum flange width

18 mm

16 mm

Layers cut

all except on die sideall

Gas-tight

yes, die sidenoLiquid-tightyes, die sidenoMinimum sheet thickness on die side

1.0 mm

1.0 mmPunched piece (slug) removal

no

yes

System complexity

mediumhighElectrical conductivity

averageaverage

Measurementsof the typical rivets

5Process competence........................................................................................................................................................

Typical industrial riveting procedures
Self-pierce rivet (SPR)
Universal and without slugs: The self-pierce
rivet punches through the first material
layer and forms the second to a closing head.
The punched piece fills the hollow rivet shaft
and is enclosed within it. This results in ahigh-strength and tight joint, which is flush at
the top. This riveting technology is ideal for
extremely flexible joints.

Full-pierce rivet (FPR)
Punching and joining in one step: The rivet
punches through all sheet layers. The layer on
the die side is formed in such a way that thematerial flows into the annular groove of therivet and forms an undercut. This rivet joint
can be formed flush on both sides and isideally suited to joining high-strength materials.

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Proven Process Quality
Continuous Quality Monitoring
A significant advantage of riveting is the simple quality
control even in series production. By continuously measuring the force-travel-curve, each rivet connection can
be checked. An additional analysis can be carried out
by cross sections (cut through the rivet). The shear andpull strength can be determined in tensile tests.
Preliminary tests in the TOX® Technical Center
Prior to collaboration, we will work on the most effective
solution for you in our lab. Here we will perform
preliminary joining tests on your samples, which wetest and analyze afterwards. We will also determine allparameters for your application, including the requiredpress force and suitable rivet-die-combinations, and wewill establish which system can be used for your joining
application.
Final Check of the Machine Parameters
Before we deliver a system, we check the realprocessing results. We will create a cross section andanalyze the joining process and the retention forces of
the rivet. Everything will be documented in a detailed
test report. The initial set-up of the delivered system isbased on these determined values and parameters.

Advantages
 Demonstrable 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

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With a cross section (cut through the rivet), the exact
formation can be examined under the microscope foranalysis. If necessary, optimizations can be made.

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System competence........................................................................................................................................................

The technology for industrial riveting
TOX® PRESSOTECHNIK, with its decades of experience, provides you with competent know-how
of systems. Regardless of the manufacturer of yourrivets, we are able to customize your application
using a wide range of components and modules.
Your customer-specific requirements are met down
to the last detail utilizing standard system components
thanks to our modular design.

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The following modules are required for riveting
applications:

TOX® Tong
Setting tools 1
The rivet head and die together form the centerpiece.
They drive the rivet into the workpiece and are adapted
individually to each rivet.
Frame 2The high forces occurring during riveting are absorbed
in a low-deflection C-frame.
TOX® Drives 3
The forces required are generated by electromechanicalservo drives or pneumohydraulic Powerpackages.

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TOX® Tong withsetting tooling for rivets

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TOX® Rivet feeding

TOX® Control andprocess monitoring4.........................
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Customer
Network

TOX® Rivet feeding
TOX® FeedingUnit 4
Preparation of the rivet occurs in our compact enclosure. The hopper, vibratory bowl, escapement and blow
feed prepare the rivet for delivery to the setting head.
Loading Station (Docking) 5
The tong fills its magazine with the required rivet here.

TOX® Control andprocess monitoring 6
 Ranging from external impulse to complete PLC
controls built to the highest safety standards
 Multi-technology controls available for additional
processes
 Monitoring of process and machine parameters

9System competence........................................................................................................................................................

Automatic Rivet Delivery for Tong Systems
Stationary BlowFeed System
The rivets will be directly
delivered to the setting
head through a chute. The
robot positions the part
inside the press for the
rivet to be set.

Robot-carried BlowFeed System
The rivets will be directly
delivered to the setting
head through a chute. The
robot will position the tong
to the part for the rivet to
be set.

DockFeed System (Magazine)
The rivets will be deliveredby chute to the docking
station. The robot carries
the tong to the dock tofill the magazine. It thenpositions the tong to thepart to set the rivets until
the magazine is empty.

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Advantages
 Simple Safe and reliable Cost effective

Advantages
 For large workpieces
 Safe and reliable FastAdvantages
 For multi-technology
applications
 Flexible
 Chute-free robot dresspack........................................................................................................................................................

Versions
Different basic designs are possible for rivet-systems.
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.
Stationary tongs
For integration in production lines and equipment,
stationary machine tongs are suitable. The workpiece
will be presented by a robot and the rivet will be inserted
by the press.
Robot tongs
A mobile tong is moved and controlled by a robot. The
rivets are either supplied by a docking station or througha feed chute.

Hand tongs
For low volume production a hand-held tong can beutilized. The rivet can be delivered from the chute, amagazine or be hand loaded.
Presses / Machines
Machines can be designed as fully automatic, semiautomatic or purely manual workstations. The workpiece is manually loaded into the machine. The machine
will then rivet per a customized plan.
TOX® PRESSOTECHNIK is certified to build safety
rated work stations.

Versions

Hand tong

Machine11Components........................................................................................................................................................

TOX® Setting heads
You define the element – we develop the suitable setting
system. The different types of rivet place different
demands on setting technique and rivet head.
Thanks to long-standing experience and the possibilityof performing lab tests at our facilities, we
supply the suitable rivet head for each rivet and eachapplication. The structural design of the rivet heads
differs depending on:

Advantages
 Die and setting head as an integrated solution
 Process-reliable separation of the rivets
 Slim tool design for tight spaces
 Maintenance-friendly design
 High guide accuracy
 Pieceparts with low wear

 Type of rivet
 Type of feeding Required press force Drive version

Versions
 OX® Setting HeadT
for self pierce rivetingTOX® Setting Headfor full pierce riveting

TOX® Dies

Feeding hoses

The die is the crucial counterpart of the setting headand ensures the correct formation of the joint.

Aflter sorting and singulation, the rivet is transported
through a specially shaped chute to the setting head.

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TOX® FeedingUnit
The TOX® FeedingUnit includes the sorting and delivery
equipment for safe and reliable rivet delivery. Thissystem is outside of the robot cell for easy refill. It
includes:Hopper: This is the fill location that holds large quantities of elements. The feeder bowl receives its rivets form
here.
Feeder Bowl: This feature orients and delivers theelement to the escapement for delivery.

Escapement:
The oriented rivets are singulated here for delivery to
the setting head. From here the rivet is typically blown
through a chute to the setting head.
The TOX® Feeding unit can fit many processes thanks
to our modular system. We also validate our designs
for each systems offered to ensure that manual
manipulation is not required.

HopperFeeder Bowl

Escapement
13Components........................................................................................................................................................

Flexible control-software for the integrated production
Flexible Multi-Technology Control
One system - many possibilities! Our multi-technologycontrol 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

Additionally, the intuitive TOX® HMI software allows easy
installation and operation of the system. It is clearlystructured and internationally understandable.

Insertionof functional
elements

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.
Processes can be continuously monitored andimproved with the data collected here. Feedback from the production process can be used to
optimize the technology parameters. 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

Process Monitoring Devices
The quality parameters of
the riveted joint can be
examined and documented
by a sperate device.

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TOX®HMI
Control andProcess unit

Customer
NetworkSensors
Optional sensor systems canbe used to check and display
fill levels, process progress andalso quality characteristics ofthe elements.

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Frames and Columns
The forces that occur during riveting are absorbed
by a C-frame or the columns of a column press. The
design takes into account interfering contours, total
weight, piece part accessibility, working conditions andoccupational safety.

Tong frame

Press frame

FramesRobust frames are used for tongs and presses. We
respond to the specific requirements with standard
frames or individual designs.
Column presses
Column presses are particularly useful for multi-point
tools. They can be manufactured in various sizes, but
all have the same precision and ease of access.

Column press

TOX® Drives
Large forces are needed to set a rivet joint. These
required joining forces are generated by electromechanical servo drives or pneumohydraulicPowerpackages.
TOX® ElectricDrive
The modular electromechanical servo drive systems
generate press forces up to 1000 kN. A maximum of
80 kN is required for riveting therefore most drives usedhave 30 – 100 kN.
TOX® Powerpackage
The strong pneumohydraulic drive, which is alreadyused worldwide in thousands of machines. Available
with press forces of 2 – 2000 kN.

Additional Components
Information about additional components like controls,part fixtures, safety devices and accessories can befound on our website www.tox.com.

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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.

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Application examples........................................................................................................................................................

TOX® Riveting robot tongs are often
used in the automotive industry.

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TOX® Press
for the testing ofdifferent rivets inthe lab.

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TOX® Press with partially automatedworkpiece handling for the setting of 16
full pierce rivets into a clutch housing.

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TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstrasse 488250 Weingarten / Germany
Find your local contact partner at:
www.tox.com
936290 / 83.202401.en Subject to technical modifications.

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