RIVET INSTALLATION METHOD AND CONSTRUCTION

Abstract: A rivet (10) installation method creates a preload on the workpieces (18, 20) being joined. The rivet shank (12) is urged to resist compression during installation while a ring (30) on the end of the shank is compressed against the workpieces (18, 20). Withdrawing the compression releases the shank to provide the preload.

Description: -1 - RIVET INSTALLATION METHOD AND CONSTRUCTION Background of the Invention This invention relates to a method of i stalling a rivet in a plurality of workpieces, and to the resulting riveted joint, as well as the rivet itself. One rivet-type fastener commonly used in aircraft constructions includes a shank with a manufactured head on one end and a tail on the other end. In use, the tail end of the shank is inserted through aligned holes of two or more workpieces with the rivet head engaging the outer face of one of the workpieces and with the tail extending beyond the outer face of the other workpiece. The tail is then deformed by means of an axial force, compressing the rivet axially and upsetting the tail material outwardly to form an upset head which is larger in diameter than the hole through the workpieces, so that the two workpieces are fastened together. In one highly successful rivet, or shear pin, of this general type, the shank which extends through the workpieces is made of a strong material which is high in shear strength while the tail is made of a more ductile material which is easier to deform than the shank. The two metals are typically joined together by friction welding. In one example of this type, the shank is formed of (95 ksi shear) 6AL-4V titanium alloy while the tail ' is formed of 55 Ti 45 Cb titanium alloy. Such a fastener is sold by the assignee of the present invention under the trademark Cherry BUCK. U.S. Patent No. 3,848,389 issued to Gapp, et al. further describes bimetallic shear pins of this general type. All types of fasteners having a tail to be upset are often installed by squeezing, wherein the ductile tail is compressed until the upset head formed attains a diameter of about 1.3 to 1.5 times the initial shank diameter. When the squeezing force used to form the upset head is released, the column of the rivet shank "springs back" or lengthens a certain distance. Although the material of the workpiece being fastened also springs ba * ck, some of the materials in common use do not spring back as much as the rivet shank, with the result that a small gap is created between portions of the upset head and the workpiece after the installation is complete. For example, a sold rivet of 2117T3 aluminum, used for many years in large quantities in the aircraft industry and commonly referred to as an AD rivet, when installed in 7075T6 aluminum material can exhibit a small gap between the ' upset head and the workpiece. However, some gap is acceptable for most practical uses except those involving high fatigue loads. In ai'rcraft structures, particularly those involving shear fatigue loading of the fastener, it is desirable that the gap between the upset head and the workpiece be zero. Ideally, the underside of the upset head should exert a compression force against the workpiece after the installation. When such a loading is achieved, the fastener is said to exert a residual tension force against the workpiece after installation. This loading is often referred to as a "preload" in the joint. While millions of rivets of the type having a ductile tail and a strong shank have been used satisfactorily, their use has been limited in areas involving shear fatigue loading due to the inability to provide a preload. A fastener of this type which provides a preload is usable in a much extended range of applications, particularly those involving shear fatigue and light tension fatigue or a combination of both. Further, the ability to use a bi-metallic fastener • in fatigue applications is of great benefit to the aircraft industry because it is the lightest shear pin type fastener available with a 95 ksi shear rating. In the aircraft industry, weight savings are very valuable. Savings of one pound of weight can be warth S1 ,000 to the designer in some critical areas of an aircraft design. Another type of shear pin fastener consists of a bolt with a small head on one end and a small * light nut threaded on the other end. The small head and nut are of sufficient strength to develop close to the full shear strength of the fastener when it is installed in two or more workpieces, but not of sufficient strength to develop the full tensile strength of the fastener. In joints involving high axial tension loads, tension type fasteners are used. Typically, these have larger and stronger manufactured heads and larger and stronger matching nuts. These tension type fasteners are, of course, heavier. The size and weight of the squeezed tail of the one piece shear pin herein described is much smaller than the nut and threaded portion of a threaded pin and nut- type shear pin fastener of the same strength. Also, the small height and size of the squeezed tail of the shear pin is advantageous with regard to the installation and positioning of other components in crowded areas within aircraft or other assemblies. A one-piece fastener is particularly desirable as opposed to a two-piece fastener in that it is easy to feed and install using automatic equipment. Most fasteners of this general type which are capable of providing a significant preload are of the two-piece design. Two- piece designs involve serious feeding problems when automatic or robot installation is attempted. Automated installation of fasteners is advancing rapidly in the aircraft industry because it is cheap and produces much more uniform and satisfactory joints. In the past, preload in a riveted joint has been achieved by using hot rivets which, after being upset, contract upon cooling and produce the desired preload in the joint. This hot rivet approach of course adds other costs and complexities; and while it is still used in large commercial structures, such as bridges, it is not used in aircraft structures. Accordingly, a substantial need exists for a method of installing a one-piece, cold, upset rivet σr shear pin fastener in a manner which can provide a significant axial preload. Summary of the Invention In accordance with the invention, an installation method is provided which produces a riveted joint with the desired preload on the workpieces through which the rivet extends. This is accomplished by applying a deforming force to the rivet tail to form an upset against the portion of the workpiece surrounding the hole in the workpiece, while applying force to the rivet shank sufficient to resist compression or to slightly stretch the shank. The elongating force is then withdrawn allowing the rivet shank to "spring back" providing a preload on the workpieces. A manufactured or an upset head is, of course, on the other end of the shank to surround the hole on the other workpiece. In a preferred approach, the installation method includes a two-step, co pressive approach using a two-part tool assembly. With the rivet tail extending beyond the outer face of one of the workpieces, a first axial compressive force is applied to the rivet using a suitable pin-like tool, causing the tail of the rivet to be deformed axially and deformed radially outwardly to form an upset head substantially larger than the hole through the adjacent workpiece. This first step is essentially the same as that currently being utilized in installing rivets of this type. As the second major step of the installation method, the tool which formed the upset head is unloaded, and a second tool which surrounds the first tool is squeezed onto the upset head. This outer tool preferably has a cylindrical opening formed therein so as to be slidably mounted on the inner pin-like tool. The circular edge of the cylindrical opening of the outer tool engages the -5- outer ring of the upset head; and as the outer tool is moved downwardly onto the upset head, it starts to shear the outer ring of the upset head. Continued downward movement of the outer tool flattens the sheared or swaged ring while it remains integrally connected at ' its inner edge with the upset head. During the forming of this ring, the upset head material is, of course, pressed against the adjacent workpiece placing the workpieces under compression. When the outer tool is withdrawn, the resulting joint construction has a preload on the workpieces applied in the vicinity of the axis of the shear pin. It is believed that one factor producing this preload is due to the nature of the metal movement which occurs during the flattening of the sheared ring. As a compression load sufficient to deform the material is applied, the ring will attempt to expand radially inwardly as well as radially outwardly. The radially inward expansion urges the length of the pin to be increased by a small but appreciable increment. When installation is complete and the cylindrical tool is withdrawn, the length of the fastener springs back to a slightly shorter length and applies compression or preload to the workpieces. An additional mechanism which contributes to joint preload also operates during the downward stroke of ' the outer mandrel. This mechanism operates as follows. The load required to shear material from the upset head of the rivet is typically about 2000 lbs. maximum, dropping to about 1000 lbs. towards the end of the operation for a 3/16 inch diameter rivet having a tail fabricated from 55 TiCB material. This 1000 lb. load compresses the rivet shank in column. When the partially sheared ring contacts the woripiece a further load is applied, typically 6000 lbs. for the rivet before mentioned. All except the 1000 lb. of this load goes to push the workpieces together and then compress them to a slightly lesser thickness locally in the vicinity of the flattened ring. When the outer tool is withdrawn the rivet shank will elongate slightly due to the spring back following release of the 1000 lb. load, and the workpieces will spring back slightly more due to release from the higher 5000 lb. (6000 lb. minus 1000 lb. - 5000 lb.) load. Thus, the workpieces will be maintained in a compressed condition between the flat ring and the preformed head. This compressed condition is referred to as preload in the joint. For simplicity, loaded areas and material modulii have been omitted. While these methods for producing a preload are particularly advantageous in the bi-metallic type rivet discussed above, the methods are also useful in any cold installed metallic rivet. In addition to the above-described method, the invention includes the resulting rivet which is formed by the method. Such rivet has a cylindrical head with a flattened larger diameter ring on the end of the head adjacent the rivet shank. The head and ring thus have somewhat of a hat shape. The invention also includes the preloaded joint construction provided by the method and includes the apparatus for performing the method. Summary of the Drawings Figure 1 is a cross-sectional view of a conventional bi-metallic shear pin or rivet. Figure 2 is a cross-sectional view of a joint construction utilizing the rivet of Figure 1 and illustrating the gap that can exist between the upset head of the rivet and the adjacent surface of the workpiece, Figure 2a being an enlargement of the gap area. The extent of the gap is exaggerated for the sake of clarity. Figure 3 is a cross-sectional view of a pair of workpieces with a rivet inserted through holes in the workpiece and with a schematic illustration of a tool about to be applied to the rivet in accordance with the method of the invention. -7- Figure 4 illustrates the components shown, in Figure 3 at the completion of the first forming step of the invention. Figures 5, 5a, 5b, 5c, and 5d are cross-sectional, schematic views illustrating sequentially the action that occurs during the second squeezing step of the rivet installation method. Figure 5e is an enlargement of a portion of the completed riveted joint of Figure 5d, illustrating schematically the material movement when the preload is obtained. Figures 6, 6a, 6b, 6c and 6d are diagrams illustrating the load versus movement of the outer tool during the various stages of the second compressive step of the rivet installation method, with the diagrams conforming respectively to the stages illustrated in Figures 5-5d. Figure 7 is a cross-sectional view of a shear pin with a tail on each end. Figures 8, 9 and 10 are perspective views of riveted joints showing ruptures of one of the workpieces at different locations when the joints are subjected to shear fatigue testing. Figure 11 is a cross-sectional view illustrating the head of the invention on a tapered shear pin. Detailed Description of the System Illustrated in the Drawings As indicated above, Figure 1 illustrates a prior art rivet or shear pin 10 having a cylindrical shank 12 with a preformed or "manufactured" head 14 on one end of the shank and a tail 16 on the other end of the shank, with the diameter of the tail tapering from that of the shank to a reduced diameter on its outer tip. Such a rivet may be made of various materials, but a commonly used rivet which is particularly useful in connection with the method of the invention has a shank formed of 6AL-4V titanium -8- alloy and a ductile, easy to form tail made of.55 Ti 45 CB titanium alloy. These two metals are joined in suitable manner by friction welding such as that disclosed in U.S. Patent No. 3,848,389. Figure 2 illustrates the rivet of Figure 1 installed in a conventional manner, fastening two workpieces 18 and 20 together. As may be seen, the tail 16 of the rivet has been upset axially and deformed radially outward to form an upset head 17 which holds the rivet in place. After the squeezing or compressive force on the upset rivet is removed, the column of the rivet shank springs back a certain distance. Although the workpieces 18 and 20 also spring baok somewhat, the materials in common use for the workpieces do not spring back as much as the rivet shank with the result that a gap V is formed between the interface of the upset head 17 and the workpiece 20, as seen in Figure 2a. This gap is acceptable for most practical uses except those involving fatigue loads. As shown in Figure 2 and Figure 2a, the shank near the upset head is expanded slightly to prevent looseness. This expansion occurs as the upset head is formed. In accordance with the method of the invention, this gap V is eliminated, and the rivet shank is under tension after installation providing a compressive force or preload on the workpieces. A two-part tool assembly is provided to install the rivet. As schematically illustrated in Figure 3, this includes an inner tool comprising a piston-like pin 24 having a flat end face with a diameter which is larger than the diameter of the rivet shank 12 but is smaller than the diameter of the upset head 28 which is to be formed, as illustrated in Figure 4. Surrounding the tool pin 24 and siidably mounted thereon is a cylindrical or tubular to * ol 26. The tool 26 has a flat annular end face which is shown flush with the end face of pin 24 in Figure 3. Note that the inner tool 24 is positioned above and axially aligned with a rivet 10 extending through workpieces 18 and 20, with the end face of the tool being adjacent the rivet tail 16. During the initial step of the installation method, the pin 24 is moved downwardly as indicated by the arrows 25 in Figure 3 to apply a squeezing or axially compressive force to the rivet tail. The rivet preformed head 14 and the workpieces are of course supported by suitable means (not shown) to withstand the load. This force axially compresses the tail and deforms it outwardly into the flattened barrel-like shape illustrated in Figure 4, forming the upset head 28. The compressive or squeezing force is not normally applied by the outer tool 26. Thus it does not normally deform the rivet during this first step. Preferably, the outer diameter of the upset head is about 1.3 to 1.5 times the original shank diameter, which as indicated in Figure 4 is larger than the inner diameter of the outer tool 26. The upset head actually has an outwardly curved or bulged outer periphery such that the diameter on the flat upper end of the upset head is about equal to the inner diameter of the end face of the tool 26, and the outer diameter of the end face of the inner tool 24, but the outermost portion of upset head 28 extends outwardly beyond the inner diameter of the outer tool 26. During the second forming step in the method of the invention, the squeezing force on the inner tool 2 is unloaded, and it may be withdrawn slightly as ' illustrateα in Figure 5. The outer tool 26 remains adjacent the upper end of the upset head. The diagram of Figure 6 indicates that a load is not yet applied. A squeezing or compressive force is then applied to the upset head by means of the outer tool. As the outer tool moves down it starts to shear the outer ring or annular portion 30 of the head 28, as illustrated in Figure 5a; and the load increases as illustrated in the diagram of Figure 6a. As the outer tool 26 approaches the largest diameter of the upset head as shown in Figure 5b, the load increases to an initial high point as illustrated in diagram 6b. With continued downward movement of the outer tool 26 to the position illustrated in Figure 5c, the load decreases slightly due to the reduction in diameter of the upset head, such slight load reduction being illustrated in Figure 6c. Continued compressive movement of the outer tool 26 deforms the sheared upset head material 30 into a flatter ring as shown in Figure 5d. As the material is compressed and swaged further into a flattened ring increasing its outer diameter, the load increases rapidly from point A to point B as illustrated in Figure 6d. The preload is produced within that portion of the loading diagram because the workpieces 18 and 20 are pressed together through the action of the compressed ring 30 which at all times remains attached to the remaining upset head 28a. As this ring 30 is compressed, it is believed that it tends to expand radially inwardly, as well as radially outwardly, causing the length of the pin to be increased by a small, but appreciable, increment. This tendency toward inward flow of material is illustrated schematically by the small arrow 36 shown in the enlargement of Figure 5e. When installation is complete and the cylindrical tool 26 is withdrawn, the length of the fastener springs back to a slightly shorter length and applies the desired compression or preload to the workpieces. An additional mechanism which contributes to joint preload, also operates during the downward stroke of the outer mandrel, 26. This mechanism operates as follows: the load required to shear the ring, 30, from the upset head of the rivet, 28, is indicated by the curve in Figure 6d between the beginning of the curve and the point A. Between the point A and point B the load on the workpiece exerted by the ring 30 increases to a maximum at B, while the load on the pin tending to collapse it in column reduces to approximately point C on the dotted extension of the curve in Figure 6d. The load at C felt by the pin is estimated to be about 1/6 of the load at B. The load at B of course represents the combined load on the pin .and the 'load on the workpieces. When the load on the outer anvil is removed, the pin will spring back a small amount due to the removal of the load C, while the workpieces will tend to spring back by a larger amount due to removal of the larger load B minus C. The pin will restrain the spring back of the workpieces and thus, the workpieces will remain in the desired preloaded condition. In practice, the two mechanisms that tend to provide preload operate simultaneously. Note that due to the action of the outer tool, the outer diameter of the flattened ring 30 has been increased beyond the diameter of the original upset head 28, as viewed in Figure 5. With the flattened ring material having been sheared from part of the outer portion of the original upset head shown in Figure 5, a more completely cylindrical head 28a, as shown in Figure 5d is left. This gives the head 28a and ring 30 combination a miniature top hat shape with the ring 30 representing the brim. While the size of the upset head 28a and the flattened ring 30 in relation to the shank of the rivet may be varied to some extent, a successful prototype had a maximum upset head diameter as viewed in Figure 5 of about 1.5 times that of the original rivet snank diameter. This was reduced to a diameter of 1.3 times the original shank 12 diameter in its sheared cylindrical form 28a shown in Figure 5d, while the flattened ring 30 had an outer diameter of 1.75 times that of the original shank 12 diameter. The expansion of the ring 30 radially inward sufficiently to produce an appreciable lengthening of the rivet shank 12 during the A to B stage of the installation, as viewed in Figure 5d, was surprising in that it was not anticipated that lengthening would be of sufficient magnitude to produce a useful result. It has been found however that a rather remarkable improvement is obtained by this mechanism and the additional mechanism also described. Based on a number of tests of 3/16 inch diameter CherryBUCK fasteners having 6AL-4V titanium for the preformed head and shear portion of the shank welded to a soft tail of 55TiCb, the following are the preferred loadings to be applied to the rivet tail by the inner anvil 24 at the first stage of installation, and by the outer tubular anvil 26 during the second stage of installation. The range of resulting preloads is also shown. Preferred Installation Loads First stage load 5,800 LB Min/7,800 LB Max Second stage load 4,500 LB Min/6,500 LB Max Resultant Preload 500 LB Min/1 ,000 LB Max A chart of lap joint shear fatigue test results is set forth below. For the rivets with preload, first and second stage installation loads were in accordance with those listed above under Preferred Installation Loads. Shown is the number of cycles to failure for the rivet with preload versus the same rivet without preload and also versus a competitive fastener sold under the trademark HI-LOK, which employs a threaded nut on a threaded shear pin. It will be noticed that each of the three different Cherry-BUCK part numbers gave consistent cycles to failure with the special upset, as compared to lower and less consistent cycles to failure with the standard upset. Noticeable also are the favorable cycles to failure of the rivets with the special upset compared to the cycles to failure of the Hi Lok. Due to its very common use throughout the aircraft industry the Hi Lok fastener is widely regarded as an industry standard with the type of fastening applications under discussion here. It is apparent from the results that a very significant improvement has taken place due to the method of installation which produces preload. This dramatic improvement for a fastener not employing a threaded nut. is particularly useful in that a one piece fastener lends itself readily to automated installation of rivets. FATIGUE TESTS PER MIL-STD-1312, TEST 21 Full Load Transfer, No Restraints CHERRYBUCK WITH PRELOAD In 2024-T3 Clad Sheets, 0.123" Thick. Each At 10 KSI Gross, R»+0.1 (1850/185 Lbs.) Clearance Holes (0.1900") Fastener Installation Fatigue Life Failure Part No , Condition (Cycles to Failure) Code CSR 926-6-4 Standard 1 ,4D 427300 C Standard 1.4D 388260 B Special 533910 A Special 599790 A CSR 924-6-4R Standard 1.4D 478450 B Standard 1.40 438840 B Special 495300 A- Special 627610 A CSR 926-6-5 Standard 1.4D 121350 C Standard 1.4D 97280 C Special 540120 A Special 490950 B Hi-Lok (HL11V6-4 Pin, Power Tool 389100 B HL70-6 Collar) 367100 A Failure Code A refers to the condition shown in Fig. 8 wherein the top workpiece in a riveted joint breaks at a location spaced from the holes in the workpieces through which the rivets extend. Failure Code B refers to that shown in Fig. 9 wherein the bottom workpiece of a riveted joint ruptures at a location spaced from the holes in the workpieces through which the rivets extend. Failure Code C refers to the condition wherein the top workpiece in a riveted joint ruptures on a line through the holes in the top workpiece through which two rivets extend. The upper workpiece is slightly weaker than the lower workpiece at that location because of the countersink in the top workpiece, whereas the bottom workpiece is not countersunk in this example. It will be noticed that with the rivets in the standard installation condition (no preload) , the failure Code C indicates that joints failed across the rivet holes, while with rivets in the special installation condition (with preload), failure Codes B and C indicate that joints failed away from the rivet holes. It is widely considered that when failures occur remote from the rivet holes, the cycles to failure are close to optimum for that particular joint and fastener configuration. It has been found that the preload is obtained whether the fastener is installed in an interference fit or in a clearance fit hole in the workpieces. It should be noted that the material sheared from the head 28 does normally not contribute much to the strength of the riveted joint. Thus the advantageous preload is obtained without appreciable loss of strength of the joint formed by the first deforming step, and without the need for additional material to be added to the rivet tail. While the method described is particularly advantageous with a bimetallic rivet, it is useful with any cold formed rivet operation. In rare situations, it may be desirable to utilize a shear pin 38 not having a preformed head on either end, as shown in Figure 7. Both tails 40 of the shear pin 38 can be upset in the manner discussed above to form an upset head 28a and a ring 30, as in Figure 5d, on each end of the shear pin 38. In theory, the preload could be doubled if both ends were simultaneously formed. The preload could also possibly be increased by restricting the radially outward flow of material when the ring 30 is being flattened. This could force more inward material flow, and thus more axial lengthening, and ultimately more "spring back" when the load * is removed. This could possibly be accomplished by forming a shallow annular recess (not shown) in the end face of the tool 26. The outer diameter of the recess would be sized to limit outward flow of the ring 30 during the flattening of the ring, so as to increase inward flow. The top hat-shaped head can, of course, be used on various types, of shear pins. Figure 11 illustrates another arrangement wherein the top hat-shaped head 52 . has been formed with preload on the small end of a tapered pin 50. The pin is forced into holes in the workpieces 54 and 56 until the large head or end 51 of the pin prevents further movement. The preloaded head on the tapered pin is more practical than an upset head of the type shown in Figure 2, wherein the gap between the upset head and the workpiece exists.

Claims: IN THE CLAIMS; 1. A method of holding two work pieces under compression with a rivet having a shank extending through the work pieces, said rivet further having a head on one end of the shank having a radially outer portion engaging one of the work pieces and having a ring integral with the head extending radially outwardly from the head and engaging said one work piece, said head including a portion which extends axially away from said ring and has a diameter greater than said shank, said method comprising: compressing said ring against said one work piece while no compressing force is being applied to the axial end of said head, the force for compressing the ring being greater than that needed to deform said ring; and withdrawing said ring compressing force. 2. The method of Claim 2 wherein said ring is initially formed by partially shearing an outer portion of the head and compressing it against the adjacent work piece form a flattened ring integral with the head. 3. The method of Claim 2 wherein said head is initially formed by applying an axially compressive force to a tail on the rivet made of deformable material and pressing the tail material axially and deforming the rivet tail against the adjacent work piece and deforming material radially outwardly to form an upset head. 4. The method of Claims 1 to 3 wherein said ring is compressed against the adjacent work piece with a force sufficient to urge material inwardly and then axially. 5. The method of Claim 3 where the flattened ring is formed with an outer tool having an end face with an opening therein and inner cutting edge defining an area larger than the rivet shank smaller than the outer diameter of the upset head. 6. The method of Claim 5 wherein said upset head is formed by an inner pin-like tool which is slidable within said outer tool. 7. The method of Claim 3 wherein said tail is more ductile than said shank. 8. The method of Claim 3 wherein the force for forming said upset head is applied until the outer diameter of the upset head is about 1.3 to 1.5 times the diameter of said shank. 9. The method of Claim 8 wherein said upset head is sheared to a cylindrical shape about 1.2 to 1.3 times the diameter of the shank. 10. The method of Claim 3 wherein said portion is compressed against the adjacent work piece with a force greater than the force required to partially shear the portion from the upset head. 11. The method of Claim 3 wherein the rivet initially has a tail on either end, and said method includes the steps of simultaneously forming an upset head and compressed ring on both tails. 12. The method of Claim 1 wherein said rivet is initially formed with a manufactured head on one end of the shank and a deformable tail on the other end of the shank, and said method includes inserting said rivet into aligned holes in the work pieces, compressing said deformable tail to form an upset head, and said ring is initially formed by partially shearing the outer portion of said upset head and flattening said outer portion to form said ring. 13. The rivet of Claim 13 made by the methods of any other preceding method claims. 14. Two work pieces and the rivet of Claim 13 joining said work pieces in the manner set forth in any of the preceding method claims. 15. The rivet of Claims 13 or 14, wherein said head and ring have a generally hat shape. 16. A rivet having a shank with a head on one end, said head having a cylindrical portion with a diameter larger than that of said shank and a flat ring portion extending outwardly from the lower part of the cylindrical portion to give the head a generally hat shape. 17. The rivet of Claim 16 wherein said shank is tapered from a small diameter adjacent said head to a larger diameter on the other end. 18. The rivet of Claim 15 wherein there is a hat shaped head on the other end of the shank.

Inventors: MATUSCHEK JOSIP, MATUSCHEK, JOSIP
Applicants: TEXTRON INC, TEXTRON, INC.
Application year: 1986
Main classification: B21J5
IPC codes: B21J15, F16B19