Assemblies

A complete service, from analysis to manufacturing.

Connection technologies

Your requirement is our challenge. With a wide range of different processes for connecting stamped and stamped-bent parts, we can offer you the ideal connection solution for your product. Our connection technologies for stamped and stamped-bent parts range from clinching, riveting and laser welding through the construction of automated assembly systems to other connection processes.

The most important connection technologies for stamped and stamped-bent parts at a glance:

Clinching is the term used for the pressure joining (tox clinching) or hooking together of stamped geometries. This is a cost-effective joining technology that creates a permanent or extremely resilient bond between at least two elements with two-sided accessibility of the joint without the need for additional parts (rivets etc.).

The connection is form-locked and friction-locked, and an adhesive bond can be created with additional stamping.

The clinching method can be used in semi-automatic and fully automatic processes to join sheet metal parts with a high fatigue strength and to bond sheet metal to other malleable materials such as plastic.

Swaging is a very cost-effective and easy way to join two workpieces together. Plastic deformation is used to produce a form-locked and friction-locked connection.

Swaging is suitable for all materials that can be deformed plastically, such as plastics and metals. These properties mean that different materials can be joined together.

Eberle makes use of press riveting, wobble riveting and radial point riveting for joining materials. Depending on the requirements, the riveting processes are monitored by measuring the force-displacement characteristics and/or using contour scanning.

Press riveting

Press riveting is a process for the plastic deformation of solid, semi-tubular or tubular rivets with a single axial feed motion in a single operation. On the side opposite the riveting die, an anvil or counterholder is required to absorb the pressing force of the die.

Wobble riveting

Wobble riveting is a cold forming process in which the forming force acts only on part of the surface of the workpiece. The end of the riveting die runs on a circular path, giving an axial caulking motion on a rotationally symmetric rivet/bolt, achieving considerable plastic deformation through the application of relatively little force.

Radial point riveting

In the radial point riveting process, the end of the riveting die runs on a hypocycloid, rosette-shaped looped path. The deformation of the rivet is punctiform, and the material is flexed outwards from the center of the rivet, giving this riveted joint excellent load capacities, both static and dynamic. Given the relatively low forming forces at the rivet head, radial point riveting is suitable for the manufacture of very precise riveted joints with narrow shoulder widths. These small shoulder widths allow a large riveting cross section with good strength and small bearing diameters with low frictional torque. With the negligible deformation of the rivet on the bearing diameter, a virtually play-free design of the bearing point is perfectly possible.

Unlike compression riveting or wobble riveting, there is virtually no structural change or hardening at the rivet head.

Depending on customer requirements, components manufactured on or fed into stamping and bending machines can be joined with a form-locked and friction-locked connection. To ensure high levels of quality, the assembly process is fully automatic and the process is monitored continuously. Monitoring of the assembly process using force-displacement sensors or camera technology guarantees joined parts of a very high quality.

We process parts made of aluminum, non-ferrous metals, soft and heat-treatable steels and all common stainless steel grades. We use our fully automated assembly lines to press ball bearings into bearing supports, plastic parts onto pole housings, rubber for vibration damping onto mounting sleeves and steel elements into sleeves or bushings. However, any number of other combinations are also conceivable.

Laser beam welding from 0.09 mm to 0.4 mm and laser deep penetration welding up to material thicknesses of 3 mm with up to 3 kW laser power have been used extensively at Eberle for many years. These are fully automated processes in which we pay particular attention to preparing the joint , the inert gas supply, preventing or minimizing weld spatter and positioning the part.

Depending on the component requirements, we use programmable focusing units, processing optics or optics with automatic joint detection in conjunction with assembly units such as stamping and bending machines that are either developed in-house or bought in.

We use our lines to weld aluminum, soft steels and stainless steels. For the feeding and welding of plates, pins and sleeves, we have developed part-specific solutions that make us a specialist in this field. Millions of manufactured components in the area of injection systems have shown that they allow us to meet the most challenging requirements in terms of flawless part quality.

Resistance welding can be used to join electrically conductive materials together without the addition of any other material. In this process, large currents are passed by two opposing electrodes for a short period to the components to be joined. The transfer resistance at the contact zone leads to heating, further increasing the resistance, which then leads to the melting of the contact zone and the welding of the components.

The power source used can be both direct current (DC) and alternating current (AC) or the discharge from a capacitor (CD).

Capacitor pulse welding in particular can achieve very large currents (500 kA) in very short exposure times. This results in very low heat input, ensuring the minimum of distortion. In resistance welding with DC or AC current, the welding current is supplied by a transformer.

The small contact zone is produced by the shape of the electrodes during spot and seam welding.

In projection welding, the current concentration at the weld joint is achieved by impressing a weld projection onto the components.

With this technology, Eberle is able to join parts made of different materials and with different thicknesses with virtually no distortion in highly productive automated facilities.