Skip to main content
SpringerLink
Log in

Stud welding within sheet metal working tools

  • Production Process
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

Sheet metal parts often have to be connected by fasteners. Within conventional process chains for the production of sheet metal parts, fasteners like bolts are mostly welded individually after the forming process and outside the working tool. This spatial separation of production steps requires complex handling operations and has negative impact upon the positioning accuracy of the fasteners. Every executable manufacturing step inside the sheet metal working tool shortens the process chain significantly. Furthermore, using a combined process the precision of position and orientation of fasteners improves. The challenges of integrating the welding process into the sheet metal working tool are some appropriate feeding technique, handling the emissions and associated pollutions of the tool as well as creating a dependable monitoring-system for the welding-process. Within the scope of a research project, a reliable technology for the integration of capacitor discharge (CD) stud welding with tip ignition was developed and tested. It complements existing solutions for integrated resistance welding processes. Due to its high-speed capability, low insertion of energy and only needed one-sided accessibility, this technique is particularly suitable for the integration in sheet metal working tools. A newly developed exhaustion-system is installed and tested for the first time by the CD arc stud welding process. The new technology produced top quality welding results along with high process stability and robustness in long-term tests.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

Abbreviations

AiF:

German Federation of Industrial Research Associations “Otto von Guericke”

CD:

Capacitor discharge

EFB:

European Research Association for Sheet Metal Working

IPH:

Institute of Integrated Production Hannover

PLC:

Programmable logic controller

SLV:

German Welding Institute SLV Munich

References

  1. Neubauer H (2003) Integration von Schweißvorgängen im Folgeverbundwerkzeug. Forschungsbericht Nr. 167, Verbundinitiative Automobil NRW (VIA), Lüdenscheid

  2. Ultra Tool and Manufacturing Inc. (2009) Advanced Manufacturing Practices: In-Die Welding. http://www.ultratoolmfg.com. Accessed 14 Feb 2009

  3. Ocon Automated Systems S.L. (2009) In Die Welding Works. http://www.ocon-ik.com/eng_home.htm. Accessed 15 April 2009

  4. Lau P, Gruß D (2008) Bolzenschweißen im Folgeverbundwerkzeug. Blech Rohre Profile (vol 3). Meisenbach Verlag, p 12

  5. Tillmich R, Welz W (1997) Bolzenschweißen—Grundlagen und Anwendung. DVS-Verlag, Düsseldorf

    Google Scholar 

  6. Lauenroth T (2002) Prozessanalyse zum Kondensatorenentladungs-Bolzenschweißen mit Spitzenzündung. Dissertation, TU Clausthal

  7. Stache K (1998) Prozessanalyse und Maßnahmen zur Qualitätssicherung beim Bolzenschweißen mit Spitzenzündung. Dissertation TU Clausthal

  8. DIN EN ISO 13918:2008–2010 (2008) Schweißen—Bolzen und Keramikringe für das Lichtbogenbolzenschweißen. Beuth Verlag, Berlin

    Google Scholar 

  9. DIN EN ISO 14555:2006–2012 (2006) Schweißen—Lichtbogenschweißen von metallischen Werkstoffen. Beuth Verlag, Berlin

    Google Scholar 

  10. Schmitt KG (1983) Untersuchungen zur Prozeßanalyse und prozeßbegleitenden Qualitätskontrolle beim Bolzenschweißen mit Spitzenzündung. Dissertation, Universität-Gesamthochschule-Paderborn

  11. Gödde J (2009) Qualitätsüberwachung beim Bolzenschweißen mit STUD-DI. http://www.schweissqualitaet.de. Accessed 31 May 2009

  12. Nickel R, Gruß D, Zech F, Cramer H (2009) Integration und Überwachung des Schweißens von Normteilen in Blech-Verbundwerkzeuge. EFB-Research report no. 300, Europäische Forschungsgesellschaft für Blechverarbeitung e.V., Hannover

  13. Gruß D, Kache H, Nickel R, Behrens BA, Jenicek A, Cramer H (2010) Integration of stud welding in sheet metal working tools. Weld Cut 9(5):313–318

    Google Scholar 

  14. Gruß D, Nickel R, Behrens BA (2010) Integration and control of arc stud welding in sheet metal tools. In: Steel research international, proceedings of the 13th international conference on metal forming 2010 81(9):1152–1155

Download references

Acknowledgments

The documented deliverables are developed in the research project Integration and control of welding of standard parts in metal-composite tools (AiF-Nr. 14.938 N). This project has been funded by the German Federation of Industrial Research Associations “Otto von Guericke” e.V. (AiF) and has been supervised by the European Research Association for Sheet Metal Working e.V. (EFB) with financial resources of the Federal Ministry of Economics and Technology (BMWi) for the period of June 2007 to May 2009. The final documentation is published as EFB research report no. 300. The authors thank all funders and partners.

Author information

Authors and Affiliations

  1. IFUM, Institut für Umformtechnik und Umformmaschinen, Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    B.-A. Behrens

  2. IPH, Institut für Integrierte Produktion Hannover gGmbH, Hollerithallee 6, 30419, Hannover, Germany

    D. Gruß

  3. Schweißtechnische Lehr- und Versuchsanstalt SLV München Niederlassung der GSI mbH, Schachenmeierstraße 37, 80636, München, Germany

    A. Jenicek

Authors
  1. B.-A. Behrens
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. D. Gruß
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Jenicek
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to D. Gruß.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Behrens, BA., Gruß, D. & Jenicek, A. Stud welding within sheet metal working tools. Prod. Eng. Res. Devel. 5, 283–292 (2011). https://doi.org/10.1007/s11740-011-0304-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-011-0304-3

Keywords

Search

Navigation