TOX® -Riveting Technology
Instruction Manual
Riveting – one of the oldest joining technologies – even reliably joins dissimilar materials
A simple joining technology
In many industries including automotive, aerospace and appliances 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. Compared to thermal joining, they also join non-weldable materials, thus making them ideal joining elements for lightweight designs and hybrid components. Fast cycling and high production rates make riveting an attractive and reasonably priced joining process.
In serial production, riveting processes without pre-drilled holes are typically used. This means the riveting elements punch through and deform themselves into the materials to join them in one work step. These joints are characterized by high strength and one or both sides flush surfaces.
The styles of rivets
An important part of mechanical joining technology is riveting. 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 joined part material are formed. In some instances, punching processes accompany the actual forming process.
Clinch Rivet®
The patented Clinch Rivet® is a simple, cylindrical rivet that deforms both materials without cutting either layer.
- Simple, symmetrical rivet
- Allows for simple feeding and pressing
- Air and liquid tight joints
- Ideal for joining thinner sheet material
Self-Pierce Rivet
The self-pierce rivet (SPR) is a unidirectional element that 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 to formable 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
Rivet Comparison
| Rivets |  | ||
| Measurements of the typical rivets | Ø = 3.5 mm Rivet length 4.0 and 5.0 mm Ø = 5,0 mm Rivet length 5.0 and 6.0 mm | Ø = 3.3 – 3.4 mm Rivet length 3.5 – 5.0 mm Ø = 5.15 – 5.5 mm Rivet length 4.0– 9.0 mm | Ø = 4.0 mm Rivet length 3.3 – 8.1 mm Ø = 5.0 mm Rivet length 3.9 – 8.1 mm |
| Material strength | < 500 MPa | < 1600 MPa | < 1500 MPa |
| Multirange capacity (different joining tasks) | low | low | very good |
| Multijoin capacity | possible | possible | possible |
| Typical number of sheets | 2 – 3 | 2 – 3 | 2 – 4 |
| Flush surfaces | punch side | punch side | possible on one side and two sides |
| Pull strength (typical) | up to 1900 N | up to 2500 N | up to 2100 N |
| Shear strength (typical) | up to 3200 N | up to 4300 N | up to 3300 N |
| Minimum flange width | 14 mm | 18 mm | 16 mm |
| Layers cut | none | all except on die side | all |
| Gas-tight | yes, both sides | yes, die side | no |
| Liquid-tight | yes, both sides | yes, die side | no |
| Minimum sheet thickness on die side | 0.7 mm | 1.0 mm | 1.0 mm |
| Punched piece (slug) removal | no | no | yes |
| System complexity | medium | medium | high |
| Electrical conductivity | good | average | average |
Typical industrial riveting procedures
ClinchRivet®
The combination of clinching and riveting: A symmetrical Clinch Rivet® is pressed into the materials and forms the clinch point in the die.
The Clinch Rivet® is formed and remains in the workpiece. This results in a high-strength connection with a one-sided
flush surface. The Clinch Rivet is perfect for thin materials and leak-proof joints.
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 fllls the hollow rivet shaft and is enclosed within it. This results in a high-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 the material flows into the annular groove of the rivet and forms an undercut. This rivet joint can be formed flush on both sides and is ideally suited to joining high-strength materials.
Proven Process Quality
Continuous Quality Monitoring
A signifi cant 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 and pull 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 we test and analyze afterwards. We will also determine all parameters for your application, including the required press force and suitable rivet-die-combinations, 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 processing results. We will create a cross section and analyze 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 is
based on these determined values and parameters.
Advantages
- Demonstrable joining quality in pre-tests and during series production
- Measurement and documentation of the shear and tensile strengths
- Documentation of the joining quality
- Production of pre-production parts
With a cross section (cut through the rivet), the exact formation can be examined under the microscope for analysis. If necessary, optimizations can be made.
System competence
The technology for industrial riveting
TOX® PRESSOTECHNIK, with its decades of ex-patience, provides you with competent know-how of systems. Regardless of the manufacturer of your rivets, 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.
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 2
The high forces occurring during riveting are absorbed
in a low-de fiection C-frame.
TOX® -Drives 3
The forces required are generated by electromechanical servo drives or pneumohydraulic Power packages.
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TOX® -Rivet feeding
TOX® -Feeding Unit 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 and process monitoring6
- 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
System competence
Automatic Rivet Delivery for Tong Systems
Stationary Blow Feed 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.
Advantages
- Simple
- Safe and reliable
- Cost effective
Robot-carried Blow Feed 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.
Advantages
- For large workpieces
- Safe and reliable
- Fast
DockFeed System (Magazine)
The rivets will be delivered by chute to the docking station. The robot carries the tong to the dock to fill the magazine. It then positions the tong to the part to set the rivets until the magazine is empty.
Advantages
- For multi-technology applications
- Flexible
- Chute-free robot dress pack
Versions
Different basic designs are possible for rivet-systems.
Crucial factors for choosing one system over another include the potential integration into production lines, optimum feed-in, the desired working speed and the size 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 through a feed chute.
Hand tongs
For low volume production a hand-held tong can be utilized. The rivet can be delivered from the chute, a magazine 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.
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 possibility of performing lab tests at our facilities, we supply the suitable rivet head for each rivet and each application. The structural design of the rivet heads differs depending on:
- Type of rivet
- Type of feeding
- Required press force
- Drive version
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
- Piece parts with low wear
Versions
 | TOX® -Setting Head for self pierce riveting |
 | TOX® -Setting Head for full pierce riveting |
 | TOX® -Setting Head for clinch riveting |
TOX® -Dies
The die is the crucial counterpart of the setting head and ensures the correct formation of the joint.
Feeding hoses
A fiter sorting and singulation, the rivet is transported through a specially shaped chute to the setting head.
TOX® -Feeding Unit
The TOX® -Feeding Unit includes the sorting and delivery equipment for safe and reliable rivet delivery. This system 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 the element 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.
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 drive independent and can be used for any technology. When a robot changes its tong, the system recognizes the parameters and can continue working immediately. This yields the highest degree of fiexibility.
Additionally, the intuitive TOX® -HMI software allows easy installation and operation of the system. It is clearly structured and internationally understandable.
Integrated Production
Using numerous interfaces, it is easy to connect the TOX® -Equipment to a company network. The system components communicate with each other via fieldbus.
Processes can be continuously monitored and improved 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.
Sensors
Optional sensor systems can be used to check and display fill levels, process progress and also quality characteristics of the elements.
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 and occupational safety.
Frames
Robust 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.
TOX® -Drives
Large forces are needed to set a rivet joint. These required joining forces are generated by electromechanical servo drives or pneumohydraulic Power packages.
TOX® -Electric Drive
The modular electromechanical servo drive systems generate press forces up to 1000fikN. A maximum of 80 kN is required for riveting therefore most drives used have 30 – 100 kN.
TOX® -Power package
The strong pneumohydraulic drive, which is already used worldwide in thousands of machines. Available with press forces of 2 – 2000 kN.
Additional Components
Information about additional components like controls, part xtures, safety devices and accessories can be found on our website tox-pressotechnik.com. 
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 the
development and design of these systems.
We look to create highly efficient systems to match our customer’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 hand quickly and reliably at all times following delivery.
Identify demand
An extensive consultation forms the basis of each concept for us – for special machines as well as production systems. We use our experience and high level of expertise to identify the basic needs, determine the required components, and sketch out an initial layout. In our lab we can produce samples with original materials, components and elements in parallel.
Development process
The specific system concept is forwarded to our design department, which creates the machine layout and generates detailed drawings for production. We produce or procure the mechanical components 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 is performed. Once everything meets customer expectations, the customer approves the system. Following delivery, set-up and installation of the system, 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.
Application examples
TOX® -Riveting robot tongs are often used in the automotive industry.
TOX® -Press with partially automated workpiece handling for the setting of 16full pierce rivets into a clutch housing.
TOX
PRESSOTECHNIK GmbH & Co. KG
Riedstrasse 4
88250 Weingarten / Germany
Find your local contact partner at:
www.tox.com
936290 / 83.202004.en Subject to technical modifications.
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