Abstract: A self -piercing rivet (10) for forming joints in stacked sheets of high or low strength, light alloy metals such as aluminium and magnesium. The rivet (10) comprises a head (11) and a substantially cylindrical shank (12) that is at least partially hollow so as to define a bore (13) that extends along at least part of its length. The outside diameter (D1) of the shank (12) is at least 6 mm, the effective length of the rivet is at least 1.3 times the diameter of the shank and the bore (13) has a volume that is at least 38% of the effective solid volume of the rivet (10). The rivet geometry is such that it has enhanced column strength to withstand the high insertion forces required and a high bore volume to accommodate displaced sheet material.

Abstract: A fastening method and apparatus (9) comprising using a control apparatus to select a first upsetting volume of an upsetting die, using a punch to push a first fastener into a workpiece and using the upsetting die to upset the first fastener, then using the control apparatus to select a second upsetting volume of the upsetting die, using the punch to push a second fastener into a workpiece and using the upsetting die to upset the second fastener, or using the punch and the upsetting die to form a clinch joint.

Abstract: A fastener delivery apparatus includes a nose assembly to releasably hold a fastener. The nose assembly includes a plurality of balls or rollers and associated biasing members to provide a biasing force which biases the balls or rollers such that they engage with the fastener. Each biasing member exerts force in a first direction and an associated ball or roller moves in a second direction which is different from the first direction. A force transfer surface is provided between the ball or roller and the biasing member, the force transfer surface acting to convert at least a component of the force exerted by the biasing member in the first direction into force exerted on the balls or rollers in the second direction.

Abstract: A method of riveting comprising using a punch (1) to push a rivet (9) through a workpiece (5) such that a shank (10) of the rivet (9) is received in a die (3) defined by a die body (3) which is in contact with the workpiece, a slug of material (16) being removed from the workpiece (5) by the rivet (9) and being received in the die, the method further comprising closing or substantially closing the die using a rod (4) and using the rod to upset the shank of the rivet.

Abstract: A self-piercing rivet includes a substantially cylindrical shank having an outside diameter and a head. The shank has a central blind bore that defines an inside diameter and an annular piercing end spaced from said head. The ratio of the difference between the outside and inside diameters of the shank in the region around the bore to the outside diameter of the shank is in the range 0.47 to 0.52.

Abstract: A fastener dispensing apparatus includes a body that defines a punch path and at least partially surrounds a punch that includes forward and rearward portions. The punch reciprocates between retracted and advanced positions in which the tip of the forward portion extends from an end of the punch path to drive a fastener towards the workpiece. A fastener feed path extends transverse to the punch path and is defined by a surface of the body, the fastener feed path receives an elongate carrier of fasteners. A fastener feeding device sequentially feeds fasteners along the fastener feed path and into alignment with the end of the punch path. An actuator is drivable by the reciprocal movement of the rearward portion of the punch. An engagement member engages the carrier and is moveable relative to the body.

Abstract: A method for forming a joint using a self-piercing rivet includes the steps of: positioning the sheet material over a die and providing a rivet having a substantially cylindrical shank and a head, the shank having a central blind bore and an annular piercing end spaced from said head. The ratio of the difference between the outside and inside diameters of the shank in the region around the bore to the outside diameter of the shank is in the range 0.47 to 0.52. The method also includes positioning a rivet over the sheet material at a position opposite the die and using a punch to set the rivet and force it into the sheet material such that it pierces the upper surface thereof and such that the shank deforms outwardly to interlock with the material but without penetration to the die side of the material.

Abstract: A self-piercing rivet includes a substantially cylindrical shank having an outside diameter and a head. The shank has a central blind bore that defines an inside diameter and an annular piercing end spaced from said head. The ratio of the difference between the outside and inside diameters of the shank in the region around the bore to the outside diameter of the shank is in the range 0.47 to 0.52.

Abstract: A self-piercing rivet for forming joints in high strength steel has a partially hollow shank of a particular form in order to ensure that it has sufficient column strength to pierce the material. The thickness of the shank is such that adequate joint strength is achieved with a lower degree of flare than would be necessary for conventional riveted joints. The ratio of the thickness of the shank (outside diameter minus inside diameter) is in the range 0.47 to 0.52. The ratio of the cross sectional area of the shank in the region around the bore to the outside diameter of the shank is in the range 3.0:1 to 3.6:1.

Abstract: Fasteners, such as rivets (60), are fed to a fastener insertion tool (1) via a buffer magazine (5) adjacent to the tool. The buffer is movable with the tool and C-frame (6) between an operative position where fasteners can be inserted into a workpiece and a re-filling position where it is docked at a docking station (13) to reload. Fasteners are delivered to the docking station from a source (14) and held there ready for when the tool docks. Once docked a transfer gate (25, 28) is opened at an interface between the buffer magazine and the docking station and fasteners from the docking station are transferred into the buffer magazine. The quantity of fasteners in the buffer magazine is detected and the last fastener is retained so as to support preceding fasteners loaded into the buffer magazine. Any subsequently loaded fasteners back to the docking station either under gravity, under the influence of a pressurized gas or both.

Abstract: A rivet is inserted into a workpiece by an apparatus that includes an internal roller screw linear actuator in which rotational movement of an internally threaded cylinder is converted into linear movement of a fastener insertion actuator assembly. The cylinder is driven in rotation by a servo-controlled motor. The angular velocity of the cylinder required to deliver the required energy to effect fastener insertion is calculated and the motor is first controlled to accelerate the cylinder up to the calculated angular velocity, the actuator assembly simultaneously being moved by the cylinder towards the workpiece. The motor is then controlled to maintain the angular velocity of the cylinder at not less than the calculated magnitude at least until insertion of the fastener. The cylinder stores kinetic energy by virtue of its inertia. Using this inertia to insert fasteners eliminates the need for position or force feedback control. The process allows for a rapid cycle time and the apparatus is compact.

Abstract: A die (13, 213, 313) is supported in a die holder (381) such as a frame or an adapter (18, 518) supported in a frame such that it is operational use in a material deforming operation. One or both of the die and the die holder have at least one gas passage which is substantially closed by at least part of the die. Gas such as pressurised air is directed into an end of the gas passage opposite the die via a hose (42, 542) connected to a gas source. If the die is broken or loose leak paths are available for the escape of gas past the die to or from atmosphere. A pressure sensor (41) connected to the hose detects the change in pressure of the gas and the magnitude of that pressure is used to determine the die condition. Alternatively a flow rate sensor is used to detect a change in the flow rate of the gas in order to determine the condition of the die.

Abstract: Fastener delivery apparatus for automatically selecting and delivering fasteners such as rivets to a setting tool. The fasteners are pre-loaded in a package and dispense via at least one fastener delivery tube that interconnects the setting tool to a fastener feeder device. The fastener feeder device releases selected fasteners from the package into the delivery tube. The fasteners are transportable individually or in groups in the tube from the feeder device to the tool.

Abstract: Fastener insertion apparatus comprises a nose having a fastener delivery passage and side entry port. Fasteners such as rivets are supplied to the nose via a fastener supply passage and a fastener feeder assembly. A punch reciprocally disposed for movement in the delivery passage drives a fastener disposed in the delivery passage out of the passage and into a workpiece. The feeder assembly comprises a gate that is movable between retracted and advanced positions. In the retracted position it is clear of the supply passage and the delivery passage so as to permit movement of a fastener from the supply passage to the delivery passage. In the advanced position it at least partially closes the supply passage so as to prevent movement of a fastener and it projects into the delivery passage through the entry port so as to retain a fastener, if present, in the delivery passage. Sensors are provided to detect the position of the gate.

Abstract: A rivet is inserted into a workpiece by an apparatus that includes an internal roller screw linear actuator in which rotational movement of an internally threaded cylinder is converted into linear movement of a fastener insertion actuator assembly. The cylinder is driven in rotation by a servo-controlled motor. The angular velocity of the cylinder required to deliver the required energy to effect fastener insertion is calculated and the motor is first controlled to accelerate the cylinder up to the calculated angular velocity, the actuator assembly simultaneously being moved by the cylinder towards the workpiece. The motor is then controlled to maintain the angular velocity of the cylinder at not less than the calculated magnitude at least until insertion of the fastener. The cylinder stores kinetic energy by virtue of its inertia. Using this inertia to insert fasteners eliminates the need for position or force feedback control. The process allows for a rapid cycle time and the apparatus is compact.

Abstract: A self-piercing rivet for forming joints in high strength steel has a partially hollow shank of a particular form in order to ensure that it has sufficient column strength to pierce the material. The thickness of the shank is such that adequate joint strength is achieved with a lower degree of flare than would be necessary for conventional riveted joints. The ratio of the thickness of the shank (outside diameter minus inside diameter) is in the range 0.47 to 0.52. The ratio of the cross sectional area of the shank in the region around the bore to the outside diameter of the shank is in the range 3.0:1 to 3.

Abstract: Fastener delivery apparatus for automatically selecting and delivering fasteners such as rivets to a setting tool. The fasteners are pre-loaded in a package and dispense via at least one fastener delivery tube that interconnects the setting tool to a fastener feeder device. The fastener feeder device releases selected fasteners from the package into the delivery tube. The fasteners are transportable individually or in groups in the tube from the feeder device to the tool. A transfer station attached to the tool or the delivery tube transfers a fastener from the delivery apparatus into the tool, the transfer station being moveable between a first position in which an exit of the transfer station is adjacent to the tool so that a delivered fastener may be inserted by the transfer station into the tool and a second position in which it is clear of the tool so as to permit the tool or a portion thereof to move towards a workpiece to insert a loaded fastener. The delivery tube has wear resistant elements.

Abstract: Fastener insertion apparatus comprises a nose having a fastener delivery passage and side entry port. Fasteners such as rivets are supplied to the nose via a fastener supply passage and a fastener feeder assembly. A punch reciprocally disposed for movement in the delivery passage drives a fastener disposed in the delivery passage out of the passage and into a workpiece. The feeder assembly comprises a gate that is movable between retracted and advanced positions. In the retracted position it is clear of the supply passage and the delivery passage so as to permit movement of a fastener from the supply passage to the delivery passage. In the advanced position it at least partially closes the supply passage so as to prevent movement of a fastener and it projects into the delivery passage through the entry port so as to retain a fastener, if present, in the delivery passage. Sensors are provided to detect the position of the gate.

Abstract: Fastener insertion apparatus comprises a nose having a fastener delivery passage and side entry port. Fasteners such as rivets are supplied to the nose via a fastener supply passage and a fastener feeder assembly. A punch reciprocally disposed for movement in the delivery passage drives a fastener disposed in the delivery passage out of the passage and into a workpiece. The feeder assembly comprises a gate that is movable between retracted and advanced positions. In the retracted position it is clear of the supply passage and the delivery passage so as to permit movement of a fastener from the supply passage to the delivery passage. In the advanced position it at least partially closes the supply passage so as to prevent movement of a fastener and it projects into the delivery passage through the entry port so as to retain a fastener, if present, in the delivery passage. Sensors are provided to detect the position of the gate.

Abstract: Fastener insertion apparatus comprises a nose having a fastener delivery passage and side entry port. Fasteners such as rivets are supplied to the nose via a fastener supply passage and a fastener feeder assembly. A punch reciprocally disposed for movement in the delivery passage drives a fastener disposed in the delivery passage out of the passage and into a workpiece. The feeder assembly comprises a gate that is movable between retracted and advanced positions. In the retracted position it is clear of the supply passage and the delivery passage so as to permit movement of a fastener from the supply passage to the delivery passage. In the advanced position it at least partially closes the supply passage so as to prevent movement of a fastener and it projects into the delivery passage through the entry port so as to retain a fastener, if present, in the delivery passage. Sensors are provided to detect the position of the gate.