Clinching tool for sheet metal joining
This is a continuation of application Ser. No. 07/930,519, filed as PCT/AU91/00120, Mar. 28, 1991 published as WO91/15316, Oct. 17, 1991 and now abandoned. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to fastening tools and in particular to a clinching apparatus for joining overlapping portions of sheet material without the need for independent fastening elements such as rivets or nails, 
     The invention has been developed primarily for use with sheet metal and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use, 
     BACKGROUND OF THE INVENTION 
     Various clinching tools are known and usually comprise a punch operable in conjunction with a complementary die to plasticly deform the overlapping portions of metal and form a clinch which fastens the sheets together. 
     One such device includes a multi-segmented die bounded by a flexible restraining band permitting the die to resiliently open during the clinching operation. In the open configuration, however, particulate debris is permitted to migrate into the clearances between adjacent die segments. Repeated use causes the die to become clogged which prevents efficient operation of the tool. 
     Known clinching tools also suffer from an additional problem in that the wall thickness of the sheet material in the vicinity of the neck of the clinch tends to be significantly reduced because of the way in which the metal is extruded into the die. In some cases, the wall thickness in the region of the clinch can be reduced by in excess of 80% of the nominal gauge thickness of the metal, which significantly reduces the maximum shear strength of the clinch. In addition, the joint so formed is highly stressed in the vicinity of the clinch and therefore more susceptible to corrosion which directly affects the longevity of the joint. In many applications, for example in the building industry, these problems have prevented the widespread commercial acceptance of clinching as a viable means of assembly and construction in sheet metal because of the resultant difficulty encountered in meeting stringent safety requirements. 
     In addition to the problems of reduced wall thickness, inadequate shear strength, and reduced corrosion tolerance, the side walls of the die in so called &#34;fixed die&#34; tools must either be parallel or diverge outwardly in order to permit release of the clinch from the die. This inherent restriction in fixed die devices limits the maximum degree of interlocking mechanical engagement between the metal sheets forming the clinch and consequently limits the maximum &#34;pull-out&#34; strength of the joint. 
     It is therefore an object of the present invention to provide an improved clinching tool which overcomes or substantially ameliorates at least some of these disadvantages of the prior art. 
     DISCLOSURE OF THE INVENTION 
     Accordingly, in a first aspect, the invention provides a clinching apparatus for joining overlapping portions of sheet material, 
     said apparatus including a top die comprising a plurality of discrete forming elements, 
     guide means adapted to force said forming elements into close abutment in a closed configuration in response to movement thereof in a first generally axial direction to define a void region bounded by an effectively continuous peripheral surface and adapted to permit the forming elements to move apart into an open configuration in response to movement thereof in a second opposite direction, 
     a centrally disposed floating bottom die defining a lower boundary of said void region and mounted for axial sliding movement intermediate said forming elements, 
     a punch selectively operable in conjunction with said dies to force the sheet material into the void so as to form a clinch fastening the said overlapping portions together and displace the bottom die in the first direction, 
     clamping means engageable independently of the punch to clamp the sheet material against a corresponding upper surface of the top die and thereby move the forming elements in the first direction to close the die, 
     and first bias means to provide a restoring force urging the bottom die in the second direction after axial displacement in the first direction and to provide an ejecting force urging the forming elements toward the open configuration upon disengagement of the clamping means. 
     Preferably, the bias means further provides an opposing force in response to axial displacement of the bottom die in the first direction. 
     Preferably, the die comprises at least two complementary collets and the guide means includes a guide block disposed within a body and defining an outwardly diverging generally frusto-conical socket. The collets together preferably define a complementary frusto-conical Outer surface slidingly engageable with the conical socket of the guide block such that movement of the collets into the socket in the first direction causes the collets to be forced tightly together into the closed configuration. Conversely, movement of the collets out of the socket in the second opposite direction permits the collets to move apart into the open configuration to release the clinch from the die. 
     The bias means preferably includes a first deformable element of predetermined resiliency disposed effectively intermediate the body and the floating bottom die. In one preferred embodiment, a second resilient compression element is disposed effectively intermediate the guide block and the floating die to provide a degree of independent relative movement between the top die, the guide block, the bottom die and the body, thereby to accommodate surface irregularities in the sheet material and provide a degree of gauge tolerance. The resilient compression means may comprise a compressible packing element formed from a suitable material such as LURETHANE, a compressible fluid, or a spring, for example. 
     In another embodiment, the bias means may include positive drive means such as an hydraulic cylinder acting in conjunction with a tapered wedge member, whereby the floating die is actively driven toward the void during the latter part of the clinching cycle thereby to &#34;flare&#34; the clinch and enhance mechanical interengagement of the overlapping sheets. 
     Preferably, the clamping means includes a press having a clamping member defining a generally annular clamping surface coaxial with the punch and cooperable with a corresponding opposed upper surface of the top die. In this preferred embodiment, selective actuation of the clamping press forces the clamping member toward the die, thereby clamping the sheet material between the annular clamping surface and the corresponding upper surface of the die. This action simultaneously drives the collets into the complementary frusto-conical socket formed in the guide block to close the die prior to independent actuation of the punch to form the clinch. In the preferred embodiment, the clamping member is formed with an outwardly protruding convex clamping surface configured to force the sheet material into the void during the clinching cycle. Preferably, the clamping surface is partially spherical and incorporates an outwardly protruding annular shoulder surrounding the punch. 
     The apparatus preferably also includes restraining means to limit the maximum axial excursion of the collets in the second direction relative to the guide block. The restraining means in one embodiment comprises a plurality of locating lugs extending inwardly from the guide block into the conical socket and engaging corresponding oversized apertures formed in the respective collets to provide a limited degree of free play in the first and second directions corresponding to the radial clearance defined between the locating lugs and the respective apertures. In another embodiment, the retaining means comprises a circlip surrounding the remote end of the die, such that the maximum axial excursion of the die in the second direction corresponds to a point at which the circlip abuts a lower surface of the guide block, which is conveniently retained with the body within an interference fit. 
     In another preferred form of the invention, the collets define a plurality of lobes or protuberances in the void such that the resultant clinch prevents relative rotation of the constituent portions of sheet material. To this end, it will be apparent that a range of non-circular die shapes such as polygonal or elliptical can be used to produce non-rotational joints. 
     According to a second aspect, the invention provides an independent multi-cylinder actuating device for a clinching apparatus substantially as described above, said actuating device including a first force exerting member reciprocably moveable by a first fluid cylinder, and a second force exerting member reciprocably moveable independently of the first member by a second fluid cylinder, an outer surface of the first member forming an inner surface of the second cylinder such that an operating volume of the second cylinder is defined partly by the first member. 
     In the preferred embodiment, the actuating device acts in cooperation with the clinching apparatus whereby the first member actuates the punch and the second member independently actuates the clamping press. The first and second cylinders are preferably hydraulic. However, it will be appreciated that pneumatic cylinders, for example, can also be used. 
     According to a third aspect, the invention provides a clinching assembly comprising a clinching apparatus substantially as described, and an actuating device substantially as described, wherein the first force exerting member actuates the punch and the second force exerting member independently actuates the clamping means. 
     The actuating device and clinching apparatus are preferably maintained in relative coaxial alignment by a generally C-shaped support frame. In an alternative configuration, however, a pair of clinching apparatus may be supported in spaced apart relationship by a generally E-shaped support frame to enable parallel flanges of a beam to be clinched simultaneously. 
     According to a fourth aspect, the invention provides a method of joining overlapping portions of sheet material in a clinching apparatus, said method comprising the steps of: 
     moving a plurality of discrete forming elements in a first direction and thereby forcing said elements together into a closed configuration by guide means to form a top die defining a void region bounded by an effectively continuous peripheral surface; 
     engaging clamping means to clamp said overlapping portions of sheet material against an upper surface of the top die and thereby retaining the die in the closed configuration; 
     operating a punch to force the sheet material into the void so as to form a clinch fastening said overlapping portions together and thereby displacing a floating bottom die in the first direction; 
     withdrawing said punch; 
     providing a restoring force urging the bottom die in a second opposite direction; 
     disengaging said clamping means; and 
     providing an ejecting force urging the forming elements in the second opposite direction towards a release configuration. 
     Preferably, the method includes the further step of providing an opposing force in response to displacement of the bottom die in the first direction. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: 
     FIG. 1 is a cut-away sectional view of a clinching apparatus according to a first embodiment of the invention with the die in the open configuration; 
     FIG. 2 shows the clinching apparatus of FIG. 1 in operation with the die in the closed configuration; 
     FIG. 3 is a sectional view showing a clinch formed with the tool of FIGS. 1 and 2; 
     FIG. 4 shows a second embodiment of the clinching apparatus according to the invention; 
     FIG. 5 is a cross-sectional view showing an alternative embodiment of the clamping member of FIGS. 1 and 2, incorporating a convex clamping surface and outwardly protruding annular shoulder; 
     FIG. 6 is a perspective view showing an alternative embodiment of the die, incorporating a plurality of lobes to form non-rotational joints; 
     FIG. 7 shows another embodiment of the clinching apparatus wherein the die is retained for limited axial excursion within the guide block by a circlip; 
     FIG. 8 is an exploded view of the punch and die assembly of the embodiment of FIG. 7; 
     FIG. 9 is a diagrammatic cross-sectional view showing a further embodiment wherein the resilient compression means incorporates a compression spring and wedge assembly operable on the floating die; 
     FIG. 10 is a cross sectional view similar to FIG. 9 but incorporating active hydraulic-mechanical drive means; 
     FIG. 11 shows an alternative embodiment of the active hydraulic-mechanical drive means of FIG. 10; 
     FIG. 12 is a cut-away sectional view showing a multi-cylinder actuating device according to a second aspect of the invention; 
     FIG. 13 is a sectional side elevation showing a clinching assembly according to a third aspect of the invention. 
    
    
     PREFERRED EMBODIMENT OF THE INVENTION 
     Referring generally to the drawings, wherein corresponding features are denoted by corresponding reference numerals, a clinching apparatus 1 for joining overlapping portions of sheet material 2 includes a top die 3 comprising a plurality of discrete mutually opposed forming elements in the form of complementary collets 5. The apparatus further includes guide means in the form of guide block 10 disposed within body 11 and defining an outwardly diverging frusto-conical socket 12. The collets 5 together define a complementary frusto-conical outer surface 15 nestably engageable with conical socket 12 of the guide block 10. In this way, movement of the top die into the socket forces the collets into close abutment in a closed configuration (as shown in FIG. 2) to define a void 16 bounded by an effectively continuous peripheral surface 17. Conversely, movement of the die outwardly from the socket 12 away from the guide block permits the collets to move apart into an open configuration as shown in FIG. 1. The sides of the socket 12 are preferably inclined at an angle of around 10° to the vertical. However, this angle can be varied to suit particular applications and material types and thicknesses. For example, with higher loads it is envisaged that an angle of around 15° would be used. 
     A selectively operable punch 20 having a domed head acts in conjunction with die 3 to force the sheet metal 2 into the void 16 to form a clinch 21 securely fastening the overlapping sheets together. The clinch 21 is released from the die by movement of the collets outwardly from the guide block toward the open configuration. 
     A floating bottom die member 22 coaxial with punch 20 is mounted for limited independent axial sliding movement within body 11 and between collets 5 to define a lower boundary 23 of the void 16. In the embodiments of FIGS. 1 and 4, the degree of axial sliding movement is passively controlled by bias means in the form of a first deformable compression element 25 of controlled resiliency disposed intermediate the body 11 and the floating bottom die 22. The resilient compression element 25 preferably has a definite end point beyond which substantially no further compressive deformation is possible, and provides a restoring force tending to urge the floating die upwardly toward the void. Similarly, a second resilient annular compression element 26 is disposed effectively between the guide block 10 and a stepped shoulder of the body 11. Resilient compression elements 25 and 26 together provide a limited degree of independent relative movement between top die 3, guide block 10, floating bottom die 22, and body 11, thereby to accommodate surface irregularities in the sheet material and provide a degree of gauge tolerance for the tool. As shown in FIG. 4, an additional compression element 27 may also be interposed effectively between the floating die and the guide block if required. 
     The resilient elements are preferably formed from a suitable material such as Lurethane which can be appropriately trimmed or &#34;tuned&#34; to provide the required degree of resilient deformation. However, it will be appreciated that various configurations of packing elements or other means such as an adjustably damped viscous hydraulic circuit, or a compressible fluid, could also be used. For example, in the embodiment of FIG. 9, the floating die is urged upwardly toward the void by a spring biased conical wedge member acting against complementary split collets abutting the lower surface of the floating die, as described in more detail below. 
     The bias means may also comprise positive drive means such as an hydraulic cylinder acting in conjunction with a tapered wedge member as will be described below in relation to FIG. 10 whereby the floating bottom die may be actively driven upwardly into the void during the latter part of the clinching cycle to increase the &#34;mushrooming&#34; effect by flaring the neck of the clinch as the sheet material is driven into the void by the punch. The positive drive means also assists in automatically releasing the clinch from the die. 
     The apparatus further includes independently operable clamping means 30 to firmly clamp the sheet material between the punch and the die during the clinching operation. The clamping means includes a press having reciprocable clamping member 32 defining a generally annular clamping surface 33 coaxial with the punch 20 and cooperable with a corresponding opposed upper surface 35 of the top die 3. Selective actuation of the clamping press forces clamping member 32 downwardly toward die thereby securely clamping the sheet material between annular clamping surface 33 and the corresponding upper surface 35 of the die. This clamping action simultaneously drives the collets downwardly into the socket 12 formed in the guide block to tightly close the die prior to independent actuation of the punch to form the clinch. 
     As shown in FIG. 5, the clamping member is preferably formed with an outwardly protruding convex clamping surface incorporating a protruding annular shoulder 37 to urge material into the void during the clamping operation and thereby enhance the strength of the resultant clinch. 
     The die also includes restraining means to limit the maximum axial excursion of the collets with respect to the guide block. The restraining means in the embodiments of FIGS. 1 and 4 comprises a pair of mutually opposed locating lugs 40 extending radially inwardly from the guide block into the conical socket 12 and engaging corresponding over-sized apertures 41 formed in the respective collets. This provides a limited degree of free play between the collets and the guide block, corresponding to the radial clearance defined between locating lugs 40 and respective apertures 41. The extreme positions of the collets relative to the guide block correspond respectively to the open and closed configurations of the die. 
     In the embodiments shown in FIGS. 7 to 11, however, the retaining means comprises a circlip 42 extending around a lower cylindrical neck portion 43 of the die. In these embodiments, the maximum axial excursion of the die in the second direction corresponds to the point at which the circlip abuts the lower surface of the guide block, which is retained within the body with an interference fit. The circlip also serves to keep the die together and operating efficiently, particularly in embodiments where the die comprises three or more forming elements or collets, such as that as shown in FIG. 6. 
     The clinching apparatus is preferably operated by an independent multi-cylinder actuating device 45 including a first piston 46 reciprocably moveable by a first hydraulic cylinder 47 and a second piston 48 reciprocably moveable independently of the first piston 46 by a second hydraulic cylinder 49. The outer surface 50 of the first piston 46 forms a common inner surface of the second cylinder 49 such that the toroidal operating volume 51 of the second cylinder 49 is defined partly by the first piston. The actuating device 45 acts in cooperation with the clinching apparatus whereby the first piston 46 operates the punch 20 and the second piston 48 independently operates the clamping member 32. Advantageously, the independence of the punch cylinder 47 in relation to the clamping cylinder 49 permits a varying depth of clinch in the overlapping sheets related to sheet thickness and material type, which again increases the guage tolerance of the tool. The actuating device and clinching tool are held in relative coaxial alignment by a generally C-shaped steel support frame 52 as shown in FIG. 10, whereby the integrated clinching assembly can be conveniently transported and used by a single operator. 
     Turning now to describe the operation of the apparatus, the overlapping portions of sheet material are first inserted between the punch and the top die as best seen in FIG. 1. The clamping press is then actuated to clamp the sheet material between clamping surface 33 of the press and complementary upper surface 35 of the top die, and simultaneously wedge the collets tightly into the guide block to close the die. The clamping action also forces the overlapping sheets together into close abutment prior to actuation of the punch to ensure that an effective clinch is formed even in the event of local irregularities or surface defects in the sheet metal. 
     With the sheet material clamped firmly in place and the die tightly closed, the punch is then actuated by the first piston 46 under the action of hydraulic cylinder 47 to force the sheet material downwardly into void 16 and outwardly into forming engagement with peripheral surface 17 of the top die thereby to form the clinch 21. It will be appreciated that the outwardly converging tapered configuration of the peripheral surface 17 of the die increases the mechanical interlocking engagement between the overlapping sheets of metal to maximise the pull-out strength of the joint. The internal void angle α (FIG. 8) defined by peripheral surface 17 is preferably in the range of around 5° to 50° to maximise the &#34;mushrooming&#34; effect, particularly in softer materials. A three or four element die such as that shown in FIG. 6 is preferred in applications requiring higher internal void angles to facilitate release once the clinch has been formed. Additionally, the clamping press prevents undesirable local distortion of the metal immediately adjacent the joint during the formation of the clinch and thereby further contributes to the resultant strength of the joint. 
     In the embodiment of FIGS. 1 and 4, the forming action of the punch simultaneously drives floating bottom die 22 downwardly in the first direction against an opposing force provided by the first compression element 25. Similarly, the guide block is provided with a limited degree of relative movement with respect to the body by means of the second resilient compression elements 26 or 27 to accommodate slight variations in gauge thickness and compliance of the sheet metal. 
     Once the clinch has been formed, the punch 20 is firstly withdrawn whereupon the first resilient compression element 25 provides a restoring force tending to urge the floating bottom die 22 upwardly toward the void against the lower face of the clinch. The upwardly directed force on the top die is reacted by the clamping assembly such that the die collets are held in the closed position. This action tends to flatten the clinch and further flare the neck outwardly within the void so as to increase the degree of interlocking engagement between the overlapping sheets and thereby maximise the strength of the joint. The clamping press is subsequently withdrawn in the second phase of what is essentially a two stage release cycle, whereby the then unrestrained restoring force provided by the resilient compression element(s) tends to urge the collets upwardly, away from the guide block and into the open configuration. This action provides an ejecting force tending automatically to release the clinch from the die. The maximum upward excursion of the collets in the second direction is limited by retaining lugs 40 acting in conjunction with respective apertures 41 which together define the open configuration for the die. 
     It will be appreciated that this arrangement provides the dual advantages of increased interlocking engagement provided by the outwardly converging tapered configuration of the void and the flaring function of the bottom die lacking in known fixed die devices, together with positive lateral dimensional control and a simple automatic release mechanism to increase the throughput in high rate production applications. This obviates the need for an independent releasing step which in some prior art devices can require a stripping force of the same order of magnitude as the shear strength of the Joint. 
     The position of the floating die, the guide block, and the collets can be conveniently adjusted relative to the body by means of threaded adjustment plug 55 to accommodate sheet metal of varying thickness. In addition, the end point of the compression provided by the resilient packing elements can be conveniently adjusted by the incorporation of tuning slots or varying the available volume into which the resilient elements can expand. 
     In the embodiment of FIG. 9, the floating die is urged upwardly toward the void by a transverse spring biased conical wedge member 62 engaging complementary split collets 63 which abuttingly engage a lower surface.