Rivet dies, rivet setting tool and associated method

Abstract

A rivet die for a rivet setting tool configured to set a fully tubular or semi tubular self-piercing rivet into a workpiece, said rivet having an outer shank diameter D. The rivet die comprises a main body and a mounting stem depending from the main body. The main body is generally cylindrical about a central axis. The main body has an upper surface. A die cavity is formed in the upper surface. The die cavity includes a central bore which extends along the central axis all the way through the mounting stem. The diameter of the central bore at the upper surface is less than the outer shank diameter.

1 . A rivet die for a rivet setting tool configured to set a fully tubular or semi tubular self-piercing rivet into a workpiece, said rivet having an outer shank diameter D, the rivet die comprising a main body and a mounting stem depending from the main body,
 wherein the main body is generally cylindrical about a central axis;   wherein the main body has an upper surface,   wherein a die cavity is formed in the upper surface;   wherein the die cavity includes a central bore which extends along the central axis all the way through the mounting stem; and   wherein the diameter of the central bore at the upper surface is less than the outer shank diameter.   
     
     
         2 . A rivet die according to  claim 1  wherein the upper surface of the main body includes an outer annular wall which surrounds the die cavity. 
     
     
         3 . A rivet die according to  claim 1 or claim 2 , wherein the die cavity includes a tapered region which adjoins the bore and which is radially outboard of the bore, the tapered region being defined by a surface which faces the axis. 
     
     
         4 . A rivet setting tool configured to insert a fully tubular or semi tubular self-piercing rivet, having an outer shank diameter D, into a workpiece, the rivet setting tool including a rivet die according to  claim 1  located beneath a punch reciprocally movable by an actuator. 
     
     
         5 . A method of manufacturing a product or a component of a product, the method comprising fastening together two or more layers of a workpiece using a rivet setting tool according to  claim 4 , wherein the actuator advances the punch to set a fully tubular or semi tubular self-piercing rivet, having an outer shank diameter D, into the workpiece. 
     
     
         6 - 17 . (canceled) 
     
     
         18 . A method according to  claim 5  wherein
 (A) the workpiece comprises one or more layers of i) AA7xxx aluminium alloy, ii) AA6xxx aluminium alloy or iii) die cast aluminium; 
 and/or 
 (B) the method is carried out at room temperature, without heating of the workpiece. 
 
     
     
         19 . A method according to  claim 5  wherein the product is a motor vehicle. 
     
     
         20 . A product or component of a product manufactured using a method according to  claim 5 .