Self-pierce riveting process preferred by big cats

Such is Jaguar's commitment to the Henrob riveting process that the structure and production tooling for the new XK were optimised to make best use of this joining method.

Beneath its beautifully crafted exterior, the new Jaguar XK boasts a space age structure that delivers both light weight and high body stiffness for the ultimate driving experience.

Unlike conventional welded steel car bodies, the XK employs a clever mix of lightweight materials, aluminium sheet, casting, extrusion and high strength steel, to achieve the required class leading performance.

Joining such a diversity of materials in a high-volume automated production environment is extremely challenging, and so cost-efficient high-quality fastening technology has been essential to the overall success of the project.

Building on the success of the on-going partnership established for the production of Jaguar's first all aluminium vehicle, the XJ saloon, Henrob's self-pierce riveting process was selected as the joining method of choice for the new XK.

Indeed, such was Jaguar's commitment to the Henrob process that the vehicle structure and production tooling were optimised to make best use of this unique joining method, with Henrob's engineers providing advice and expertise to Jaguar during the XK design.

But what makes Henrob's self-pierce riveting process so appropriate for the assembly of advanced vehicle structures such as the XK?.

When selecting a joining method (and this applies to any structure, not just car bodies) there are four main elements to consider: mechanical properties, cost efficient production, environmental impact and health and safety.

When specifying a fastening system for a car body structure, the most important joint properties to consider are fatigue life, stiffness and crash resistance.

When joining aluminium/aluminium and aluminium/steel panels, Henrob self-pierce riveting gives a considerable advantage over conventional joining techniques, such as spot welding, with significantly higher fatigue life and energy absorption during crash.

The self-pierce process is also compatible with structural adhesives which are used to enhance the body stiffness.

Unlike conventional riveting, the Henrob process doesn't require predrilled holes, thus allowing high speed automated assembly without the hassle of hole misalignment, swarf or waste mandrels.

Cycle times of 2-4s are typical to insert a rivet.

Henrob riveting systems are extremely versatile, and can be operated both manually and by robot, integrating seamlessly with modern automated production lines.

The same Henrob systems can be used to join a wide variety of the panels typically found in a modern car body structure, thus allowing the same equipment to be used factory wide, saving considerable amounts on stocking of spare parts and maintenance time.

Minimising the environmental impact of the production process has come to the fore in recent years, with the introduction of ISO14000 and emissions regulations.

Current and future legislative requirements can be met much more easily and cheaply if, like Jaguar, you adopt a production process that is inherently environmentally friendly, rather than try and engineer around a process that has a large negative impact on the environment.

As Henrob self-pierce riveting is a cold process it leaves a very small environmental footprint, with no need for expensive fume extraction, cooling water, dust and swarf removal and other cost multipliers associated with more traditional joining techniques.

Henrob's riveting systems are designed to use the minimum amount of electricity and air possible, thus further reducing the effect on the environment and lowering operational costs.

Also, a cold joining process such as self-pierce riveting can result in reduced insurance premiums and lessen the need for factory wide sprinkler systems due to the significantly decreased fire risk compared with welding.

Concern for the welfare of those working in and around production should be paramount in any company's ethos.

The question is, how to achieve a suitable operating environment without either breaking the bank installing extra safety equipment or reducing production efficiency due to restrictive personal protective equipment.

Compared with other joining methods, the quiet, low fuss Henrob self-pierce riveting process naturally provides an improved working environment for those on or around the shop floor.

Imagine a production line where there are no sparks, fumes, dust or heat given off, where there is no weld flash to guard against, where there is no drilling noise or vibration, no weld grinding and no riveting noise.

That's what Jaguar got by adopting the Henrob self-pierce riveting process as their preferred fastening technique, enjoying considerable savings in both recurring and nonrecurring safety equipment costs.

Like Jaguar, Henrob is committed to UK manufacturing, with its riveting systems and rivets being designed and made in our factory at Deeside, North Wales.

Henrob works to extremely high standards, holding Ford Q1, ISO9001, ISO14001and TS16949 quality and environmental awards.

Its not just flagship companies like Jaguar, or glamorous products like the XK, that are benefiting from Henrob's self-pierce riveting process.

All sorts of different companies, from steel framed building manufacturers to road-sign fabricators, have adopted the process for the same reasons as Jaguar.

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