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→Solid Contact Rivets
Solid contact rivets are the oldest utilized contact parts. Their manufacturing requires a ductile contact material and is done without scrap on fully automated special cold heading machines. A wire slug is cut off and the rivet head is formed by pressing and hammering. This way contact rivets with various head configurations such as flat, domed, spherical or pointed can be manufactured, depending on the final application and switch or relay design.
*Typical Contact Shapes of Solid Contact Rivets (<xr id="fig:Typical_Contact_Shapes_of_Solid_Contact_Rivets"/>)
*Dimensional Ranges (<xr id="fig:Dimensional_Ranges"/>) <br /> The respective parameters cannot be chosen independently of each other. They mainly depend on the ductility of the required contact material. Before a final decision on the dimensions we recommend to consult with the contact manufacturer. <br />
*Qualitätsmerkmale und Toleranzen (<xr id="fig:Qualitaetsmerkmale_und_Toleranzen"/>)
<div class="multiple-images">
<figure id="fig:Typical_Contact_Shapes_of_Solid_Contact_Rivets">
[[File:Ty_pical_Contact_Shapes_of_Solid_Contact_Rivets.jpg|right|thumb|Figure 1: Typical Contact Shapes of Solid Contact Rivets]]
</figure>
<figure id="fig:Dimensional_Ranges">
[[File:Dimensional Ranges.jpg|right|thumb|Figure 2: Dimensional Ranges]]
</figure>
<figure id="fig:Qualitaetsmerkmale_und_Toleranzen">
[[File:Qualitaetsmerkmale und Toleranzen.jpg|left|thumb|Figure 3: Qualitaetsmerkmale und Toleranzen]]
</figure>
</div>
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<table class="twocolortable" border="1" cellspacing="0" style="border-collapse:collapse"><tr><th><p class="s13">Characteristics</p></th><th><p class="s13">Form A Form B Form C</p><p class="s13">Rounded headf Trapeziodal Trapeziodal head, radiused head,flat</p></th><th><p class="s13">Suggested test equipment</p></th></tr><tr><td><p class="s13">a) Head diameter d<sub>1</sub> [mm]</p></td><td><p class="s13">d<span class="s14"><sub>1</sub></span><u><</u> 4 + 0,06 During optical measurement</p><p class="s13">d<span class="s14"><sub>1</sub></span>> 4 - 0,06 disregard corner</p><p class="s13">radius R<span class="s14"><sub>3</sub></span></p></td><td><p class="s13">Comparator,</p><p class="s13">Measuring microscope</p></td></tr><tr><td><p class="s13">b) Head thickness</p><p class="s13">k [mm]</p></td><td><p class="s13">d<span class="s14"><sub>1</sub></span><u><</u> 4 + 0,03</p><p class="s13">d<span class="s14"><sub>1</sub></span>> 4 + 0,08</p></td><td><p class="s13">Micrometer, Dial indicator</p></td></tr><tr><td><p class="s13">c) Shank diameter d<span class="s14"><sub>2</sub></span> [mm]</p></td><td><p class="s13">d<span class="s14"><sub>2</sub></span><u><</u> 2 - 0,06</p><p class="s13">d<span class="s14"><sub>2</sub></span>> 2 - 0,08</p></td><td><p class="s13">Micrometer</p></td></tr><tr><td><p class="s13">d) Shank length [mm]</p></td><td><p class="s13">+ 0,15</p></td><td><p class="s13">Micrometer, Dial</p><p class="s13">indicator, Comparator</p></td></tr><tr><td><p class="s13">e) Radius at center</p><p class="s13">of contact surface</p><p class="s13">R<span class="s14"><sub>1</sub></span> [mm]</p></td><td><p class="s13">Form A und B: Within the head thickness</p><p class="s13">tolerance</p><p class="s13">Form C: Allowable deviation from flatness: convex: within head thickness tolerance</p><p class="s13">concave: 0.005 d<span class="s14"><sub>1</sub></span></p></td><td><p class="s13">Comparator,</p><p class="s13">Comparator template, Radius gage</p></td></tr><tr><td><p class="s13">f) Radius at edge of contact surface R<span class="s14"><sub>2</sub></span> [mm]</p></td><td><p class="s13">Form A: Smooth transition to R<span class="s14"><sub>1</sub></span></p><p class="s13">Form B: 1.5 R<span class="s14"><sub>2</sub></span> allowed</p><p class="s13">Form C: <u><</u>0,1d<span class="s14"><sub>1</sub></span></p></td><td><p class="s13">Profile template,</p><p class="s13">Comparator, Radius gage</p></td></tr><tr><td><p class="s13">g) Radii</p><p class="s13">R<span class="s14"><sub>3 </sub></span>and R<span class="s14"><sub>5</sub></span> [mm]</p></td><td><p class="s13">Sligth rounding allowed</p></td><td><p class="s13">Comparator</p></td></tr><tr><td><p class="s13">h) Transition radius head underside to shank R<span class="s14"><sub>4</sub></span> [mm]</p></td><td><p class="s13">d<span class="s14"><sub>2</sub> </span><u><</u> 2 R<span class="s14"><sub>4</sub> </span><u><</u> 0,08 if covered by DIN 46240 pg.1 d<span class="s14"><sub>2</sub> </span>> 2 R<span class="s14"><sub>4</sub> </span><u><</u> 0,1</p><p class="s13">d<span class="s14"><sub>2</sub> </span>> 3 R<span class="s14"><sub>4</sub> </span><u><</u> 0,2</p></td><td><p class="s13">Comparator if in doubt: microsection</p></td></tr><tr><td><p class="s13">i) Allowed deviation</p><p class="s13">from cylindrical shape</p></td><td><p class="s13">max. 7° 30’: or d<span class="s14"><sub>2</sub> </span> <u><</u> l, l <u>></u> 0,7 mm and k <u><</u> 0,6 d<span class="s14"><sub>1</sub></span>.</p><p class="s13">max. 15°: for all other rivets</p></td><td><p class="s13">Comparator</p></td></tr><tr><td><p class="s13">k) Concentricity between head and shank center line [mm]</p></td><td><p class="s13">d<span class="s14"><sub>1</sub> </span><u><</u> 4 0,15</p><p class="s13">d<span class="s14"><sub>1</sub> </span>> 4 0,2</p><p class="s13">in general: approx. 70% of allowable deviation</p><p class="s13">per DIN 46240</p></td><td><p class="s13">Comparator, Special</p><p class="s13">turn fixture</p></td></tr></table>
