Fastener + Fixing Technology #10 by Fastener + Fixing Magazine

I ss u e 1 0 July - Se pte mbe r 2 0 1 3

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editorial

Will Lowry - Editor

In each issue of Fastener + Fixing Technology we look to focus on the benefits specific fastening technology can offer a particular market sector. Our July issue concentrates on the rail industry and includes some insightful articles that underline how fastening technology can be used for a wide variety of applications and how the technology can help improve productivity/efficiency.

rticles include how Bossard recently worked with the Swiss Federal Railways in developing a stable bolted connection for use on wheel drive systems; how Ferdinand Gross’ revolutionary FALCON 2.1 solution has put the control of C-part management back into the hands of a leading German rail manufacturer; how Flaig + Hommel’s FS-All-Steel lock nuts have been successfully applied in the European rail industry; and the benefits of Böllhoff’s ECOTECH service and how its engineers can offer technical advice to rail manufacturers and suppliers. Also in this issue, our Cover Story gives an insight into Italian manufacturer Ambrovit Srl and its commitment to provide the best fasteners for customers through its fully automated warehouse. We also have a fascinating case study from Nord-Lock on how its Superbolt range was recently used in the development of an innovative offshore gas platform that can be dismantled and relocated when necessary. In addition to this we have a report from the recent Fastener Fair India show; the latest developments in sheet metal fastening; as well as an insight into NORMA Group’s new business area – infrastructure – and how it focuses on the requirements of the construction, sanitary, heating and air-conditioning sectors.

Contents

www.fastfixtechnology.com Group Publishing Director Jamie Mitchell info@fastfixtechnology.com Editor Will Lowry editor@fastfixtechnology.com Executive Editor Phil Matten Assistant Editor Claire Edwards Senior Advertising Executive Harry Whyte harry.whyte@fastenerandfixing.com Senior Advertising Executive Claire Lake claire.lake@fastenerandfixing.com

Production Manager Andy Clow andy.clow@fastenerandfixing.com

Cover story A question of screws (and more)..........................12-13

Disclaimer

Market focus - Rail Bossard puts rail company back on track................ 14 Even more precise, smarter and faster.................... 16 FS-All-Steel lock nuts for the railway industry........ 18 Böllhoff - Partner of the railway industry................. 20 Lederer offers secure assembly................................ 22 DIV Group - On the right track................................... 22

14-22

Exhibitions Fastener Fair India report..................................... 24-26 Sheet metal fastening Quality engineered fasteners.................................... 28 Welding studs and RIV1066....................................... 28 Double-sided tape for sheet metal fastening.......... 29

The Publisher cannot be held responsible or, in any way, liable for errors or omissions, during input or printing of any material supplied or contained herein although the utmost care is taken to ensure that information contained is accurate and up to date. The Publisher also cannot be held liable for any claims made by advertisers or in contributions from individuals or companies submitted for inclusion within this publication. The opinions expressed are not necessarily those of the Editor or Fastener Fairs Limited.

Thread forming technology Design engineering assistance with EJOT®............. 32 Direct screwing in one step....................................... 34

Entire contents copyright © Fastener Fairs Limited 2013. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without the prior permission of the publisher.

Features NORMA Group’s infrastructure business gains momentum................................... 30-31 Nord-Lock - Opening up new fields.....................36-37

Advertisers index....................................................... 42

Tel: +44 (0) 1727 814 400 Fax: +44 (0) 1727 831 033

Advertising Executive Emiliano Pagliaroli emiliano.pagliaroli@fastenerandfixing.com

Industry news Latest fastener industry news................................ 6-10

Product news.........................................................38-42

Part of the Mack Brooks Group Romeland House, Romeland Hill, St Albans, Hertfordshire, AL3 4ET, UK

28-29

4 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

Fastener industry news

NORMA Group earns Ford Go Further award Ford Motor Company hosted its 15th annual World Excellence Awards (WEA) ceremony to celebrate 47 of its top-performing global suppliers of 2012. During the event, NORMA Group was recognised with the Go Further award for its contributions to the Evonik fire recovery and emergency resourcing actions.

ccording to Ford, the tireless work and assistance of the suppliers recognised with this award helped minimise production disruptions at Ford during a time of hardship. “Our global team demonstrated great commitment, customer focus and creativity during this challenging event,” said Werner Deggim, CEO of NORMA Group. “We are very proud to receive this award on behalf of the NORMA Group employees who helped to mitigate the crisis with great dedication.” Following the incident that occurred in March 2012, NORMA Group instantly formed a global team of sales, engineering, purchasing, quality, logistics and operations experts to identify and implement solutions in cooperation with customers and suppliers in order to avoid interruptions in vehicle production.

Sunseeker is an iconic, global brand synonymous with the ultimate in marine luxury. From the overall design of the boat’s hull and the high-performance of its powerful engine to the exquisite craftsmanship of the interior and the quality of its tiniest components, Sunseeker is always in the pursuit of excellence and innovation.

ne of Sunseeker’s key supply partners is TR Fastenings, with which it has worked closely for many years. A manufacturer and supplier of industrial fasteners and fixings, TR Fastenings is well positioned to supply Sunseeker with a vast range of fasteners and chandlery fittings. TR Fastenings prides itself on the service and support it is able to offer and works closely with Sunseeker to help save time and reduce costs. “We aim to tailor the most efficient solution for Sunseeker,” explains Jerry Howe, general manager of TR Fastenings’ marine division. “Whether for boat fastener kits for gearboxes, exhausts, trim tabs and water inlets, brass buzz bars for the electrical division, chandlery fittings or small value, ‘high hassle’ items such as brackets, caps and hinges.” Corrosion is a major consideration too and TR is able to supply Sunseeker with suitable non-corrosive parts, including a new MT3510 organic finish black screw – with the benefit of a 240 hour salt spray test for protection. Similarly, TR’s

6 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

Sunseeker and TR partnership

The team managed to quickly detect alternative materials, obtain the required approvals and introduce these options onto the market. Consequently, NORMA Group continued to meet its customers’ requirements at all times following the event. “We want to recognise those suppliers who have demonstrated excellence despite the unforeseen challenges that have happened over the past year,” said Mark Fields, chief operating officer of Ford. “Thanks to your unwavering commitment, we are closer than ever to reaching our goal of delivering profitable growth for all.” The WEA honours production and non-production suppliers. The award-winning suppliers represent thousands of employees across the globe who bring diverse cultures, values and ideas to Ford. www.normagroup.com

new range of strong, lightweight and non-corrosive plastic cable management and wiring accessories provide the ideal water resistant solution for Sunseeker. Manufactured in highperformance and versatile nylon 6 and nylon 6/6, TR’s plastics range includes UL-approved nylon cable ties, push mounts and screw mount cable ties, knot ties and releasable cable ties. In addition, TR offers a range of self-adhesive and push mount plastic fasteners and standard injection-moulded fasteners. “TR’s marine division, based in Poole, Dorset, is ideally situated to service the Sunseeker sites with fasteners and other add-on products,” comments Nick Low, procurement manager at Sunseeker International. “Its portfolio has grown with the business to become one of our key suppliers, and with its product knowledge and direct support of our staff at all levels, it meets our demanding production needs. We rely on TR, not only to supply our production fasteners, but also special and bespoke parts that can often make a huge difference.”

Fastener industry news

Lesjöfors acquires Slovakian spring manufacturer Lesjöfors has signed an agreement to acquire the Slovakian spring manufacturer Centrum B – which has a broad base of customers mainly in the automotive business.

esjöfors is one of the largest spring manufacturers in Europe and in 2012 had sales of approximately 175 million euros. Lesjöfors operates in Sweden, Norway, Finland, Denmark, the UK, Germany, Slovakia, Latvia, Russia, China and Korea. Centrum B´s sales in 2013 are expected to be approximately 1.5 million euros, with the company having approximately 25 employees. Centrum B will strategically complement primarily Lesjöfors´ German companies, which thanks to the acquisition will get a qualified spring producer in an attractive cost position as a partner. Centrum B’s production area includes wire springs and wire forms. Kjell-Arne Lindbäck, CEO of Lesjöfors, comments on the acquisition: “This acquisition strengthens Lesjöfors´ position in Germany and central Europe. With Centrum B in our Group, a competitive business with high growth potential is added.”   For Centrum B the acquisition means that the company gains access to new market channels and a strong expertise through Lesjöfors’ global organisation. Ján Macuha, CEO and previous owner, comments on the sale: “The network of expertise within the spring market and access to a global sales organisation within the Lesjöfors Group will further strengthen Centrum B’s market position and significantly increase our growth.” www.lesjoforsab.com

Threaded inserts for marine industry Tappex UK is able to supply two families of threaded inserts, both self-tapping, that can be used for a wide variety of applications found in the marine industry.

he first family of threaded inserts is the Tappex Trisert-3 which is available in two grades of stainless steel - 303 (A1) and 316 (A4) - both of which are passivated as standard. The Trisert-3 employs three cutting facets that provide balanced cutting forces to ensure a consistent, robust installation process. The reduced head design offers an increased bearing surface over which the application torque may be spread whilst helping to ensure the correct orientation. Recently 6270M6-316 and 6270M10B-316 were specified for racing yachts competing in the Volvo ‘round the world’ series. In addition to its corrosion resistant properties this blind variant was chosen to eliminate the chance of swarf becoming trapped in the internal thread. For this application the product can be installed by hand or with a tapping head into filament wound glass fibre using the Tappex Production Driver. The second family of products is Tappex Foamserts, which are made from brass (in itself having some reduced corrosion performance) with a coarse, external truncated thread form and internal thread (either Metric M2.5 to 8mm or Unified Standards are available). Typical applications include medium and high-density foams, woods and some laminated polymer constructions. This makes them suitable for the internal furniture and decor of sailing boats and pleasure crafts. During the installation process the cutting action of self-tapping inserts results in slight outward stress. Tappex says this is reduced to an absolute minimum with the Foamsert and enables the insert to be used where there are thin walls. The balanced cutting load of the Foamsert also reduces side thrust caused by predominantly only one cutting edge. This has the effect of guaranteeing much closer axial alignment of the insert in the hole.

8 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

Single source solution Harrison Silverdale is currently working in partnership with a leading automotive moulder on a new battery box application for a major UK automotive manufacturer.

he box houses a battery that powers a compressor for the self-levelling suspension system in the rear of the vehicle. It consisted of an inner and outer moulding, a large steel pressing and a heat shield. After receiving basic CAD models of the fixings Harrison Silverdale refined the designs and returned them for approval. Due to the different materials and the configuration of the box, the range of fixings was quite diverse. They included two different M6 brass inserts, two sizes of compression limiters, a large diameter flat washer, a push on fix and an M6 x 30 bolt. Harrison Silverdale’s extensive product range meant it was able to supply all the component parts to its customer - providing them with a single source solution. Harrison Silverdale points out that only two of the seven fixings for the application were standard - the bolt was changed so an existing part could be utilised and a push on fix to hold the heat shield in place. As development progressed it became apparent that standard M6 brass inserts would not withstand the high torque requirement. Harrison Silverdale therefore developed two bespoke inserts with oversized bodies. The compression limiters also had to be designed due to the special geometry. Prototype samples were manufactured and submitted for testing until the final designs were signed off and bulk production could commence. The project was completed within the tight time constraints ready for the vehicle launch at the end of 2012. www.harrisonsilverdale.com

www.ambrovit.it

evolving Technology

Ambrovit is one of the most bigger stockist of screws in Europe of HEX LAG SCREWS

NUTS, WASHERS, BOLTS

CHIPBOARD SCREWS

THREADED RODS

DRYWALL SCREWS

TAPPING SCREWS

DOME SCREWS

DRILLING SCREWS

AND EURO SCREWS MACHINE SCREWS

PVC SCREWS S.S. A2 SCREWS

Ambrovit is one of Europe’s largest wholesale distributors of chipboard, self-tapping, self-drilling screws and bolts. Thanks to its new automated warehouse, Ambrovit is now able to store around 22.000 ready-to-ship pallets as well as offer a Special Service to guarantee quick delivery.

BLOCKFRAME NEW PRODUCTS 2O13

SELF DRILLING

STANDARD PRODUCTS 2O13

CARPENTRY

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Ambrovit S.p.A. Via Giulio Natta, 29 - 27026 Garlasco (PV) Italy Tel. +39.0382.810280 Fax +39.0382.1760014 email sales@ambrovit.it

Fastener industry news

Maintenance-free BobTail used in wind turbines Lockbolts manufactured by Alcoa Fastening Systems (AFS) have been selected for use by German steel construction specialist Butzkies GmbH in the production of three new wind turbine towers.

t a height of 100m each the towers will be built using the maintenance-free Huck ® BobTail system with the aim of providing durability, stability and a reduced lifetime cost in comparison to conventional threaded fasteners. Mechanical anchoring and fastening elements are particularly exposed to extremely high vibration in wind power plants. The tension on the wind turbine tower increases significantly the taller it is, even to the point where gusts of wind could cause the entire structure to start swaying. (l - r) Alexander Petri, Detlef Bengs, managing director of Butzkies Stahlbau GmbH, explains: key account sales manager, “No conventional threaded fastener is permanently resistant to extreme Alcoa Fastening Systems and mechanical tension or vibration. Threaded fasteners loosen over time which can Detlef Bengs, managing director culminate in considerable problems with a wind turbine tower. To fully comply of Butzkies Stahlbau GmbH with the regulations for operational stability, the threaded fasteners must be repeatedly checked, re-tightened and, if required, replaced. This can cost the operator large sums of money over the years. From the start, we wanted to avoid this problem with our tower construction. This is why we took a deliberate decision not to use conventional threaded fasteners and alternatively to build our test plant by fitting the Huck BobTail Lockbolts from Alcoa Fastening Systems.” To ensure the idea was subject to the appropriate rigorous tests, Butzkies GmbH constructed a special 61.5m tower, which was fitted with a total of 4,360 Huck BobTail Lockbolts. Alcoa says its Huck BobTail fastener can be installed approximately 75% faster than comparable conventional threaded fasteners and as a result reduced the prototype’s construction time by approximately 14 hours. In addition, the clamp force of the Huck BobTail system is very high, predictable and extremely reliable. This added value eliminates time-consuming and high-cost maintenance work, currently 15,000 euros per annum for a large wind turbine tower at 130 metres high.

Spirol provides solution for military vehicles Spirol Industries has provided a quick delivery of adjustable shim packs for the spacing of armoured vehicle door hinges for a military vehicle manufacturer.

his spacing is critical to the welding process, providing proper sealing and locking engagement of the door systems. The customer designed an adjustable shim pack based on surface bonded shim material requiring 94 layers of 0.05mm thick laminates, however due to the size and configuration of the parts, surface bonded materials were problematic in cost. The amount of time needed for dimensional adjustment, as well as a long lead-time required for manufacturing also needed adjusting. Spirol’s application engineers worked with the manufacturer to determine the required adjustment and developed three edge-bonded shim set proposals. The advantages were evaluated and a proposal offering safe, quick adjustment, a 70% cost reduction and a short manufacturing lead-time was selected. The solution was provided without tooling cost using Spirol’s tool-less manufacturing technology. Spirol offers free samples and application engineering support. The company’s application engineers will review a customer’s application needs and work with its design team to recommend the best solution.

10 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

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COVER STORY

A question of screws (and more) For 16 years Ambrovit’s goal has always been the same - to provide a wide ranging clientele a total supply service, ensuring added value beyond the traditional business relationship with the supplier, with commitment and a serious approach.

ounded in 1997 by two managers with years of experience in nuts, bolts, and screws, Ambrovit, based in Garlasco, Pavia, Italy, is confident that it is currently a leading player in fastening systems. Why? Paired with the quality of its products, the service it offers is the decisive factor - prompt delivery and exceptional focus on the needs of the customer.

and for merchandise translation. Here, a modern building is home to the management, sales, and administrative offices. The advantages of the new centre? Greater simplicity and efficiency. In fact, the Garlasco facility also boasts a fully automated weighing and storage system that allows for optimum logistics management, ensuring the utmost efficiency in operations, both on a daily basis and in emergency situations.

A technological facility

Various products

Today Ambrovit’s facility covers 12,000m², 6,000m² of which are occupied by warehouses. The company recently opened a completely automated warehouse - 28 metres high, for storage capacity of 22,000 pallet places and 1,400 pick rows. It is a technological space in which two automated Bilwinco packing lines operate with a daily capacity of 18,000 boxes - destined for customers in every sector from the furniture industry to manufacturers of doors and windows, as well as wood carpentry, joinery, metal structural work and garden furniture.

Ambrovit produces a wide range of products, both in terms of the types of screws and bolts it offers and in terms of finishings and galvanising processes. Today, the catalogue offers accessories for fasteners, hex lag screws, screws for wood carpentry, chipboard and drywall screws, dome screws and Euro screws, machine screws, nuts, washers, bolts and threaded rods, tapping screws, drilling and S.S. A2 screws, as well as carbon steel fasteners (PVC-UP windows). These products range from 2mm to 30mm in diameter and from 4mm to 600mm in length. Each item is manufactured with specific steels depending on their type, and use, and undergo a range of processes including a carbonitriding heat process that helps the screws penetrate hard materials. Ambrovit can also offer galvanisation to confer colour and resistance to atmospheric agents, including trivalent white zinc coating in accordance with European Directive RoHS 2011/65/CE (Restriction of Hazardous Substances Directive) – yellow and black zinc coating is available from stock. Cosmetic bronze-plating, nickel-plating and brass-plating treatments are also available. The special RUSPERT 1,000 hours treatment will soon be available for wooden carpentry screws. This three-layer non-organic ceramic coating delivers advanced resistance to corrosion. In addition to guaranteeing up to 1,000 hours of resistance in salt fog in accordance with ISO 9227, this finish also improves the performance of the screw. Special zinc finishes are also available upon request, offering advanced resistance of up to 380 hours in salt fog.

Storage systems The new logistical offices, built in 2009, also made it possible to improve the control and storage of large quantities of material, making it easier to handle orders

12 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

“ At Ambrovit the concept of quality touches every area of the company. The new lab features the latest generation of tools for quality control and the most sophisticated software, underlining Ambrovit’s commitment.”

Packaging and logistics Product packaging plays a pivotal role at Ambrovit with items boxed internally to ensure quality in this area. All products in the catalogue are packaged in corrugated cardboard boxes printed with labels identifying the product, bundled or delivered loose in 20kg cardboard boxes, in polypropylene sacks or in recyclable plastic bags up to a maximum of 1kg.

Looking abroad Ambrovit is increasingly open to foreign markets, thanks to its participation in international fairs, including Fastener Fair Stuttgart, Hannover, Russia, Batimat in Paris, and Eisenwarenmesse Köln. These are all opportunities that have allowed the company to take on a leading role worldwide, opening itself to new importing countries. These include: Germany, France, the UK, Spain, Portugal, Greece, Belgium,

Russia, Slovenia, Croatia, Hungary, Romania, Bulgaria, Slovakia, the Czech Republic, Poland, Estonia, Lithuania, Latvia, Albania, Macedonia, Sweden, Denmark, Austria, Bosnia Herzegovina, Cyprus, Montenegro, Morocco, the Netherlands, Switzerland, and Tunisia. Growth in Europe has seen exports increase to 40% of current sales.

The future for Ambrovit “Professionalism and a serious approach will continue to be the company’s prime features. Over the years the company will continue to grow the level of its service and strengthen its presence to respond to the new challenges posed by national and international markets. It will continue to hold its name high. Our motto remains – ‘We’re by your side in the world of fasteners’.” www.ambrovit.it

It’s all certified At Ambrovit the concept of quality touches every area of the company. The new lab features the latest generation of tools for quality control and the most sophisticated software, underlining Ambrovit’s commitment.

n 2011 Ambrovit earned Quality Management System Certification in accordance with ISO 9001:2008. Periodic oversight audits performed by TÜV on all manufacturing processes also guarantee compliance with all requirements of the international standard. Other certifications include European standard 14592, which dictates all the size

parameters, tests to conduct, and quality control methods that the product must satisfy to be declared compliant and receive the CE mark. During the quality control process for incoming products, Ambrovit also conducts various checks and tests in its internal laboratory, and in addition works in collaboration with mechanical and structural engineering department

laboratories at the University of Trento. On the Russian market, Ambrovit has also earned the Gost R certificate of conformity, demonstrating its compliance with essential safety requirements. Also for the Russian market, Ambrovit has earned certification from the Russian Association of Wood Housing.

www.fastfixtechnology.com

RAIL

Bossard puts rail company back on track The Swiss Federal Railways (SBB) was faced with challenges to stabilise its system of bolts that were causing high maintenance and downtime costs.

riginally hexagonal bolts had been used - type DIN 931, 10.9, M12 x 140. The bolts were applied in the wheel drive system and due to the load that was applied, transverse to the bolt axis, the bolts became instable after a short time in use. Even though there was no security risk at any time, SBB was highly interested in finding an efficient solution. After analysing the reasons for the problem, the engineering teams of SBB and Bossard AG worked in very close cooperation to develop a stable bolted connection that also increased functional safety. Various solutions were originally considered - for instance using dowel pins to improve the force transmission, but since the spare parts need to be interchangeable, this turned out not to be the optimal approach. Finally, the solution was the use of a bolt with waisted shank, which had a lot of advantages. There is a low level of loss in tightening force when setting up the connection. That leads to considerable security against it coming unscrewed by itself. The low level of sensitivity to bending reduces the additional forces that occur during thermic strain. Also its ability to change shape plastically ensures a high degree of safety when tightening up over and beyond

14 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

the yield point. Optimised mating surfaces mean that the torsional or transverse stresses in the waisted shank can be eliminated. Finally, the durability is substantially greater than for conventional standard bolts, even under a vibrating load. “Since we have used bolts with waisted shank, we have increased the availability of the locomotives,” says Hans-Peter Luethi, strategic purchasing at SBB. “At the same time, we could significantly reduce maintenance and repair costs.” Furthermore, the bolts with waisted shank prevent displacement against each other. A larger diameter in the segment under load leads to increased shearing resistance. The elastic thin shaft guarantees high safety when tightening beyond the yield point. Moreover there is no loading on curves in the area of the thread and head. www.bossard.com/ffm

A Bossard bolt with waisted shank

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We contribute to your success with our expertise in the following areas: • Productivity enhancement through proactive design and development collaboration • Efﬁcient processes thanks to intelligent fastening solutions • Lean supply chain with ship-to-line solutions Call us today for a consultation or visit us online at: www.bossard.com/ffm

rail

Even more precise, smarter and faster The fastening specialist Ferdinand Gross has further developed FALCON, its revolutionary solution for integrated C-part management, and is now sending Release 2.1 into the market.

erdinand Gross introduced FALCON at the end of 2012, stating that it took Kanban systems to a new level, by offering its customers a new powerful control instrument. The FALCON software solution visually displays where a certain C-part is located in the relevant Kanban shelf. It enables absolute visualisation of all Kanban storage locations together with all products and data – via PC, iPad and now also via smartphone. The operator simply enters the article number or article designation in the system, and FALCON will immediately show the user where the relevant C-part is located – even three-dimensionally. In addition to this, users can display the entire delivery chain with FALCON. “With this intuitive tool, Ferdinand Gross has returned overview and control of C-part management to the purchaser – and thus not only closed a gap existing for 50 years in the Kanban system, but at the same time has precisely met the needs of its customers.” Deutsche Bahn AG, which has been exclusively supplied by Ferdinand Gross with fastening parts since summer 2012, immediately implemented the FALCON system.

Release 2.1 opens up completely new possibilities Ferdinand Gross has, however, not rested on this positive feedback – it has continued to further develop the software and will continue to do so in the future. Its current development is Release 2.1, which has now been launched as a new milestone, with the update opening up completely new possibilities. Thanks to the Microsoft Excel export function in FALCON 2.1, the purchaser can now control use of their C-parts even more purposeful and effectively. This is done with the help of individually designed filters. Statistics, evaluations and a quick response to demand peaks no longer present a problem owing to the evaluation profile – and for this, all data from consumption via handling and up to the price have been made completely transparent. This is in-line with Ferdinand Gross’ philosophy that all data, especially those from a C-part management system, belong to the customer and not to the supplier. This data in particular is one of the most important foundations to be successful in the market. Further highlights of the new Version 2.1 include: • Apart from covering additional demands, it is now possible to deactivate bins and filling quantities. • The extended search function enables targeted access to a suitable product - saving both time and energy, above all in case of shelves with comprehensive product ranges. • With the variable _*_, it is possible to search for related parts saving cost by using already existing parts and avoids creating similar parts anew.

Advantages for quality management and construction Ferdinand Gross underlines that quality managers and designers will also benefit immensely from the extended possibilities now offered by FALCON. Release 2.1 means that

16 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

quality managers/designers now have complete access to drawings and testing results – extensive searches and time-consuming inquiries are therefore a thing of the past. In its role as a reliable service provider, Ferdinand Gross will provide its complete data management system to its customers via FALCON – a mouse click is all they need to download the required data. In addition to this customer drawings can be visualised instantly – a valuable tool when the right article for the relevant purpose has to be found rapidly. Furthermore, the storage locations can be mapped by means of real-time images enabling a more transparent analysis of the actual state.

The customer retains control A new and very extensive logging function in Release 2.1 guarantees transparent representation of all functions and actions used. This is to ensure that the customer is able to manage the entire system themselves and has the ability to create their own users for C-part management. “One aspect of online based systems that is often perceived by the customer as a disadvantage is anonymity. Quite often the direct contact between customer and consultant is missing,” explains Thomas Erb, managing director at Ferdinand Gross. “However, this is not the case with FALCON 2.1. The new system even complements personal contact since the consultants are visualised by means of a picture – the customer thus knows instantly with whom they are dealing with.”

Now via smartphone An additional benefit to FALCON 2.1 is the availability of an App for smartphones – both for iOS and Android. This means that the customer is always informed about the state of their Kanban bin no matter where they are. The barcode label is scanned and then the coordinates of the bin are visible. In addition to this, all master data of the article together with the relevant consumption and history data are displayed. Furthermore, the original label and an image of the article can be shown on request as well. “Whether in the office or on the road – with FALCON 2.1 C-part management becomes even more precise, smarter and faster.” www.schrauben-gross.com

FIRST-CLASS CONNECTIONS

„Finding instead of searching“: a new dimension of Kanban At Deutsche Bahn AG, safety comes first. As a result, all locomotives and rail cars are regularly dismantled and all connecting parts replaced. Since Summer 2012, Ferdinand Gross has been sole supplier of Deutsche Bahn AG, guaranteeing their smooth supply of high-quality C-parts. Kanban at the highest level – FALCON 2.1 lets the Swabian company show its impressive innovation and

competence. Ferdinand Gross has brought the Kanban system to a new level with FALCON, putting a powerful instrument of control into its customers‘ hands: This unique software solution provides a visual representation of which C-part is where and on which Kanban shelf. „Finding instead of searching“ is the motto now – even on the tablet PC or smart phone.

Curious? Get in touch with us: Ferdinand Gross GmbH & Co. KG | Daimlerstraße 8 | 70771 Leinfelden-Echterdingen +49 711 / 1604-1653 | info@schrauben-gross.com | www.schrauben-gross.com

FS All-Steel Lock-Nut

OUR CORE COMPETENCE IS SAFETY!

FS-All-Steel lock nuts for the railway industry For more than 20 years, FS-lock nuts from Flaig + Hommel have been successfully applied by the European railway industry.

Fastening problems with dynamically highly stressed threaded joints have lead to the development of the FS all-steel lock-nut. It has a flexible and completely threaded locking element which is fitted into the nut body. Double safety – the locking element works both in radial and axial direction.

Flaig + Hommel GmbH | Verbindungselemente Heerstraße 1 | D-78554 Aldingen | Tel.: +49 (0) 7424 - 962-0

www.flaig-hommel.de

he FS-lock nuts are made up of two parts. The locking disc acts in both axial and radial direction and provides maximum security against loosening of the nuts - even under the highest dynamic stress. Right from the first generation, all ICE trains have been equipped with FS-All-Steel lock nuts. The nuts are applied at the bogie, the brake systems and to attach a variety of components. In the early 1990s, the DB - German Railway AG carried out an extensive study testing the effectiveness of locking devices for screwed connections. The results led to a ban of many ineffective locking devices and a reassessment of the product range. A selection of only a few, but verifiably highly effective safety elements were approved - including the FS-All-Steel lock nut. Flaig + Hommel says that this marked the beginning of the triumphant success of the FS-lock nut. Other national railway companies followed suit and certified the lock nut including the Netherlands, Belgium, Denmark, Switzerland, Austria, Italy, Croatia, Hungary, the Czech Republic, Poland, Spain and many others. Companies such as Siemens, Alstom, Bombardier, Stadler, Skoda and Transmash Holding apply the FS-lock nuts in locomotives, carriages, passenger cars, trams and metro trains. Flaig + Hommel points out that the FS-lock nut’s simple assembly and maximum safety even in situations of high dynamic stress convinced the designers, the responsible personnel in the workshop and the train operators. Knorr-Bremse, Faiveley, SAB Wabco, Dako-Bremse, Ibre and other major manufacturers of brakes also rely during the assembly of their brakes and brakes discs on the safety of FS-All-Steel lock nuts. www.flaig-hommel.de

rail

Böllhoff – Partner of the railway industry Böllhoff is a supplier and international service provider for fastening and assembly technology and a recognised partner to railcar manufacturers and their suppliers.

n order to remain competitive, railway operators have to be able to transport more and more people and goods with ever greater speed, reliability and efficiency. This, in turn, increases the performance and specification of the rail vehicles and transport systems. Project related business, with individual customers involving highly complex technology and relatively low batch sizes, reflect the particular challenges of the railway and transportation industry. At the same time, global competition brings immense pressure on costs and innovation. Therefore, technological potential and innovative ability ultimately determine the success of railcar manufacturers and their suppliers. The Böllhoff Group adopted these challenging guidelines early on and says it was one of the first companies in the

world to be IRIS-certified. This distinction represented another major milestone for Böllhoff in its systematic quality management programme.

Böllhoff develops the perfect solution The Böllhoff ECOTECH service (Economic Technical Engineering) enables railcar manufacturers and suppliers to benefit from technical advice from Böllhoff’s engineers. Their know-how and advice covers all areas of fastener technology, corrosion protection and screw retention for the railway industry. Böllhoff explains that the simultaneous standardisation and optimisation of fasteners in the development stage simplifies assembly and reduces tool costs. In view of the ever faster technological development and the

increased competitive pressure, this service is a crucial advantage in the railway industry. Successfully implemented projects include a newly developed element that increased the assembly productivity at a full-service provider of railway technology and services. Another project included the worldwide market leader in rail transport sector and the use of riveting technology, which revolutionised the whole roof construction. “Ever shorter product cycles, the use of new lightweight and environmentally friendly materials and an ever changing division of labour require innovative capacity and a high degree of flexibility. Future-oriented and safe mobility sets high technological requirements, which Böllhoff, as a specialist in fastening technology, follows.” www.boellhoff.com

“ …simultaneous standardisation and optimisation of fasteners in the development stage simplifies assembly and reduces tool costs…” 20 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

Efficient and secure

RIPP LOCK® screw lock ■ Excellent locking against self unscrewing ■ Easy assembly and removal – multiple re-use ■ No considerable setting ■ Economic benefits due to reduction and standardization of parts ■ Available from stock

Phone +49 (0)5 21/44 82-629 dlv@boellhoff.com

rail

Lederer offers secure assembly Lederer says that its railway engineering product spectrum provides all the elements that are required in secure assembly and long-term deployment for track and overhead contact line construction, bogies, superstructures and rail automation.

ll the fastening technology necessary for applications in the railway industry can be supplied within the company‘s overall programme. This includes parts that are in accordance with DIN and ISO standards, as well as customised fasteners and special parts manufactured in accordance with prototypes and drawings. “Renowned customers from a variety of railway engineering segments all over the world have put their trust in Lederer and have done so for many years. This is because of our conscientious cultivation of business relationships. Our yardstick is customer satisfaction – with a view to long-term collaboration, and reciprocal trust, geared towards optimum service and the fulfillment of customer’s procurement needs.” Lederer’s range contains a wide range of fasteners and clamps suitable for all

areas of railway engineering, taking into account the specific requirements that prevail in the industry. Lederer can offer much more than just fasteners, it can also supply many services on request. Lederer can offer mechanical processing, coating, bolt and screw locking, and finally meticulous quality assurance. Lederer points out that in many applications areas, maximum precision is indispensable. In the production of electronic and fine mechanical components, for example, preference is given to totally burr and chip free articles. As this state cannot always be guaranteed by the usual production and control processes, Lederer offers the alternative option of the most stringent quality assurance possible. Articles with L-Precision are subjected to a 100% control procedure; every part in a delivery, without exception, is examined and any foreign material present is removed.

All incoming and outgoing parts undergo systematic quality control and appraisal. Physical and chemical properties are investigated and compared with the requirements using modern measuring equipment. The DGQ-trained employees in Lederer’s in-house testing department have state-of-the art tools for quality assurance at their disposal. The diverse spectrum encompasses mechanical measuring devices such as micrometers, depth gauges and plug gauges, material testing apparatus and projectors, and the latest x-ray and spectral analysis devices. All measurement and test results are documented in a software solution developed especially for this purpose. Lederer says that these permanent tests force its suppliers to deliver nothing but high quality products, as Lederer does not collaborate with any manufacturers that fail to reach this standard. www.lederer-online.com

On the right track DIV Group is specialised in processing, manufacturing and trading fasteners, other machine parts and products in south east Europe.

IV Group has a dedicated production site specialising in railway accessories such as: • Spike screws for wooden and conrete sleepers. • Coach screws. • Fishplate bolts and other bolts with various types of protection. • Elastic clips SKL1, SKL1A, SKL2, SKL12, SKL MD, K-clamps, flat ring washers, as well as single and double spring washers.

DIV is also able to offers customers Fishplate for 60E1, 49E1, fishplates for isolation joints, Ribbed base plates for rails type 60E1 and 49E1, with or without inclination, tram rails, crane rails, light rails, as well as rolling stock components - buffers, draw gears, truss rods, and light railway machinery. DIV Group points out that it also has a factory for concrete sleeper production in Svrljig, Serbia, which has helped strengthen its position in railway track accessories production. The DIV Group portfolio also includes plants for hot and cold forming, sheet metal processing and other light constructions, as well as machined part processing. www.divgroup.eu

22 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

Firmly in place: C-parts to get you from A to B. Fasteners for railway engineering. Normed and standardized parts DIN, ISO and in-house Stainless steel, regular steel and non-ferrous metals Special parts and special materials C-parts management

www.lederer-online.com

exhibitions

Busy aisles at Fastener Fair India The second edition of Fastener Fair India closed its doors after two days of busy aisles, demonstrations and business meetings.

eld at the Bombay Exhibition Centre in Mumbai from 17th – 18 th April the show, organised by Inter-Ads – Brooks Exhibitions (India) Pvt Ltd, presented a range of industrial fasteners and fixings, assembly and installation systems, and fastener manufacturing technology to the distributors, suppliers and end users in the Indian market. More than 130 exhibitors filled the Fastener Fair aisles with India and other Asian countries, such as Taiwan and China, as well as German and Italian companies, representing the majority of exhibitors at the show. Whilst most stands were predominately ‘shell-scheme’ there were some very impressive ‘space-only’ stands. Kadimi International Pvt Ltd and Agarwal Fasteners Pvt Ltd dominated the front of the hall with two imposing

stands. On the Kadimi International stand was a Chun Zu machine (Kadimi International is Chun Zu’s business partner in India), which received a lot of interest across the two days. Other striking stands included Faco Fasteners Pvt Ltd, Mitter Fasteners and Deepak Fasteners Ltd, with the latter using Fastener Fair India as an opportunity to meet up with a range of customers in one location. During the show Deepak carried out several demonstrations on a VibrationMaster J100 portable Junker Test bench demonstrator to highlight the importance of quality and how quickly inadequate fasteners can fail. “We are satisfied with the customers we had to our stand,” reported Sanjeev Kalra, managing director at Deepak Fasteners Ltd. “However, compared to the previous show in 2011 it seems to be quieter, with less end user visitors than before.”

24 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

Heads & All Threads Pvt Ltd was another stand that drew a lot of attention from visitors, especially when a fish tank on display was accidentally knocked over on the first day. Thankfully no fish were harmed and the company was pleased with how the show went. “The show has been good with at least half a dozen good quality leads that if converted would make the show worthwhile,” commented Steve Ward, group sales director at Heads & All Threads. “We have been in the Indian market for 2.5 years and we are now starting to see the benefits of having a dedicated premise in India.” Dörken MKS-Systeme used Fastener Fair India as an opportunity to promote the Dörken brand and create awareness of its wide range of approved products. “It has been a good show, with lots of customers to our stand who wanted to find out more about Dörken and what products we have to offer,” commented

Special Screws directly from stock!

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exhibitions

Thirumuru Sashidhar Reddy, Dörken country head for India. Dörken was not the only German based company that had a successful show. First time exhibitor at Fastener Fair India – BAER Company, stated that it was a respectable show. “Over the two days we had over 100 visitors to the stand, commented Paul Daroszewski, business development manager at BAER. “Obviously it is difficult to say how many of these leads will become future customers, but we are content with the show.” Titgemeyer GmbH, exhibiting with its Indian partner - Veauli Engineers Pvt Ltd, also reported having a satisfactory show. Titgemeyer showcased its TIOS15 blind bolt tool as well as its Rivetec range of tools. Sven-Thorsten Buchweitz, head of sales at Titgemeyer, commented: “Our stand was busy throughout the first day of the show. On the stand we displayed our wide range of Rivetec tools, but also featured our TIOS15 blind bolt to underline our capabilities to visitors.” Newly formed subsidiary - Lee Spring Company PVT Ltd also exhibited

at the show and displayed its Series 19 catalogue, which features Stock Spring designs, including 2,000 recent Metric size additions, ranging from Compression, Torsion, Extension and Redux™ wave springs to the latest Leep™ plastic composite and Banntam™ mini compression springs. Organisers reported a total of 4,028 trade visitors across the two days of Fastener Fair India. The visitor survey revealed that the quota of visitors from top management was very high, with 31% of the visitors being company owners, 26% being managing directors, board members or department heads, 16% being engineers and technical specialists and 13% having purchasing responsibility. Visitors at Fastener Fair India 2013 were mainly fastener and fixings manufacturers (36%), users (29%), distributors/supplier to users (19%) and wholesaler/supplier to resellers (16%). Key industry sectors to which the visitors belonged were the automotive industry (16%), mechanical engineering (15%), hardware/DIY retailing (9%), electrical

26 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

products/domestic appliances (8%) and construction (6%). Information on Fastener Fair India 2015 will soon be available at the show website.

Co-located with BLECH India Co-located alongside Fastener Fair India was BLECH India, an exhibition for sheet metal working. BLECH India took place from 17th April – 20 th April and included 180 exhibitors from 14 countries – presenting a variety of new products and services for sheet metal working. Machines on display at BLECH India included grinding machines, bending machines, hydraulic press brake machines, water jet cutting machines, coil feeding lines for automatic stamping, thermal drilling, surface polishers, CNC hydraulic shearing machines, CNC turret punch presses, as well as sheet metal laser cutting machines. Free flow of visitors between the two shows was encouraged, with visitor badges being quickly scanned by staff positioned between the two shows.

With over 19,000 stock springs, extensive custom capabilities and over 90 years of expertise, Lee Spring responds to yesterday’s needs, today’s demands and tomorrow’s technology. Whether you need 10 springs or 10 million springs, our World-Class Service and comprehensive website make finding the right spring easy. Call or email us today to learn more.

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10/09/2012 17:30

A global source for all your products

You need to use Advance Spares Ltd! High quality fasteners from low cost sources Flange Bolts • Shoulder Rivets and Bolts Trilobular Screws and Bolts • SEMS Cold Formed Specials • Machined/Turned Parts Plastic Trim Panel Fasteners • Metal Edge Clips Tubular Brass Rivets • Kitting

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sheet metal fastening

Quality engineered fasteners Harrison Silverdale Ltd has been supplying sheet metal fasteners to major OEMs and fastener distributors across Europe since 1982. It has an extensive range of self-clinch fasteners, rivet nuts, cage nuts and spring steel U nuts.

arrison Silverdale points out that its range of cage nuts offers customers a cost effective captive fastener. The cage, which can be spring steel or stainless steel, holds the nut in place on blind applications so the mating screw can be placed later in the assembly or during servicing on-site. The square nut, which can also be mild steel or stainless steel, has some float (movement) that allows for misalignment or production tolerances on the mating component. Typical applications include 19 inch server racks used in the IT and audio industries, electrical enclosures and other metal cabinets. The cage nuts are available in a range of sizes from M3 to M12 with various hole size combinations. Some more specialised parts have earthing barbs for earth continuity on coated or painted panels. A male threaded version is also available but not as common. Harrison Silverdale can also offer installation tooling for the more popular sizes. “It has always been one of our core objectives to deliver quality engineered fasteners at competitive prices, whilst maintaining our commitment to customer service and technical support. We supply many of the major 19 inch rack manufacturers and are one of the largest stockists in Europe.” Harrison Silverdale states that it’s one of the few fastener companies to include a design service within the scope of its ISO 9001:2008 approval. Also, its 3D CAD facility means it can work closely with customers on special applications. www.harrisonsilverdale.com

Welding studs and RIV1066 Rivit Srl, based in Bologna, Italy, is confident that it is a leader in the production and distribution of fastening systems and tools for assembly and sheet metal working.

stablished in 1973, Rivit’s forty years of experience has enabled it to develop a wide range of products including: blind rivets, rivet nuts, self-clinching nuts, welding studs, blind bolts, latches, cage nuts, spring clips, as well as the related tools for their installation. The welding studs are fastening systems that are used on plates and shims to create threads. Thanks to the welding studs the outer surface on which the application has been performed remains smooth to safeguard aesthetics. The application is very easy and does not require accessibility from both sides of the sheet, as the products can be blind placed. The studs can be welded onto plates of the same material. Users can choose among threaded studs, internal thread tapped studs, 1 or 2 contact fastons and insulation nails, which are available in steel, AISI304 stainless steel, aluminium and brass. For the installation of the welding studs, Rivit recommends the use of the RIV1066 - a capacitor discharge studwelding tool for studs up to M8. Rivit points out that being completely electronic it is not subject to any kind of wear and it automatically stabilises the variations of the line voltage. The gun which comes with the tool works according to the contact welding system - the centering of the studs can be done following an outline, by means of a centering template.

28 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

Double-sided tape for sheet metal fastening Here tesa, a global tape manufacturer with a range that includes over 800 adhesive tapes, looks at the benefits of using double-sided tape for sheet metal fastening.

etal has a high surface energy (HSE) that makes it easy for an adhesive to bond to. It is also smooth, which means double-sided tapes with any type of carrier can be used, increasing the choice of the most suitable tape for the intended application. To ensure an optimum bond is achieved there are some initial considerations to take into account. Firstly, as metals often come with a thin film of milling oil it is essential that this is removed and that the surface is clean, dry and free of any contaminants. Secondly, it is preferable for tape to be applied at around 18°C - 22°C. The substrates to be bonded should ideally be at the same temperature. For example if they have been stored in a warehouse overnight during the winter, it is advisable to allow them to warm up and let any moisture evaporate. This is because if either the tape or substrates are cold, this affects the ability of an adhesive to ‘wet-out’ - i.e. spread out evenly on the surface. Finally, firm and even pressure needs to be applied across the tape to activate the adhesive. Rollers from tesa aid this process and this is typically all that it is required.

The advantages of using double-sided tapes include: • Double-sided tapes provide a very good initial bond – often enough to allow movement of the bonded part to the next production stage. Depending on the type of adhesive, maximum bond strength is typically realised within 3 days. • No curing time is required, as is the case with wet glues. • They are ‘clean’, i.e. there is no oozing of adhesive at the edge of a joint. This means there is no contamination and no additional cleaning required. • There is no need for protective equipment to be worn, as is the case with welding. • Tapes offer equal distribution of stress across the whole of the bond area. This is in direct contrast to traditional means of bonding metals using screws, bolts and riveting which can potentially lead to localised weak points and even damage the metal surface, leaving it vulnerable to corrosion.

Fastener + fixing technology

NORMA Group’s infrastructure business gains momentum In early 2012 NORMA Group founded its business area – infrastructure – which specifically focuses on the desires and requirements of customers from the construction, sanitary, heating and air-conditioning, as well as from water and shipbuilding industries.

new catalogue was launched in March 2013 at the ISH trade fair in Frankfurt, Germany, which shows NORMA’s complete offering for the construction, sanitary, water management and shipbuilding sectors.

New product portfolio for supporting and fixing Besides its range of pipe connectors and couplings for the building, construction, water management and shipbuilding business, the catalogue also contains a new product offering of supporting and fixing solutions for pipe systems and electrical installations. Launched in July 2012 on the test market France, the new Pipe Support System (PSS) portfolio targets distributors in the sanitary, heating, air-conditioning, and construction sector. At the ISH exhibition in March the product range was introduced to the German market. PSS complements the current NORMA Group infrastructure product offer.

“This is especially true for customers from the construction sector who can now get everything from one supplier, from pipe couplings to pipe support systems.”

Infrastructure products in use all over the world The infrastructure products are used in building and infrastructure projects all over the world. In Choutrana, Tunisia, sewage works are being upgraded in order to supply Tunis’ growing population with fresh tap water. In order to provide the new activated sludge tanks with compressed air - 4.5 kilometres of new pipes are being installed, which are connected with 600 NORMACONNECT FGR pipe connectors. The Indonesian island Bali is home to a luxury 170 room resort that is being constructed. Its sewage pipes made of cast iron and other materials are connected with NORMACONNECT DCS RAPID couplings and NORMACONNECT DCS FIX to make them leak-proof. The cast-iron pipes of the drainage system of Frankfurt airport’s parking spaces in Germany are connected with NORMACONNECT DCS RAPID couplings and NORMACONNECT DCS universal restraint collars. The two joining products withstand high pressures while keeping the system tight, and protect against downpours and large amounts of water.

Market and customer requirements in focus

New Pipe Support System (PSS)

NORMA Group states that the markets for sanitary, heating and air-conditioning technology have changed significantly over the past years. Customers expect

30 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

high quality and reliable supply combined with outstanding client service. Products need to be functional, i.e. easy to handle and install without expensive and highly complicated tools. NORMA Group offers exactly the right products to meet these requirements. Today, producers and suppliers use modern communication tools and order systems, as does NORMA Group. The process starts with capturing and directly confirming the incoming order all the way through to confirming shipment. Wholesalers use modern warehousing systems. In this context, NORMA Group makes use of the master data system ARGE Neue Medien (new media ARGE). To function flawlessly, the supply chain depends crucially on efficient work processes. These in turn require state of the art and reliable production, on-going quality surveillance of the production process and outgoing goods inspection. NORMA Group has all these elements in place and also uses a modern order management system to always meet the highest client standards.

Expanding the water management business NORMA Group has underlined its focus on the infrastructure business with its recent acquisitions in the Asia-Pacific region. In November 2012 NORMA Group acquired 85 percent of shares in Chien Jin Plastic headquartered in Malaysia. The company has been in the market for more than 20 years and produces thermoplastic joining elements for plastic and iron pipe systems. These products are used in different application areas, in particular for drinking and domestic

“ Products need to be functional, i.e. easy to handle and install without expensive and highly complicated tools. NORMA Group offers exactly the right NORMACONNECT FGR

water distribution, and irrigation systems. In addition, Chien Jin Plastic produces components for sanitary appliances and globally distributes its products to more than 200 distributors in approximately 30 countries. Shortly after this acquisition, in January 2013, NORMA Group added Australian based Davydick to its company group thus expanding its distribution network in Asia-Pacific. For more than

products to meet these requirements.” 20 years Davydick has distributed various elements in the transportation of water in irrigation systems. Valves and pumps for agricultural, as well as hardware and plumbing markets, are part of Davydick’s portfolio too. Davydick services more than 700 customers with its products. By acquiring Davydick NORMA Group has expanded its competencies in the water management market, added products to its infrastructure portfolio and extended

its distribution network in Australia. NORMA Group points out that it has also recently agreed to acquire the Australian business Guyco, which specialises in the design, manufacture and distribution of fittings and valves for freshwater distribution, irrigation, agricultural, plumbing and industrial market sectors. With its 32 employees, Guyco supplies over 700 customers in Australia and New Zealand. www.normagroup.com

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Customer Value through Innovation.

NORMA Group’s Engineered Joining Technologies and applications know-how provide cleaner, more efficient use of precious resources in areas such as Cooling Systems, Air Intake & Induction, Emission Control and Fixing Systems.

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thread forming technology

Design engineering assistance with EJOT

Here EJOT® focuses on its EJOT® DELTA CALC prognosis programme and how it can be used for the pre-dimensioning of direct fastening into thermoplastics.

he EJOT® DELTA CALC can offer valuable support for design engineers and developers as it can calculate, depending on the material and pilot hole dimension, the fastening parameters of the DELTA PT® screw. The EJOT DELTA PT® screw (pictured above) is the high capacity fastening element for reliable and trouble free direct fastening into thermoplastic. A research programme based on the mechanical parameters of many thousands of applications and test assemblies has proven that reliable clamp load calculations are also possible for thermoplastic material (compared to VDI 2230). On this basis, the DELTA PT® geometry and the corresponding prognosis programme EJOT® DELTA CALC have been developed. Based on the VDI 2230 many effective calculation programmes are available today, but their application range is limited to the calculation of metric screw joints in metallic materials. For the calculation of self-tapping joints in plastics, the guidelines of the VDI 2230 are not completely applicable. In particular the process of thread-forming and the specific material properties of thermoplastic material have not been considered. With the development of the DELTA CALC prognosis programme EJOT has addressed this problem in order to offer an optimum design aid to the customer. The result is an effective and precise calculation tool, which has already been proven in many applications and is also subject to ongoing optimisation and further development. Brief characteristics of the possible applications of the EJOT® DELTA CALC prognosis programme include:

Clamp load oriented design The clamp load, the actual quality criterion of a screw joint, is the main parameter for the calculation with DELTA CALC. By specifying the clamp load and the mating and clamping material, a reliable calculation of the screw dimension and required tightening torque is possible, which is needed to safely reach the specified clamp load in a process reliable way. A reverse calculation, which means the specification of the tightening torque for determination of the clamp load, is also possible with DELTA CALC.

Calculation of the optimum assembly parameters DELTA CALC is able to calculate (see diagram 2) different failure modes (e.g. stripping, screw fracture) and their occurrence (e.g. clamp load at stripping). With this knowledge it is possible to set the optimum installation parameters with the programme in order to minimise the risk for errors and guarantee a process reliable assembly.

assembly line

imag. assembly line

female thread damaged boss upset

screw fracture

Design of the boss hole For dimensioning of the boss hole the default DELTA CALC calculation applies the design guidelines of the EJOT DELTA PT®. In practice these specifications often vary. The effect of these variations can be simulated with the programme within realistic boundaries (see diagram 1). With a tied in material data bank a selection of approximately 150 different thermoplastics is available for the calculation of the joint.

Prognosis of the long term performance of a screw joint The clamp load created by the tightening torque decreases due to the relaxation behaviour of plastic depending on time and temperature. With the indication of time and temperature the loss of clamp load can be prognosticated with DELTA CALC. This and other functions for the precalculation of screw joints lead to a clear reduction of development time and thus significant costs savings in component design. With DELTA CALC these savings potentials can be recognised and used early in the process. Over dimensioning of the screw joint is prevented, material and thus weight is saved. Time consuming and cost intensive tests on the component are also reduced to a minimum.

32 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

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thread forming technology

Direct screwing in one step Bossard France recently worked on a project involving the modernisation of a 5km stretch of the Nanterre La Défense tunnel in Paris, France, using the latest in thread forming technology.

he renovation work on the Nanterre La Défense tunnel was part of an extensive renovation programme involving 22 tunnels in Paris, which included a significant modernisation of the tunnels, as well as increasing their safety in the event of an accident or fire. In order to protect the walls of the Nanterre La Défense tunnel over 240,000m2 of pre-fabricated fire protection boards were chosen to be directly fastened to the concrete wall or onto a metal-metallic substructure. Bossard France was awarded the contract to develop a solution for fixing the insulating panels on the metal supports. Realising the very stringent safety requirements and product performance, the Bossard engineering team came up with a solution called ecosyn ® -MRX. It is a fastener constructed with special martensitic, hardened and tempered chrome steel. ecosyn ® -MRX can resist at least six hours in extreme high temperatures up to 1,200°C. This is the result of a new development in material technology. In addition to that, the self-drilling thread is designed for high performance drilling. Self-drilling screws drill their own tapping hole to close tolerances and form their mating thread themselves. The specially formed and stamped drill point prevents any drifting around the surface of the component and allows rapid spot drilling. No drilling or thread-cutting tools are needed, no pre-drilling is required and there is no need for any additional securing elements. Bossard states that thanks to these properties the ecosyn ® -MRX can reduce costs and be used quickly and efficiently – therefore significantly increasing productivity. The ecosyn ® -MRX can be used in sheet metal construction, heating and ventilation ducts, household machines, vehicle body construction, window frames and blinds, façade construction, as well as a variety of other applications. www.bossard.com/ffm

Starlock

Push-On Fasteners

Starpress™ Precision Pressings Baker & Finnemore Limited, 199 Newhall Street, Birmingham, B3 1SN, UK Tel: +44 (0) 121 236 2347 Fax: +44 (0) 121 236 7224 e-mail: sales@bakfin.com

Fastener + fixing technology

Opening up new fields It seemed like an impossible task. Build an offshore gas platform that was strong and stable enough to withstand the elements in the middle of the North Sea, yet flexible enough that it can still be dismantled and relocated. Using Superbolt assemblies almost six metres long, Heerema Fabrication Group achieved a world first.

he F3-FA gas platform is located in the Dutch sector of the North Sea, around 240km from the Netherlands. On the surface, it looks like any other offshore oil and gas platform – but it boasts one important difference. Unlike all other platforms, when the gas field runs dry, the platform doesn’t need to be decommissioned. It will simply be packed up, moved to another location and continue production. Never before has a self-installing platform of this size and magnitude been constructed in water this deep. The entire structure, including topside, four suction piles and legs, reaches a total height of 133 metres and weighs over 8,800 tonnes. It’s installed far out to sea, in deep water where it will be subjected to strong winds and high waves. Heerema Fabrication Group (HFG), the company commissioned to build the platform, estimates that over one million man hours have gone into the project. The result is an incredible feat of engineering, and something that is set to change the whole offshore oil and gas industry. Gas was first discovered at the F3-FA field of the North Sea in the early 1970s, but has been left untouched until now as the gas deposits are too small to

justify building a permanent platform. The industry’s current economic model dictates that the value of deposits in any given field must exceed the cost of erecting an offshore rig. However, since the new reusable platform can service multiple fields in its lifetime, it will change the whole industry and the ramifications are huge. All of a sudden, it’s now economically viable to tap into the world’s smaller reservoirs of oil and gas. The project started in 2009 when HFG was originally commissioned to build a SIP (self-installing platform) – an offshore platform that can be installed without the need of a crane vessel and heavy piledriving equipment. Similar SIPs had been used before, however only for smaller platforms in shallower, calmer seas. The new installation needed to support a much heavier platform, in much harsher conditions. On top of all that, it also needed the ability to be dismantled and relocated. So how did HFG solve this seemingly impossible task? Its solution was to use the simplest and oldest fastener in human engineering history – bolts. Supplied by the Nord-Lock Group, the bolts are 5.5 metres long, 24cm in diameter and weigh over 2,000kg. Even

36 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

the nut-style Superbolt tensioners used weigh over 350kg. “The Superbolt assemblies we supplied offer the same security as welding, except they are faster and easier to install,” says Franz Raymann, service manager, Nord-Lock Group. “We used a special sealed design, which protected the jackbolts in rough conditions. Each of the 36 jackbolts per Superbolt tensioner is individually sealed to protect it from corrosion and conserve the lubricant. Thus, the jackbolt can be loosened without any damage and the entire connection can be reused.” With a project of this magnitude having never been attempted before, Nord-Lock engineers were also able to assist the project team with testing, calculations and installation. Another advantage offered by Superbolt assemblies was the ability to check load and preload at any time. The entire platform, including legs, was constructed onshore and then transported out to sea via a flattop barge. On arrival at the F3-FA gas field, the legs were lowered to the seabed floor, where they were fixed to four suction piles. Using strain jacks, the platform was lifted off the barge and moved to the top of the legs. Once

in position, it was fastened with sixteen Superbolt assemblies – four on each leg – preloaded to 12,000kN each. When fastened, the strain jacks were removed, leaving the entire 4,000 tonne platform hanging on just 16 Superbolts. Total installation time, from the time the barge arrived on location, took just two days and four hours – quite remarkable for a construction of this size. “Compared to any other fastening method, Superbolt is much quicker and easier,” adds Raymann. “Speedy installation was also important as the barge was vulnerable to rough weather until the platform was secured.” Raymann continues: “The use of Superbolts also ensures the installation process is reversible and repeatable. Bolts can be unfastened and reused, which is the essence of a re-locatable platform.” For HFG, the Superbolts are a perfect solution. “Nord-Lock’s nicely designed Superbolts and the smart tensioning system made the innovative F3-FA platform possible,” claims Frank Slangen, the F3-FA project manager for HFG. www.nord-lock.com

Franz Raymann, Nord-Lock service manager, checks the preload on one of the sixteen Superbolts. Throughout the whole project, Nord-Lock engineers were able to assist with the installation

Your global trusted partner in bolt optimization

From design to operation, the Nord-Lock Group is a world leader in bolt securing. Our innovative solutions include multifunctional wedge-locking technology and Superbolt tensioners. Trust the bolting experts for your critical bolting applications. www.nord-lock.com

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Wrentham – Ensuring success Wrentham Tool Group (WTG) has been a supplier of cold heading tools since its founding in Wrentham, MA, USA in 1948. WTG has undergone many changes since then including ISO 9001:2008 certification and continues to re-invent itself to better serve the ever changing global market.

n 2004, Wrentham Steel Products was purchased by Phillips Screw Company and was renamed Wrentham Tool Products. Phillips Screw Company holds patents on several innovative recesses such as the POZIDRIV®, MORTORQ ® Super and HEXSTIX®. In July 2010, WTG purchased RICO and Astro ® from PCC. RICO and Astro® are known around the world for their high quality industrial, automotive, and aerospace punches and associated tooling. As a result of this acquisition, Wrentham Tool Products was renamed Wrentham Tool Group. The close proximity of RICO/ Astro® allowed WTG to retain most of its highly skilled work force. In April 2012, Wrentham acquired the Acument Pin Shop from Acument Global Technologies. The Acument Pin Shop was the primary manufacturing location for TORX®,

TORX PLUS ®, and TORX PLUS ® AUTOSERT punches. WTG states that its mission is to “provide world-class quality, value pricing and unparalleled customer service.” To achieve these goals WTG has dedicated significant financial and human resources to ensure success. WTG has expanded its product line to include the latest fastener recess innovations such as MORTORQ ® Super, HEXSTIX® and TTAP ®, as well as MOAC™ coating and Black Diamond Gages™. WTG also manufactures carbide and steel heading tools including hex inserts, hex pins, and trim dies. Finally, WTG has increased stock levels and appointed sales agents in strategic locations around the world to better serve the customer and ensure continued expansion. www.wrenthamtool.com

Dry bonding opens up new opportunities As the requirements in terms of energy efficiency and living comfort are increasing, good heat insulation of windows and other glass surfaces is becoming increasingly important.

dvances in the design of insulating glass and its bonding mean that extensively glazed buildings and energy saving construction are no longer mutually exclusive. At the forefront in this respect is Lohmann GmbH & Co KG’s dry bonding process – which offers greater design flexibility in window construction. Dry Static Bonding from Lohmann is an insulating glass bonding process that bonds the sheet of glass directly into the window sash using a high-end adhesive tape. The double-sided mounting adhesive tape from the DuploCOLL 56000 range offers the required profile stability and provides a reliable barrier against the cold. “The high final strength and ageing resistance of the adhesive tape give the bonded frame a stable structure and guarantee a reliable load transfer,” explains Harald Krämer, market manager architecture. A stabilising steel core inside the window profile is no longer required, saving the manufacturer material and production costs. Lohmann points out that another advantage is the absence of any steel strengthening, which reduces the weight of the window and frees up the profile chamber for additional insulating material. Thermal bridges are thus eliminated and the heat insulation of the window is improved. The design of the window also offers greater protection against break-ins, as the bonding joint around the edge of the glass makes the sheet more difficult to prise out. The profile manufacturer can apply the adhesive tape directly to the existing window profile. Alternatively a suitable adapter profile that is already equipped with tape may be applied to the window profile. Both options can be integrated into the existing process so there is no need to invest in new machinery.

SPRINGS - HIGH PERFORMANCE • Inconel • Nimonic • Hastelloy • Elgiloy • MP35N • Titanium • High-tech calculations

Lesjöfors Sales, Stockholm • Phone +46 8 445 88 88 • info.vby@lesjoforsab.com

A leading manufacturer of high performance springs and stampings – www.lesjoforsab.com

Revolutionary Keep-Nut insert Specialising in fastening applications for metal sheets and sections, solid parts and wood, as well as plastics and composite materials, Specialinsert has introduced the Keep-Nut insert.

pecialinsert says that the Keep-Nut is a revolutionary press-in insert with mechanical anchoring to create threaded seats on thin panels made of marble, granite or other stones, and can also be used in composites, carbon, corian, HPL, glass and other compact materials. Keep-Nut is manufactured in stainless steel and itâ&#x20AC;&#x2122;s made of a threaded bush with a set of elastic crowns and a plastic ring for holding the complete parts. The Keep-Nut comes in different lengths, with or without flange, to fit to several different panel thicknesses. Specialinsert points out that the Keep-Nut can be easily installed as the user simply needs to drill the material with the correct hole diameter and press-in the insert. Additionally it can be

customised with different versions and sizes, in order to fit customer needs. The assembly by pressure is fast and easy and it doesnâ&#x20AC;&#x2122;t require any additional

resins or adhesives. The Keep-Nut also enables internal assembly without external dimension, facilitating the handling and storage of materials.

In use the elastic crowns are solicited by axial force, acting radially against the hole walls due to the bending and pressure - avoiding the leakage of the system. Moreover the not-through threading of the internal bush assures secure fastening while eliminating the risk of extraction as a result of over penetration of the screw thread. Specialinsert points out that lab tests have ensured high pull-out strength performances, up to 2,500N on marble panels and 4,800N on HPL, making the Keep-Nut suitable for the most demanding conditions of applications. The Keep-Nut insert is specifically developed for ventilated facades, wall-coverings, dĂŠcor and interiors, furniture, as well as kitchen and sanitary elements fastening.

products

HEROSLAM launches new range of thread rolling dies HEROSLAM has recently launched a new range of thread rolling dies to cover the increasing demands of fastener producers within the automotive, aerospace, construction and hi-tech industries around the world.

lberto Gabika, managing director at HEROSLAM, commented: “Fastener producers face important technical challenges and we want to be their partner as a provider of top quality tooling for improving their thread rolling process. We are detecting an increasing demand for quality tooling conceived to consistently roll hard materials such us stainless steel, Grade 10.9, 12.9 steel and superalloys such as titanium or Inconel ®.” Many fastener producers perform the thread rolling operation before heat treatment and once the fastener is hardened, it needs to be rolled again to guarantee the thread is correct. This re-work process implies significant costs that fastener producers are looking to avoid. HEROSLAM offers customers a completely new range of thread rolling dies (flat, planetary and cylindrical) conceived to roll hard material fasteners in one single operation, thus avoiding

re-works and secondary operations. This new range of thread rolling tools combines top quality steels exclusively developed for HEROSLAM tools, homemade coatings such as GG coating and HEROSLAM’s expertise on thread rolling thanks to more than 70 years of experience producing thread rolling dies. The GG coating can be ordered with both flat or cylindrical dies and works extremely well in cold rolling as well as warm and hot rolling. HEROSLAM points out that its RRO (Radiused Root Runout) features, developed for specific customer needs, also play a very important roll in achieving the necessary thread quality. RRO makes the end of the thread progressive, thus alleviating the tensions on one of the zones most prone to having problems of collapse due to the concentration of tensions. In turn, RRO positively impacts the tool’s performance, since it extends its service life. HEROSLAM offers many different types of RRO depending on

the application. Alberto Gabika adds: “Our new range of tools is helping our customers improve the quality of the fasteners they produce and achieve longer tool service life in thread rolling of hard materials. Thus, our customers are reducing their manufacturing costs by significantly reducing quality issues, avoiding rework operations, and carrying out fewer machine preps and changes, minimising machine down time.” HEROSLAM’s new range of dies includes M2 and M42 material flat and cylindrical dies, planetary dies, knurling dies, grooving dies, ogival dies, licensed dies, nail dies, woodscrew dies, aerospace cylindrical dies, reed 2-die and 3-die cylindrical dies in J-form and R-form, control major and minor dies, expanded lead dies for warm and hot rolling, as well as special thread forms upon the customer’s request. www.heroslam.com

TAURUS® C with setting process monitoring GESIPA® has announced that its TAURUS® C tool comes with setting process monitoring, which is achieved by a direct online analysis of traction force and traction course recorded during the setting of the rivet.

ll system components necessary for operation are included in the tool itself. The setting analysis takes less than 1 microsecond and its result is directly displayed by a green or red LED installed in the tool base and, optionally, by a warning tone. Moreover, a collective analysis of the complete work piece is also included. The TAURUS C stores more than 260,000 individual setting processes, which can be recalled at any time. The system also identifies failure patterns and memorises those for failure analysis and troubleshooting. The tools can be operated as standalone or as part of integrated production systems using the GESIPA® interface.

40 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

The new interface developed by GESIPA® is based on an embedded PC system and provides 24 digital in and out control system ports, Ethernet connection via a RJ45 connector, as well as status LEDs. Connection ports for a protocol converter supporting all common bus systems and for external storage media, as well as a USB port for fast data transfer, complete the features of the new interface. In addition, the GESIPA® interface has a process database for storing 250,000 of the most current process data (date, time, rivet position, process curve, analysis, etc). www.gesipa.com

TAURUS® C

with setting process monitoring poweRfUl & SAfe The setting process monitoring is achieved by a direct online analysis of traction force and traction course recorded during the setting of the rivet. All system components necessary for operation are included in the tool itself.

NEW

Advantages for the user: • • • • • •

Fault detection and fault storage for failure analysis and troubleshooting Short assessment duration for a setting process (less than 1 µs) Results directly shown by a light signal or by an acoustic signal Storage of more than 260,000 setting process data Can be operated as stand-alone devices or as an integrated part of a customer´s production system via the GESIPA®-interface. Reduction of downstream quality costs

GESIPA Blindniettechnik GmbH Nordendstraße 13-39 64546 Mörfelden-Walldorf Germany A company of

T +49 (0) 6105 962 0 F +49 (0) 6105 962 287 info@gesipa.com www.gesipa.com

products

One product, two ranges Bülte Plastics is offering hex head slotted screws with two options - full nylon screws or plastomet (plastic with metal inserts) screws.

he nylon products are available in sizes M4, M5, M6, M8 and M10 with lengths between 6mm - 80mm. The standard material is natural nylon (polyamide 6.6) and on request these screws can be offered in PVDF, PE, PC or PP and manufactured in all RAL colours. The plastomet products are available in sizes M4, M5 and M6 with lengths between 8mm - 30mm. The standard material is black polyamide 6 with steel inserts. Brass or stainless steel is available on request where minimum quantities will apply. The slotted hex head offers two choices of tightening, the hexagon external drive with a spanner or socket and the slot with a screwdriver. The extension under the head provides a larger bearing surface to spread the load and preserve the work piece, avoiding the need for a separate washer. www.bulte.com

New three-piece locknut system Ferrule-Lock™ has launched a new three-piece locknut system that it says has greater holding power for high vibration applications.

errule-Lock’s patented design utilises a simple and effective innovation borrowed from the tube fitting industry, which it says is easy to install and outperforms other locknut fasteners. It is a three piece system comprised of two identical Ferrule-Lock™ nuts and a ferrule. The bolt is customer supplied to meet the application. The first Ferrule-Lock nut is threaded onto the bolt and torqued to the designed clamp load and standard specifications. The ferrule is slipped over the bolt and seated in the chamfered face of the clamp nut. The second Ferrule-Lock nut - acting as a jam nut - is threaded onto the bolt until the ferrule seats into the chamfer of the jam nut. The final step is to tighten the jam nut to compress and bind the ferrule into the two Ferrule-Lock nuts, creating a joint that will not vibrate loose. The Ferrule-Lock system has been rigorously tested using the Junker Test, with the testing procedure consisting of a fastened joint between a stationary and a movable plate. A load cell is placed on the bolt and the two plates are fastened together under a specified clamp load and subjected to vibration using an amplitude of 10 percent of the diameter of the bolt and 12.5 hertz for 1,000 cycles. An added benefit of the Ferrule-Lock system is that the load on the clamp nut has no impact on the vibration proof quality of the Ferrule-Lock system. The only requirement is that the ferrule be compressed between the opposing Ferrule-Lock nuts. This feature is very useful in applications where minimal clamp load is required. “Ferrule-Lock is designed to provide a serviceable joint. It is a simple matter of loosening the jam nut, removing and discarding the ferrule, and removing the clamp nut as you would normally. Ferrule-Lock nuts are reusable with a new, replacement ferrule.”

42 Fastener + Fixing Te chnology • Issue 10 Jul - Sep 2013

Advertisers index Adolf Pühl GmbH & Co. KG..................................................................7 Advance Spares................................................................................. 27 Albert Pasvahl GmbH + Co................................................................25 Alloy & Stainless....................................................................................2 Ambrovit........................................................................................... 1, 9 Anochrome Group............................................................................. 11 Baker & Finnemore Ltd.......................................................................34 Bollhoff GmbH.................................................................................... 21 Bossard Ltd......................................................................................... 15 Bülte Plastiques SA..............................................................................42 Canco Fasteners................................................................................33 DIV D.O.O........................................................................................... 19 EFC International................................................................................ 11 Ferdinand Gross GmbH & Co. KG...................................................... 17 Flaig + Hommel GmbH..................................................................... 18 GBK UK Ltd..........................................................................................29 GESIPA Blindniettechnik GmbH........................................................... 41 Harald Böhl GmbH............................................................................. 41 Harrison Silverdale Ltd........................................................................29 Heroslam, S.A.L.................................................................................. 41 Jupiter Clamps...................................................................................25 Lederer GmbH...................................................................................23 Lee Spring.......................................................................................... 27 Lesjöfors AB........................................................................................38 Nord-Lock International...................................................................... 37 Norm Civata AS....................................................................................5 NORMA.............................................................................................. 31 Peter Schröder GmbH........................................................................33 Precision Technology Supplies Ltd......................................................43 PSM International................................................................................35 Rotor Clip Ltd......................................................................................25 Staytite...............................................................................................44 Top Screw Metal Corp........................................................................33 Wrentham Tool Group........................................................................39

ION F A S T E NE R T C E T O PR

www.bulte.com ®

BÜLTE GmBH - KunsTsToffErzEuGnissE Carl-Sonnenschein Str.22, D- 59348 Lüdinghausen - Germany Tel : 02591 / 91 94-0 - Fax : 02591 / 59 77 bulte@bulte.com - www.bulte.com

All Metal Lock-Nuts From Stock

Bi-Way nuts features side indentations which slightly distort the centre thread. This creates a locking action when the distorted threads engage the threads of the mating part

Staytite nuts resist vibration and loosening because the insert flexes downwards and is ‘pulled’ into closer contact with the screw thread by the upwards anticlockwise rotation of the nut body

Stover nuts, a simple deformed nut that offers a cost effective solution to your application

HardLock nuts resist loosening in environments where high vibration occurs. They provide a secure fastening to many applications including railways, civil engineering, radar, power masts, pylons, wind turbine towers and masts.

email: distributors@staytite.com Tel:+44 (0) 1494 462 322 • Fax +44 (0) 1494 464 747

www.staytite.com

...dedicated to meeting all your fastener needs