Fastener + Fixing Technology #14 by Fastener + Fixing Magazine

I ss u e 1 4 July â&#x20AC;&#x201C; Se pte mbe r 2 0 1 4

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EDITORIAL

Fastening technology insight Part of the Mack Brooks Group Romeland House, Romeland Hill, St Albans, Herts, AL3 4ET, UK Tel: +44 (0) 1727 814 400 Fax: +44 (0) 1727 831 033 www.fastfixtechnology.com

Group Publishing Director Jamie Mitchell info@fastfixtechnology.com Editor Will Lowry editor@fastfixtechnology.com Executive Editor Phil Matten Deputy Editor Claire Edwards Senior Advertising Executive Harry Whyte harry.whyte@fastenerandfixing.com Senior Advertising Executive Tom Allen tom.allen@fastenerandfixing.com Advertising Executive Emiliano Pagliaroli emiliano.pagliaroli@fastenerandfixing.com Production Manager Andy Clow andy.clow@fastenerandfixing.com

Disclaimer 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.

The July edition of Fastener + Fixing Technology includes a host of exclusive interviews and contributed articles that focus on the latest fastening technology. The experience and knowledge of the contributors/interviewees has resulted in some insightful articles that highlight the fastening Will Lowry – Editor capabilities that are available to end user markets.

here is an exclusive interview with Piero Bruno, sales manager for Alcoa Fastening Systems’ (AFS) industrial division, who talks about AFS’ rail fastening capability and how the company is able to partner with customers to find the optimum solution. In the Rail Fastening Technology feature there is also an article that looks at AFS’ history of servicing critical applications and the latest developments in the company’s Huck® range. Other articles in the feature include HEICO Befestigungstechnik GmbH and its HEICO-LOCK® range; Ferdinand Gross’ launch of its new Kanban visualisation software – FALCON; the Stauff Group and how it has been supplying the rail industry with clamping components and systems for almost 35 years; as well as an insight into the upcoming InnoTrans exhibition in Berlin, Germany. The exclusives don't stop there. There is also an interview with Jonathan Heywood, director of product engineering EMEA at NORMA Group, which focuses on NORMA’s capability to work with customers on future developments and how the company’s products can be used to help improve cost savings. We also have two fascinating technical articles that make for thought-provoking

12-22

reading. Peter Witzke, vice president engineering/quality at Bossard AG, gives an insight into the DIN 7500 standard and Jeffrey Finkernagel, technical sales engineer at Rotor Clip, calculates endplay take-up for bevelled retaining rings. Further articles include an insight into OTTO ROTH as the German manufacturer of precision turning and finishing parts celebrates its 100th anniversary; as well as NOF METAL COATINGS EUROPE explaining how the growing use of light alloy parts, the increase of tightening speed, and high preloads, require more and more efficient topcoats. The Cover Story focuses on Croatian based DIV d.o.o, a member of the DIV Group, and how the company’s broad range of capabilities, and recent investments, enable it to service a selection of industries around the world. Finally there is a special feature on the upcoming EuroBLECH 2014 – the international sheet metal working industry exhibition – in October. We have a preview of what visitors can expect at the show, as well as news from fastener related exhibitors – including Heinz Soyer, Gesipa, TITANOX, Unifast and Nord-Lock.

Contents Fastener Industry News Latest fastener industry news..................................4-8 Cover Story DIV d.o.o - determined to succeed....................... 10-11 Rail Fastening Technology No longer just a permanent way to meet rail applications... 14-15 InnoTrans 2014 approaching...................................... 16 Kettling: Nothing is impossible................................. 16 Intelligent. Flexible. Unique....................................... 18 HEICO-LOCK® expands product range..................... 20 Withstanding extreme conditions............................ 22 Features Alcoa Fastening Systems – partnering with customers... 12 NORMA Group – improving cost savings........... 24-25 Perfect tightening control..................................... 26-28 OTTO ROTH – tolerances have top priority.........44-45

Copyright Entire contents copyright © Fastener Fairs Limited 2014. 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.

Exhibitions EuroBLECH 2014 preview......................................30-36 Fastener Fair Hannover report.............................46-47

30-36

Technical An insight into DIN 7500 standard.......................38-39 Calculating endplay take-up for beveled retaining rings..40-42 Product News........................................................48-49 Advertisers Index....................................................... 50

www.fastfixtechnology.com

FASTENER INDUSTRY NEWS

NORMA Group receives PACCAR 50PPM award For its locations in Saltsburg, USA, and Juarez, Mexico, NORMA Group recently received the 50PPM award from PACCAR Inc – the US motor vehicle manufacturer – for 2013.

he quality seal is a reward for selected suppliers with a defect rate of 50 parts per million (PPM), with NORMA Group receiving the award for the third year running. PACCAR’s 50PPM award process examines the quality of suppliers over rolling six-month periods. Additional nomination criteria for the award include product innovation, the production parts approval process (PPAP), the number of warranty cases, and timely delivery. Eligible candidates must also have quality systems in accordance with QS-9000, ISO/TS 16949 or ISO 9001 for 2008 in place and successfully pass performance testing by PACCAR. “We are very pleased to receive the PACCAR quality award for the third year running,” says Werner Deggim, CEO of NORMA Group. “The 50PPM award recognises the consistently strong quality of NORMA products in conjunction with our employees’ outstanding commitment to always meet the expectations of our clients.” NORMA Group has been providing PACCAR with V-band profile clamps, UniStrap, T-Bolt and worm-drive hose clamps, as well as fluid components, since 2006. The joining products are manufactured inter alia in the NORMA Group sites in the USA and Mexico. www.normagroup.com

AFS helps shape iconic Kelpies monument The Huck® brand C50L® fastener from Alcoa Fastening Systems (AFS) is one of the key components in a major iconic Scottish construction project, due to be officially opened later this year.

he Kelpies is a 30 metre high steel monument paying homage to central Scotland’s horse-powered heritage and providing a dramatic gateway to the Forth & Clyde Canal entrance, on the country’s east coast. With recommendation from design company Atkins, Huck products were supplied by AFS distributor Permalok Fastening Systems Ltd. “The internal frame was designed, fabricated and installed around a tubular steel skeleton. A tubular steel secondary frame carried the many brackets to which the stainless steel ‘skin’ was attached using C50L fasteners,” explains John Rickers, systems development manager at AFS. “The C50L’s powerful clamp strength combined with Huck’s hydraulic tooling enabled the sheet to be immediately shaped into place during installation, thus eliminating the additional time it would have taken using a conventional nut and bolt system. Not only did the solution meet the mechanical requirements of holding everything in place, but the fasteners were quick and easy to install.” Tim Burton, sales and marketing manager at SH Structures, had considered more conventional fixings. However, he believed that the C50L provided a perfect, structurally sound, tamper-proof solution. “The most time-consuming part of the work was the fact that the plates were flat and had to be cold formed or bent to match the complex profile created by the brackets. Using the C50L fasteners with the hydraulic rig definitely helped the process as drawing the connection to close required a significant load, which the combination was able to deliver faultlessly every time.” David Tyas, managing director at Permalok Fastening Systems, added: “Permalok is extremely proud to have been involved

4 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

with this prestigious project, supplying over 12,000 Huck C50L lockbolts and the hydraulic installation tooling required to complete the construction of the two sculptures. The C50L lockbolt is historically a heavy industry fastener, and this application showcases the enormous strength of the product – as shown in its ability to bend the sheets to the supporting frame – and the ease with which it can be installed. It is also interesting to see how the fastener has been incorporated into the aesthetics of the sculptures.” www.afshuck.net

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FASTENER INDUSTRY NEWS

RotaBolts for wave power project

Aquamarine Power has ordered RotaBolt® measurement technology for its Oyster 800 wave power project, which captures the energy in nearshore waves and converts it into clean sustainable energy. The fasteners will be fitted to an underwater flange that is part of the system’s main ’water hydraulics’.

ichard Montague, lead mechanical engineer, commented: “There were two main reasons why we ordered RotaBolt ® technology. Firstly, we needed to be confident that we were achieving the correct bolt tension on this pipe flange to assure its operational integrity. We also wanted to make maintenance checks as simple and quick as possible. Through experience of using RotaBolt technology before joining Aquamarine Power, I hope our divers will be able to carry out checks for correct tension without re-torquing. This will be a significant maintenance benefit.” The technology incorporated into each RotaBolt fastener assures that the correct tension is achieved at installation and then throughout the life of the bolted joint. The design features a RotaCap on the top of the bolt, which allows for instant fingertip checking of correct tension – making it ideal for applications where operators are looking for operational integrity and also maintenance savings.

The Oyster 800 project is situated off the Orkney Islands and has been operational since 2012. Essentially it is a wave powered pump consisting of a buoyant, hinged flap that is attached to the seabed at depths of between 10m and 15m, around half a kilometre from the shore. The hinged flap, which is almost entirely underwater, pitches backwards and forwards in the nearshore waves. The movement of the flap drives two hydraulic pistons, which push high pressure water onshore via the subsea pipeline to drive a conventional hydro-electric turbine. The project is being continually refined and improved by Aquamarine Power and it is expected that next winter’s weather will provide a fuller testing of RotaBolt’s ability to assure integrity, before a final assessment is made next spring. The hydraulics system has a number of flange connections, which could potentially also benefit from RotaBolt technology.

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Jubilee secures pole position The 2014 motorsport calendar is in full swing and once again Jubilee Clips will be used extensively across a number of series and models and at some of the most prestigious races, such as Le Mans and the Monaco Grand Prix.

his season has a special focus for Jubilee Clips as the company has reached an agreement to sponsor Amigo Motorsport driver Rob Gaffney in the single make UK Ginetta GT5 series. If there is one thing racing drivers hate it is being beaten by an equipment failure, which means that selecting the right components is critical – which is why Ginetta specified the Jubilee brand. “In all of the years I’ve worked on racing cars I can honestly say I have never been let down by a genuine Jubilee Clip,” commented Fred Marsh, Amigo Motorsport’s chief mechanic. “Those guys have more experience than anyone in making hose clips and I can see why Ginetta specified Jubilee by brand.” On Jubilee’s involvement in supply hose clamps, Ian Jennings, managing director at Jubilee Clips, said: “I am a big fan of motorsport, I love to see engineering pushed to the limits because going further and faster and competing for the win is what it is all about. Like our company, Amigo Motorsport is a family venture, proving that enthusiasm is more important than budget. They’ve been very welcoming to us and we were very happy to help them out with their ambitious plans.”

Rotor Clip receives AS9100 certification Rotor Clip has taken another step in its goal to continuously improve its products and processes, and increase overall customer satisfaction, by recently meeting all the requirements for AS9100 certification.

otor Clip can now offer the aerospace industry a ‘one stop’ shop for tapered, constant section and spiral retaining rings, wave springs, and self-compensating hose clamps. In addition, the industry has at its disposal technical engineering staff to advise on the most economical way to use its products including suggestions on the best type, dimensions, material, finishes and packaging to use for a particular application. According to Sara Mallo, VP of sales, the certification is good news for aerospace customers looking for additional sources for these products. “We’ve always prided ourselves on offering choice to our customers in the type of retaining rings they purchase,” said Mallo. “We’re now pleased to offer the same type of choice to the aerospace industry.” Mallo noted that the process of applying for the AS9100 has been “extremely positive,” enabling the company to uncover key areas of improvement and a greater command of its manufacturing processes. Mallo added: “What we have learned through the AS9100 process is how to take our current Lean thinking and improve upon it to provide our customers with an exceptionally high level of quality, reliable products, delivered when and where they need them.” The certificate reads that Rotor Clip ‘has established and applies a quality system for the manufacture of tapered section, constant section and spiral wound retaining rings; Truwave ® coiled flat wire wave springs (single and multi-turn); as well as Rotor Clamp self-compensating hose clamps, in accordance with customer and industry specifications.’ www.rotorclip.com

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COVER STORY

Determined to succeed DIV Ltd, a member of the DIV Group, is a specialist in processing, manufacturing and trading fasteners, as well as machine parts and products, with the ultimate aim of becoming synonymous with quality and fast delivery, whilst at the same time creating long-term relationships with customers.

eadquartered in Samobor, Croatia, DIV Group (DIV) has more than 3,000 employees in the group. DIV has a special production facility in Knin, Croatia, where it specialises in the mass production of screw elements. Other affiliates making up the DIV Group include MIN-DIV Svrljig a.d, Serbia – which focuses on the manufacturer of accessories for rail; TVIK-DIV d.o.o based in Valjevo, Serbia; Debeljak Industrija Vijaka, Sarajevo, Bosnia and Herzegovina, DIV Concrete Sleepers Ltd, Serbia, as well as Shipbuilding Industry Split Inc – Croatia’s largest shipyard. The family run business has one key philosophy that runs throughout the company: ’To become the biggest producer of fastener elements in the world.’ “Today it is not enough just to sell products,” explains Tomislav Debeljak, president at DIV Group. “It is important that you are able to build relationships and partnerships with customers. It is only through building long lasting partnerships that you can ensure that you grow as a company, and your customer also grows with you.” DIV offers global solutions across a range of industry sectors, supplying goods to the majority of countries in the European Union, as well as countries in Africa. The company is also looking to expand into new markets such as Russia, America and Canada. “When it comes to innovations and providing total solution for fasteners, we continuously adapt our products and services,”

states Darko Pappo, member of the board. “In order to recognise and meet the expectations of customers, our fastener factory is certified according to ISO 9001:2008 through the TÜV Group.” Recognising the needs of the market and following regulatory requirements and EU directives, DIV is currently certified for key standards tied to the European directive for construction 305/2011 and equipment under pressure PED 97/23. The products manufactured in compliance with the European directives are also accompanied by Declarations of Performance, and labelled with CE marking, so that every manufacturer can install them into their own final product. Tomislav Debeljak adds: “At DIV we are very conscious of making sure that all our products meet the very highest standards. For instance, whilst we already meet our national legal regulations, we will be looking to meet standards for environmental care and safety at work, by attaining certification according to ISO 14001 and OHSAS 18001.” Tomislav continues: “In addition our primary production is based on DIN, EN, ISO, ANSI and UNI Standards.” DIV’s production takes place on modern production lines using automatic cold forming, ranging from two blow to seven station progressive transfer headers, and automatic/ semi-automatic multiple-stroke hot-forming machines. The group has a wide range of capabilities available across its various sites including: Chemical descaling and phosphate

DIV’s rail capabilites DIV is certified for EN 15085-2:2008 Railway applications – welding of railway vehicles and components – Part 2: Quality requirements and certification of welding manufacturer (EN 15085-2:2007). This gives DIV the right to manufacture steel construction for railway vehicles. In the same market sector DIV also has certification from Deutche Bahn AG for retaining rings for railway accessories. DIV is able to supply a wide range of products for the rail industry, including threaded railway fastening, rolled railway accessories, rail track stabilising accessories, synthetic railway accessories, rails, elastic railway accessories, light railway machinery and rolling stock components. The company will be exhibiting at the upcoming InnoTrans 2014 exhibition in Berlin, Germany. “At the InnoTrans show

10 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

HALL 26 STAND 204

we will be showcasing our wide capabilities for the rail market,” comments Darko Pappo. “We invite all customers to our stand so that they can find out more about DIV.” In addition to the rail sector, DIV also focuses on other markets including the automotive industry. “Our recent focus on the automotive industry has resulted in us adopting the demands of the ISO TS 16949 in our own processes,” mentions Darko Pappo. “We will be looking to attain ISO TS 16949 certification in the future.”

“ We recently opened a new factory, valued at 25 million euros, representing the largest investment ever by DIV Group.” coating (for raw material wire and bars), drawing, shot blasting, annealing and normalisation, cold and hot forging, thread rolling, stamping, grinding, milling, heat treatment and case hardening. This wide range of manufacturing capability means that DIV can produce an extensive range of products in standard and non-standard dimensions, and is equipped for OEM production according to special customer requirements. DIV has the capacity to produce cold-formed products from M2 to M27 x 250 using multi-die bolt making machines, with a capacity of over 120,000 tonnes per year. Hot forged products range in dimensions from M8 to M120 x 1,200, using automated machines with presses up to 630 tonnes, with a total capacity of 100,000 tonnes per year. Thread rolling capacity ranges up to M120 (metric thread, UNC, UNF, Whitworth, RD, TR and others), using flat die, planetary die, thru feed and in-feed thread rolling machines with up to 50 tonnes of pressure, and total capacity of 30,000 tonnes per year. DIV is also able to produce steel sheet and profiles through laser, plasma, and gas cutting. DIV’s heat treatment is carried out in-house by hardening and tempering of fasteners in continuous flow furnaces with protective atmosphere. These have a capacity of 7.5 tonnes per hour. DIV can offer all types of surface protection, including electroplating and galvanising, hot dip galvanising, decorative surface protection, highly corrosive resistant surface protection and coatings for reducing installation friction. All protective coatings meet the requirements of REACH and RoHS and do not adversely affect the environment. To add to its large selection of products, DIV has incorporated a modern approach to warehouse management, using a highly sophisticated transport and network – including a warehouse of over 40,000 pallet positions and more than 100,000 items ready for delivery. DIV is also able to provide Kanban and Just-in-Time delivery systems. DIV’s packing department is equipped with six semi-automatic packing facilities with a capacity of 8 – 10 tonnes per hour. Properly packed products are stored in high rack storage while 13 loading ramps are ready and waiting to load goods from Knin to all corners of the globe. “We recently opened a new factory, valued at 25 million euros, representing the largest investment ever by DIV Group,” mentions Darko Pappo. “Annual production capacity of the new factory is 100,000 tonnes, which increases export from the current 20 million to 100 million euros.”

The new factory (pictured above) is located on the site of an existing industrial plant and covers more than 22,000 square metres of production and handling space. With this new investment DIV intends to achieve mass production of standard fastener products, especially ISO 4014, ISO 4017, DIN 931 and DIN 933. The new factory also offers storage capacity for raw materials of over 10,000 tonnes. “This new factory will enable us to continue to serve our customers with a wide range of standard and non-standard fasteners,” explains Tomislav Debeljak. “Our satisfied customers are the best sign that we are on the right path. By expanding our operation we are ensuring that we can continue to satisfy our current and new customers. It also underlines our determination to succeed.” DIV Group undoubtedly has a vast range of skills and capabilities that enables it to service a selection of industries around the world. With the new factory adding additional capacity, what plans does DIV have for the future? Tomislav and Darko are both in agreement: “As a company we will continue to plan for growth and development in all segments of our business processes. Most importantly we will continue to work with our customers in creating long-term partnerships that ultimately lead to success for us and our customers.” www.divgroup.eu

www.fastfixtechnology.com

FASTENER + FIXING TECHNOLOGY

Partnering with customers Piero Bruno, sales manager for Alcoa Fastening Systems (AFS) industrial division – covering France, southern and central Europe – has worked for Alcoa Fastening Systems for the past 10 years. His current position involves the management of five sales engineers and four internal sales staff, all of whom have the experience and knowledge to work with customers to find the ideal product for every application.

Which markets/industries is AFS able to supply and which ones is it currently focusing on? “At Alcoa we are involved in a wide spectrum of markets, as our fasteners are used in practically every application and every market. As a rule we do not focus on a particular market segment. Instead we concentrate on applications where we can add value. These applications are normally found in defence – military applications, building, construction, industrial air conditioners, agriculture, as well as our core markets such as automotive, truck and trailers, and rail. A more recent sector, which we are currently actively pursuing, is the green energy market (wind and solar energy). We have been working on some interesting applications for this sector and see it as a growing market for us in the future.”

What presence does the company have in the rail industry? “There are two separate markets in the rail industry that we supply. The first is the infrastructure side – the track, the overhead cabling, cable exchanges and construction of stations. The second market is train carriage construction – in its simplest form that means everything that is moving on the tracks. Our customers are all the major players in the industry. The reason our customers choose Alcoa is because they do not want to compromise on safety. Our products are used in critical, high safety, and technically demanding applications, and provide quality fastening over many years.”

How does AFS work with rail customers and what are the advantages to the customer of this relationship? “Whilst the sales team at Alcoa Fastening Systems does get involved in the commercial aspect – prices, terms and conditions, etc, we are predominately sales engineers. This

12 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

means we are able to understand what the customer is looking for and we are able to translate it to our engineering team. Our sales team is always involved in the process and is able to help customers find the ideal solution for their application. Our sales engineers tend to work directly with the customers’ engineering and production departments. We present our products, demonstrate the benefits we provide, analyse what type of products our customers are using and for what applications, and because we have built a strong relationship with our customers – and have a strong reputation in the railcar industry – they speak to us about specific applications and ask for recommendations on what products we think will work best. This means that right from the beginning of working with us customers are benefiting from our experience and technical expertise, resulting in them finding the perfect solution for their applications, as soon as possible.”

AFS has a European network of facilities. How does the Group ensure that it presents a consistent service across Europe? “With manufacturing and distribution facilities on all major continents AFS has extensive experience working with customers on a global scale, as well as providing for the fastening needs of local manufacturers. This means that when a customer moves to a new market or creates a new plant in a country, we are able to serve and support them immediately. As a business we are technically innovative and flexible. We are able to solve our customers’ issues as they are looking for a solution to their application. We have the capability to customise products to meet the application requirements or produce a totally new fastener if needed. Our ability to provide innovative products, combined with our long-standing leadership and commitment to excellence, makes us the best choice for the rail markets fastening needs.” www.afshuck.net

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RAIL FASTENING TECHNOLOGY

No longer just a permanent way to meet rail applications Alcoa Fastening Systems (AFS) has a long history of servicing critical applications on the UK rail permanent way. In many cases, permanence – in the sense of extended fatigue life, security and vibration resistance – has, indeed, been decisive in the selection of Huck® products. One of AFS’ latest developments, though, now presents high levels of surety combined with the flexibility of assembly and disassembly using conventional hand tools.

afety critical rail applications for which AFS, and in particular its C50L® and BobTail ® lockbolts and lockstuds, have provided major advantages over conventional threaded fasteners are to be found in both the switch and crossing zones of the permanent way. The key benefits are immediately recognisable to any engineer familiar with AFS’ Huck ® fasteners. The speed and ease of installation of Huck ® products increases productivity and reduces labour costs. Consistent, high clamp force and mechanical strength ensures maximum joint integrity, extending its life and that of associated components. Inspection is a simple visual process to confirm correct installation. In contrast to conventional threaded nuts and bolts, Huck fasteners will not loosen, even under the constant and often extreme vibration experienced in permanent way applications. The benefits to the rail network are faster patrolling and reduced spanner work for maintenance teams. Permanently tight fasteners also mean reductions in vertical impact loading, subjecting point operating mechanisms to less vibration. This extends operational life and reduces the risk of failure of other components. More recently, the permanence of AFS’ Huck fasteners has contributed substantially to the UK rail systems fight against a menace that costs an estimated GB£16 million annually and impacts the convenience and safety of rail users and staff. The theft of copper cable is a really serious problem. Searching for a more robust replacement for easily removable standard nuts and bolts used at spider junction boxes, Network Rail engineers carried out a series of rigorous trials in Newcastle upon Tyne, UK, leading to the issue of a Certificate of Acceptance authorising the use of Huck fasteners

and associated tooling in this application. Conventional threaded fasteners were replaced with Huck C50LR-BR20-12G and C6LB-R12-12G fasteners, attaching cable to both track and junction box. John Rickers, AFS Telford systems development manager, is confident the solution provides a superior upgrade and a significant deterrent to thieves. “Stolen cable is not only expensive to replace, but incurs significant labour costs as well as inconveniences rail customers. When a cable is stolen, the area has to be located, isolated, re-jointed and tested, often requiring specialist teams to carry out the repair. Conventional nuts

Huck fasteners’ ‘fit and forget’ strength clearly does not help here. Recent developments at Alcoa Fastening Systems’ headquarters in Waco, Texas, USA, though, present the rail industry with a new Huck product, which successfully combines the security and vibration resistance of a Huckbolt ® lockbolt with both rapid and easy assembly and disassembly with standard hand tools. At first sight, Huck 360 ® lockbolt looks very much like a conventional threaded bolt and nut combination. In fact, there are very significant technical and even more significant performance

and bolts, unlike Huck fasteners, can be removed relatively quickly. The longer a thief spends attempting to remove fasteners, the higher the probability he will be caught in the act.” Ironically, ‘permanence’ has in some applications been a limiting factor for Huck products. Many safety critical rail applications require regular disassembly for maintenance and adjustment, and

differences. For the Alcoa Fastening Systems’ development team, the goal was simple – to design a high strength bolting system that resists vibration loosening no matter how extreme the environment, delivers superior fatigue strength, and holds tight under high cyclic fatigue loads. And just to add to the challenge, it must also be capable of rapid installation and removal using

14 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

“ At first sight, Huck 360® lockbolt looks very much like a conventional threaded bolt and nut combination. In fact, there are very significant technical and even more significant performance differences.” conventional tooling. Jonathan Craven, AFS Telford operations director, explains how Alcoa Fastening Systems’ ingrained instinct for effective innovation has delivered a new product with unique capabilities. “Huck 360 lockbolt has a shallow proprietary thread form that concentrates 27% less axial stress in the root than conventional bolt threads. This stress concentration is the primary contributing factor leading to stress corrosion cracking and fatigue failures. Huck 360 lockbolt’s thread flanks are effectively locked preventing the nut from moving relative to the bolt – in contrast to a

conventional threaded bolt where thread flanks are able to slide when subjected to transverse vibration, resulting in the nut moving relative to the bolt.” “Additionally, when the Huck 360 lockbolt nut is tightened, it plastically deforms around the thread. The resultant intimate contact is circumferential, helping to generate vibration resistance previously only achievable by using a lockbolt.” Huck 360 lockbolt nuts can be simply hand spun onto the bolt unlike conventional lock nuts where prevailing torque requires almost immediate use of a tool. This significantly speeds up assembly times, with final setting carried

out with a conventional torque wrench. An assembly speed comparison video at www.huck360.com provides an excellent visual demonstration. “We recognise that the rail track sector is understandably extremely cautious in assessing new product developments for safety critical applications,” says Jonathan Craven. “We are confident that, as engineers are able to assess first hand the capabilities of the Huck 360 lockbolt, it will gain approval and come to make a very substantial contribution to rail safety, efficiency, and economics.” www.afshuck.net

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❚ A permanent, mechanically locked fastener ❚ Unlike conventional nuts and bolts, they will not work loose, even during extreme vibration ❚ Pintail-less design eliminates material waste, reduces installation noise & improves corrosion resistance

0800 019 8180 info@afshuck.net www.afshuck.net

RAIL FASTENING TECHNOLOGY

Nothing is impossible Kettling Verbindungselemente GmbH has established itself as a specialist manufacturer of connecting elements across all industries, supplying around the world. The company’s key strength is its expertise in materials, made to measure instruments and consultancy, as well as its flexibility and the service it provides.

or 30 years Kettling has been specialised in the production of U-bolt clamps and other connecting elements based on round steel (with diameters up to 65mm). For instance, Kettling can produce round steel shackles, according to DIN 3570, and non-standard screw fasteners in a range of sizes from M5 to M72 – made of stainless steel and steel in conjunction with all surface finishes. In addition, welded connections such as pressings and stampings can also be produced. These products can be used for a variety of sectors including agriculture, heavy-duty vehicles, structural engineering, power plants and the rail industry. At Kettling the emphasis is not on manufacturing ‘mass produced products’, but rather on special solutions with

stringent demands in terms of load and purpose. The company’s vast experience ensures that the customer receives a high consultancy competence with respect to material selection and dimensioning of the articles. In addition, the operational structure at Kettling results in an extremely prompt and flexible processing of customer requests. The production is characterised by modern manufacturing facilities and in-house tool engineering, enabling Kettling to supply tailor-made connection technology solutions – made of steel and stainless steel – to customers’ demands. “When you next take an ICE train on a high-speed rail line rest assured that the overhead line is carried at the mast by stainless steel U-bolt clamps from Kettling Verbindungselemente GmbH.”

InnoTrans 2014 approaching

At the tenth InnoTrans – which takes place from 23rd – 26th September 2014 in Berlin, Germany – the main emphasis will once again be on railway technology, railway infrastructure, tunnel construction, interiors and public transport.

nnoTrans, organised by Messe Berlin, is the world’s leading business meeting place for the rail industry. A full range of rail vehicles are presented in static displays on the Messe Berlin tracks located outside the exhibition halls, in addition to the 40+ exhibition halls showcasing the latest developments in rail transport technology. At the last event more than 2,500 exhibitors from 49 countries presented their rail industry innovations to over 125,000 trade visitors who came from 140 countries – with InnoTrans organisers expecting a similar numbers for the 2014 event.

16 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

Fastener related exhibitors at InnoTrans includes: Flaig + Hommel GmbH Verbindungselemente, Ferdinand Gross GmbH & Co KG, Walter Stauffenberg GmbH & Co KG, DIV d.o.o, Lederer GmbH, Adolf Würth GmbH & Co KG, Keller & Kalmbach GmbH, Gally SpA, Bossard AG, Nord-Lock GmbH, J. Lanfranco & Cie, Bufab Industries SAS, Otto Fuchs KG, Growermetal Srl and HEICO Befestigungstechnik GmbH. More details about InnoTrans and current developments in international transport technology are available online. www.innotrans.com

HALL 8.2 STAND 217

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

RAIL FASTENING TECHNOLOGY

HALL 10.2 STAND 305

Intelligent. Flexible. Unique.

ontinuity, experience and quality have been the watchwords for Ferdinand Gross for 150 years, with the company among the largest suppliers of fastening technology in Germany. One specialty of the Swabian company is intelligent C-parts management, which is now bundled under the name Ferdinand Gross Kanban. Ferdinand Gross says that the consistent advancement of Ferdinand Gross Kanban into a holistic and absolutely flexible delivery system underlines its abilities as a service provider for the industry. With Ferdinand Gross Kanban, the company takes on the administration of small parts and organises the stockholding for customers. In addition, with an individual fleet of vehicles – the Kanban-Express – Ferdinand Gross can ensure trouble free and continuous delivery, giving customers the certainty that their products will always be up to date so that they can benefit from a competitive edge.

Deutsche Bahn banks on Ferdinand Gross and FALCON One of the companies that have relied on the services of Ferdinand Gross for years is Deutsche Bahn AG. The transport company relies on Ferdinand Gross Kanban in all plants. The company was also one of the first to recognise the potential of the Kanban advancement FALCON and implemented the revolutionary software immediately. In late 2012, Ferdinand Gross brought Kanban systems to a new level with FALCON, putting a powerful instrument of control into its customers’ hands. The FALCON software solution provides a visual representation of which C-part is where and on which Kanban shelf. The FALCON system also enables absolute visualisation of all Kanban storage locations with all products and data – on PCs as well as tablets and smartphones. Ferdinand Gross says it has returned the overview and the control of its C-parts management to the purchasing agent with this intuitively operated tool.

18 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

Fastening specialist Ferdinand Gross GmbH & Co KG has repositioned its Kanban activities and simultaneously launched a new release of the Kanban visualisation software FALCON. New innovative search options In the newly released 3.1 version of FALCON, Ferdinand Gross has implemented numerous suggestions of customers. The full text search now allows not only searches for DIN and customer item numbers, but also for dimensions, quality levels or item texts. A combination of different types of data is also possible – for instance if the design engineer enters 10.9 8x25 in the search mask, they will find all screws with the appropriate dimensions and quality level. They will also know immediately which standard screws are already in stock. Wildcards are also possible: Entering 10.9 8x2* will call up a list of all screws with this quality with the diameter of 8mm and a length starting with 2. Ferdinand Gross points out that the search options are almost unlimited – whether searching for item numbers across the entire site or only on the shelf – the results are visible immediately. FALCON can also search for item designations, product properties, container numbers, delivery notes and even batches. A combination of these search options with wildcards (*) or a positive (+) or negative query (-) increases the possible results. This makes the web-based software even more productive and additionally flexible and profitable for all departments – whether it is production, logistics, purchasing, quality assurance or controlling. FALCON 3.1 can also display information on items requiring certification, as well as the warehouse coordinates of the containers including storage location designation.

No installation needed The new features are already implemented in the system – and because FALCON is still an internet-based software, all FALCON customers can benefit immediately from the innovative add-ons without installation. “Whether in the office or on the road – with FALCON 3.1 from Ferdinand Gross, C-parts management just got a little bit more transparent and more convenient.” 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 3.1 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

RAIL FASTENING TECHNOLOGY

HEICO-LOCK® expands product range

HALL 8.2 STAND 103

In 2010, German manufacturer HEICO Befestigungstechnik GmbH founded the new business unit HEICO-LOCK®.

EICO-LOCK® stands for high-quality anti-vibration security for the most demanding bolted joint applications – even under extreme vibration or dynamic loads – providing maximum security. HEICO explains that HEICO-LOCK is a wedge lock system consisting of two special shaped washers. When the bolt or nut is tightened the external radial teeth of the HEICO-LOCK Wedge Lock Washers embed themselves in an interlocking fashion with the respective mating surface. If the bolt or nut tries to rotate loose, movement is only possible between the internal, wedge shaped washer surfaces. Due to this movement, an expansion in thickness occurs. This expansion leads to an increase of the clamping force within the bolted connection and therefore to a self-locking behaviour. HEICO-LOCK Wedge Lock Washers are available from M3 – M76 in both steel and stainless steel with a normal or an enlarged outside diameter. Besides the basic HEICO-LOCK Wedge Lock Washers, HEICO launched two further innovative products based on the proven HEICO-LOCK principle:

HEICO-LOCK® Ring Lock Washers The ring locking system guarantees that the two wedge lock washers are always secured in the correct position with the wedge-shaped cams on the inside and the radial teeth on the outside. Whereas the wedge lock washers secure the bolted connections reliably, the polyamide ring on the outside holds the two individual washers together in the correct position permanently. HEICO says that this means

20 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

the bolt locking system is always easy, safe and quick to install, even for non-special users and repeated use. HEICO-LOCK Ring Lock Washers are available from M4 – M24 in both steel and stainless steel and with a normal or an enlarged outside diameter.

HEICO-LOCK® Wedge Lock Nut The nut and the HEICO-LOCK Wedge Lock Washers are combined in a captive and rotary way, ensuring that the HEICO-LOCK Wedge Lock Washers and the nut are fixed permanently in the correct position. HEICO explains that due to the one-piece design of the HEICO-LOCK Wedge Lock Nut it eliminates the risk of misuse and breakdowns in production lines – caused by faulty bolted connections. It also ensures a safe and fast assembly, as well as easy handling, especially in hard to reach areas, and the captive design of the HEICO-LOCK Wedge Lock Nut guarantees a safe and fast reuse in most applications. The nuts are available in carbon steel from M6 – M22 in both coarse and fine thread. “Customised HEICO-LOCK products are available with non-standard dimensions or special materials such as Inconel or SMO254 and are available upon request. Our global customer service and in-house laboratories offer a high level of technical advice, as well as individual testing facilities. For further information please visit our website or contact us directly.” www.heico-lock.com

RAIL FASTENING TECHNOLOGY

HALL 10.2 STAND 104

Withstanding extreme conditions: Stauff clamps meet the requirements of Russian railways The Stauff Group has been a supplier to the rail industry for almost 35 years, with the first project being Stauff UK supplying clamping components and systems for pipes, tubes, hoses and cables to the Metropolitan Cammell Carriage and Wagon Company (MCCW) – a former Birmingham based manufacturer of railway carriages and wagons.

riginally Stauff clamps were used for trains on the Jubilee Line of London’s underground railway system, which was officially opened on 30 th April 1979. Over the years, Stauff’s specialist clamp development and manufacturing capabilities have enabled the company to accommodate the increasing safety demands of the global rail industry, with a range of clamp body materials meeting all commonly used international fire protection and safety standards and regulations. All Stauff clamp body materials available are capable of being moulded to any configuration, providing an industry solution for all pipe, tube, hose and cable support requirements, for both manufacturers and sub-contractors. In February 2013, Stauff clamp bodies made of SAV0, a thermoplastic elastomer with V0 classified fire protection capabilities according to UL 94 plastics flammability standard released by Underwriters Laboratories, were successfully tested in the test centre for railway transport vehicles in the Russian Federation. The testing procedures included the inspection of clamping/ holding forces of SAV0 clamp bodies of the Standard Series according to DIN 3015 – properly assembled with metal mounting hardware such as elongated weld plates, hexagon head bolts and cover plates – under the influence of mechanical and climatic factors. These were namely the exposure to vibration at regular and extreme ambient temperatures down to –55°C. All tests were performed according to GOST state standards 15150-69 and 30631-99.

22 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

In conclusion, no sliding or movement of pipelines related to their original position could be observed, and the clamp bodies maintained their full elasticity, which is an important contribution to efficient noise reduction and vibration damping in industrial applications. The test results also provided Stauff with the final technical approval to supply SAV0 clamp bodies and metal mounting hardware for the Desiro RUS project – an electric multiple unit passenger train developed by Siemens AG for Russian Railways (RŽD), which branded them ‘Lastochka’ (Russian for ‘little swallow’). In mid-2013, a joint venture of Russian Sinara Group and German Siemens AG named Ural Locomotives, commenced production of a second batch of ‘Lastochka’ trains at the Ural railway engineering plant located in Yekaterinburg, after the Siemens plant in Krefeld, Germany, had fulfilled Russian Railways’ initial orders for 54 of these units since April 2011. While the first batch of trains had to be designed to be fully operational at ambient temperatures as low as –40°C for use in the western/European part of the Russian Federation, the requirements for the trains built in Yekaterinburg were even higher. All components have to withstand extreme ambient temperatures down to –55°C while maintaining their original performance properties. According to the contracts signed in 2011, a total of 36 trains of the new ‘Lastochka’ series manufactured at the Ural plant are scheduled to be supplied to RŽD by 2015. Overall, the contracts include the delivery of up to 1,200 passenger cars during the period from 2015 to 2020. www.stauff.com

Hall 10.2 Stand 104

Original STAUFF Clamps Systems and solutions for the quick, easy and secure installation of pipes, tubes, hoses, cables and other components; made of ﬂame-retardant materials, tested and approved according to international ﬁre-protection standards (BS 6853, CEN/TS 45545-2, DIN 5510-2, NF F 16-101 and UL 94)

STAUFF  Walter Stauffenberg GmbH & Co. KG Tel.: +49 02392 / 916-0  Fax: +49 02392 / 916-160 sales@stauff.com  www.stauff.com

Fastener + Fixing Technology 2014 07.indd 1

27.06.2014 15:18:16

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

NORMA Group – improving cost savings NORMA Group has more than 60 years experience of manufacturing and developing a comprehensive range of engineering joining technology in the clamp, connect and fluid categories. Will Lowry spoke to Jonathan Heywood, director of product engineering for EMEA at NORMA Group, about NORMA’s ability to work with customers on future developments and how NORMA products can be used to help improve cost savings. To start with can you tell me about your current role and your career at NORMA Group? “I moved to the NORMA Group in 2011 and was attracted by the success of the company and the wide reaching product portfolio in diverse markets. NORMA Group is not focused on one particular product or market, but is a key development partner and supplier for companies in a diverse variety of business areas such as vehicles, ships, trains, aircraft, domestic appliances, plumbing and pharmaceutical. I lead the product engineering departments based at all of our plants throughout Europe, who are responsible for designing our products for current applications and future innovations – securing our future and the future of our customers.”

NORMA Group provides engineered joining technology solutions. How does the Group ensure it is providing the technology its customers need? “The NORMA Group has a large product portfolio of some 30,000 engineering joining technology products, with a rich design and production experience in both metals and thermoplastics. The ability to provide products for a whole range of related applications is something outstanding from NORMA Group. For instance, as well as supplying thermoplastic pipes and connectors for UREA applications in the exhaust system, we also design and supply the associated metal clamps and fasteners. It is using the knowledge from one side of our business and applying it to other products that enables us to offer our customers the complete solution.”

How can NORMA’s products be used to help improve cost savings? Do you have an example? “It is not just about designing the individual products, it is about providing the comprehensive solutions that take into account our customers individual requirements. These include reduced assembly times or warranty costs. On top of that it is about fitting our solutions into ever tighter engine compartments. We have a highly qualified development team that is able to provide state of the art technology and to cater to our customers’ needs and requirements. We anticipate future developments – therefore not just existing applications, but

24 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

the innovations we are going to need in 2, 5, or 10 years time. We translate them into products that offer a benefit that goes beyond the normal product. To give you an example: When looking to save weight of the overall systems, we have an application where we have replaced rubber hoses with plastic pipes, which results in a weight reduction of 3.5kg. That 3.5kg helps reduce emissions, because it reduces the weight of the car and therefore there is less fuel consumption. We also concentrate on sustainability. For instance we were the first Tier 1 supplier to be able to extrude high temperature PPA resin based plastic, which is based on a renewable vegetable food stock. In addition, communication with the customer is absolutely critical, we have learnt this over the years and one of the areas we excel in is making sure that there is an absolute understanding of what the customer wants, so we can design the best solution. More and more we see customers coming to us for the complete package. For instance, there are several companies that supply V-profile clamps for exhaust connections, but we don’t just supply a V-profile clamp – we provide the solution. We recommend what type of gasket should be used, we specify and define the flange geometry for the customer – including all the tolerances – and then based on that we propose the best solution for that joint. Not just the clamp, but the joining system. A typical example of one of our products helping customers to save costs is the V2PP clamp, which saves our customers assembly time due to its easy handling.”

What are the features/specifications of the V2PP clamp that make it easy to handle? “V-profile clamps are connecting elements for flanged pipes and are used in various applications such as exhaust gas, cooling water and UREA systems. Typically, such clamps require the bolt to be assembled on the production line at the customer. However, the V2PP profile clamp is characterised by a pre-assembled bolt. This significantly reduces the assembly time, whilst simultaneously eliminating the danger of cross threading the bolts during assembly, which can lead to a costly stoppage of the production line. How do we do this? Our patented design features a clip on the side of the clamp opposite the bolt, which together with the integrated spring allows the easy pre-assembly of the clamp using only two fingers. This is a significant improvement for an assembly operator, who is normally juggling 3 or 4 components at the same time – two pipe parts, a clamp for connecting them, and often a gasket as well. The V2PP clamps are pre-assembled at NORMA and are packaged so that they can be taken out of the packaging with two fingers and directly assembled on the flanges. In addition, the V2PP is characterised by low weight, which helps to reduce the overall weight of the system, and is optimised for extremely tight packaging spaces, making it even more suitable for automotive applications.

We went into mass production of the V2PP clamp in January 2013 with a well known Tier one supplier and a major OEM. We also have active projects with all key exhaust system and UREA system suppliers.”

NORMA has the ability to work with customers on future developments. What are the benefits to the customer of this relationship? “The sooner the customer approaches us, the better the solution we can design. We produce an amazing variety of different products for a wide selection of markets, but each market and application is individual, which is why we always aim to be involved in the development of applications as early as possible. The benefit to the customer is that we like to create close working relationships with our customers, and being involved in the development stage helps us to do that. Also, as a company we are constantly monitoring the global megatrends, which influence the industries, as well as collecting feedback from customers. By monitoring these requirements and taking into consideration what we are hearing from the close working relationship with the customers, we are able to anticipate what the customers are going to need. We are able to be ahead of the curve by developing products now, which our customers will ask for in the future.” www.normagroup.com

10-1Z-6-130610-SE

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.

www.normagroup.com

LIGHTWEIGHT APPLICATIONS

Perfect tightening control NOF METAL COATINGS EUROPE explains how the growing use of light alloy parts, the increase of tightening speed, and high preloads, require more and more efficient topcoats.

or many years now, the topcoat PLUS ® VL applied on the basecoat GEOMET® 321 has become a key requirement in the German automotive industry – providing excellent anti-corrosion performances and perfect tightening control at a very competitive price. Long before the implementation of the European directive concerning the recycling of end of life vehicles (2000/53/CE), NOF METAL COATINGS Group – the only supplier of zinc flake anti-corrosion coatings whose chemical compounds are in an aqueous phase and contain only a few Volatile Organic Compounds (VOC) – has offered completely chromium-free (chrome VI and III) solutions under the trademark GEOMET®.

When in an automated production process the preload on aluminium can vary or sometimes even be out of tolerance, which can become critical for security relevant assemblies such as chassis and suspension parts. To provide more precise requirements Volkswagen included additional criteria in the last version of the 01131-1/2 standard including: • The need for five consecutive tightening procedures onto e-coat surfaces. • An assembly onto aluminium with a torque exceeding the yield point. • A list of reference parts (bolts, nuts, aluminium and e-coat plates) from a sole supplier.

Approved by Volkswagen since 2004

Other car manufacturers have also developed their own internal test procedures to make sure the friction behaviour fulfils the complex requirements of real assembly situations.

As a result, PLUS ® VL was tested and approved by Volkswagen in 2004 after industrial trials on different types of fasteners. In 2006, the new internal standard VW 01131 was published and some tightening criteria was included in the VDA235-203 standard. GEOMET 321 + PLUS VL became the most widely used zinc flake system in Germany and Europe thanks to a network of highly qualified applicators united by the unique quality system of the NOF METAL COATINGS Group.

Materials evolution and precise tightening conditions Today an important number of assemblies are made with increased rotation speeds but also with a torque-angle sequence procedure. Certain bolt geometries, in combination with volume produced e-coat surfaces, may present a higher tendency for stick-slip occurrence. In addition, the obligation to decrease vehicle weights has led to an increased use of light materials such as aluminium either for the bearing surface of the screw or for the thread tapped into large parts where the threaded length is larger than 2.5 times the thread diameter of the screw.

26 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

PLUS® VLh: The standard for consecutive tightening NOF METAL COATINGS Group decided to improve PLUS VL, which already showed excellent results, by taking into account these new requirements. PLUS ® VLh solves the problems mentioned on assembled, cataphoretically pre-coated surfaces and also provides exceptional tightening results on and into aluminium and even aluminium critical assemblies.

Total torque in Nm

At the same time, topcoats were also developed with improved anti-corrosion performances and close control of friction coefficients. However, the increased use of cataphoretic coated steel showed new problems when tightening such as stick-slip. Volkswagen therefore introduced additional testing procedures that would help detect potential problems in real assembly situations: • Pre-tightening at 200rpm and final tightening at 20rpm. • Consecutive tightening. • Loosening at 150ºC.

Cumulated rotation angle in degrees (°)

Consistent performance of the GEOMET® 321 + PLUS® VLh system in consecutive tightening into aluminium

C o m p l e m e nt a r y to p c oat fo r G EO ME T ® Unequalled friction performance under difficult tightening conditions at 150°C

Good loosening performance

Multi-tightening on and into aluminium

with very low deviation onto catophoretic paint

No stick-slip tightening Specifications : VW TL245 –

Ofl t647 DAIMLER DBL9440.40

www.nofmetalcoatings.com

is a registered trademark of NOF CORPORATION

performingtopcoat

LIGHTWEIGHT APPLICATIONS This topcoat is applied under the same technical conditions and temperatures as its predecessor. The coat uses the same IMDS number, as the optimisation of the properties was achieved by a very subtle evolution of PLUS VL. All product characteristics such as nominal friction value, corrosion resistance, the influence on dimensional tolerances, remain unchanged and as a consequence, the new topcoat PLUS VLh can easily be used as a complete replacement of the existing solutions. Industrial line trials at Volkswagen and Daimler proved the general usability of PLUS VLh and also its capability to solve the most critical tightening circumstances. The torque values remained in the specified range and the torque-angle sequence procedure showed a significantly lower variation and better repeatability of the final load. Since the end of 2013, PLUS VLh is used according to the Volkswagen (TL245 t647) and Daimler (DBL 9440.40) standards. Other carmakers are currently testing this topcoat in order to include it in their technical anti-corrosion/ tightening standards in the near future.

Unique performances even in offshore atmospheres Business sectors such as offshore, wind power and building are also very interested in this system. Indeed, GEOMET 321 + PLUS VLh was certified by the institute Germanischer Lloyd who confirmed corrosion resistance according to DIN EN ISO 12944-6:1998, C5-M High, as well as salt spray testing being extended from 1,440 hours to 2,016 hours. This demonstrates that it provides excellent performance in marine and offshore atmospheres. PLUS VLh is already applied in serial production by a worldwide GEOMET licensed applicator. www.nofmetalcoatings.com

Fixed. And fastened. By Hopwood. In partnership with Southco.

Experience & professionalism since 1966

E3 Vice Action Compression Latches

M1 - Compression Latches

R4 Rotary Latch

Connect. Create. Innovate. As the UK’s biggest authorised distributor of Southco products, we’ve an extensive stock of highly engineered fasteners and access solutions - for all your industry’s fastener challenges. Whatever your fastener need, Roy Hopwood will fix it.

Tel: 0845

Bonfatti Filettature offers a wide range ready for your warehouse, including:

• Production of high-strength bolts: 10.9 - 8.8 - 6.8 • Partially or fully threaded rod / threaded rod grade • 8.8 Clamping bolts • M4 to M100 - Rolled threads and metric trapezoidal

519 6066

E-mail: sales@rhf.co.uk Hibbert Street • Whitehill Ind. Estate Stockport • SK4 1NS Leading the way in fastener distribution, quality and service

www.rhf.co.uk

Bonfatti Filettature s.r.l. Via De Nicola, 42 - 41100 Modena, Italy Tel: +39 059 251604 Fax: +39 059 254226 email: info@bonfattifilettature.it w w w.bonfa ttifil ettatu re.it

MASTER-PLATETM

3rd International Exhibition for Fastener and Fixing Technology

BUSHES AND STUDS FOR BONDING

FASTENER FAIR RUSSIA • ST PETERSBURG

Your path to the Russian market

The flexible solution for every mounting need

24 – 26 March 2015 Expoforum Convention and Exhibition Centre Russia’s fastest growing region, St Petersburg is a key centre for: • Automotive production • Shipbuilding • Emerging optical, IT, electronics, metal working and environmental industries

• SHORT DELIVERY TIME • 100% MADE IN ITALY • DIFFERENT SIZES AND SHAPES AVAILABLE • ZINC PLATED STEEL AND AISI 316 STAINLESS STEEL AVAILABLE • EASY APPLICATION WITH ADHESIVE

RESOURCES • KNOW HOW • DEVELOPMENT • RELIABILITY • QUALITY

FOR INFO: export@specialinsert.it - www.specialinsert.it

To exhibit, contact us on: Tel: +44 (0)1727 814 400 Email: russia@fastenerfair.com www.fastenerfairrussia.com

EUROBLECH 2014

Sheet metal working industry keeps focus on international business From 21st – 25th October 2014 the international sheet metal working industry will meet again for the leading industry fair – EuroBLECH 2014 – in Hannover, Germany.

total of 1,411 exhibitors from 41 countries have to date booked their stands, covering 86,500m2 of net floor space across eight halls of the Hannover Exhibition Centre. This represents a 3% increase in exhibition space compared to the previous show. Major exhibitor countries next to Germany are Italy, China, Turkey, the Netherlands, Spain, Switzerland, Austria and the USA. Half of all exhibiting companies come from outside Germany. Organisers state that this high percentage of international exhibitors once again confirms EuroBLECH’s position as the world’s leading exhibition for the sheet metal working industry. It also demonstrates that the industry sector continues to focus on international business contacts in order to be successful with their products in the long run. “The sheet metal working industry is currently facing an economic environment of diverse regional market situations within our globalised world. In addition, there is a demand for an ever growing choice of products, which needs to be met by using innovative and flexible fabrication processes. In this challenging but highly promising environment, it is essential for companies in the sheet metal working industry to invest in innovative technologies and tailor-made machines and systems. Intelligent process chains and efficient networks are indispensable,” explains Nicola Hamann, exhibition director EuroBLECH on behalf of the organisers, Mack Brooks Exhibitions.

Smart solutions for modern production “As the technological showcase and business barometer of the sheet metal working industry, EuroBLECH offers its audience a comprehensive overview of the prevailing technological trends. For companies in sheet metal working looking to find suitable machinery and smart solutions for modern production, the exhibition is the key global event. Visitors can find an extensive product range, from conventional systems through to advanced, high-tech processes and also gain an overview of what is available worldwide,” adds Nicola Hamann. The show profile of the 23rd international sheet metal working technology exhibition represents the entire sheet metal working technology chain: Sheet metal, semi-finished and finished products, handling, separation, forming, flexible sheet metal working, joining, welding, tube/section processing, surface treatment, processing of hybrid structures, tools, quality control, CAD/CAM systems, factory equipment and R&D. EuroBLECH 2014 will once again be held in halls 11 – 17 and 27 at the Hannover Exhibition Grounds. With its dedicated exhibition profile, EuroBLECH targets all sheet metal working specialists at every management level in small and medium sized companies, as well as large enterprises. Visitors include engineers, production managers, quality managers, buyers, manufacturers, technical directors and experts in associations and R&D. EuroBLECH 2014 is open from 9:00am – 6:00pm on Tuesday 21st October to Friday 24th October 2014, and from 9:00am – 3:00pm on Saturday 25th October 2014.

Visitor information A visitor brochure including important information for trade visitors to EuroBLECH 2014 can now be ordered online in twelve separate language versions. The show website also offers detailed information about the exhibition, as well as photos and videos, an up to date exhibitor list, and useful tips on travel and accommodation. Interested visitors can also subscribe to the EuroBLECH Bulletin, a regular online newsletter offering the latest updates on the exhibition as well as industry news and articles about the products being showcased in October. www.euroblech.com

30 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

23rd International Sheet Metal Working Technology Exhibition

Fastener related exhibitors at EuroBLECH 2014 Fastener Related Exhibitor Arnold & Shinjo

Hall/Stand No 13.A32

Avdel

13.A18

Bรถllhoff Verbindungstechnik

13.D24

Dirak

17.G20

Ejot

13.C72

Emhart

13.A18

EMKA Beschlagteile

16.C12

Fixi Srl

13.G60

Gesipa Blindniettechnik GmbH

13.F40

Haeger Europe BV

12.D26

Heyman Manufacturing GmbH

13.B68

Honsel

13.F73

Industrilas AG

16.E03

Nord-Lock

27.J81

Profil Verbindungstechnik

13.C18

Rivelit (Titanox)

13.E01

Sala Punzoni

13.G67

Schmeck Verbindungstechnik GmbH

13.F20

Heinz Soyer Bolzenschweisstechnik GmbH

13.E08

Stanley Engineered Fastening

13.A18

Titgemeyer

13.D55

TOX Pressotechnik GmbH & Co KG

13.D59

Unifast

17.B122

Vogelsang

17.E12

VVG Befestigungstechnik

13.F73

Wafios AG

15.H05

21 - 25 October 2014 Hanover, Germany Sheet metal, Tube, Sections

Handling

Forming

Finished products, Parts, Assemblies

Separation, Cutting

Joining, Welding

Flexible sheet metal working

Tube / Section working Tools, Dies

Machine elements

Composites

Surface treatment

Data capture / processing

Safety at work

Controlling, Regulating, Measuring, Inspection R&D

Factory and warehouse equipment

CAD/CAM systems

Environment protection, Recycling

www.euroblech.com

EUROBLECH 2014

HesoMatic-9 stud welding station replaces up to three units

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As a specialist for fastening and joining technology with over 40 years of technical experience, Heinz Soyer Bolzenschweißtechnik GmbH has recently launched a new mobile stud welding station named HesoMatic-9.

his pioneering technological development combines energy source, control unit and feeding unit in a single compact housing. The fully automatic welding of weld studs from 3mm – 8mm in diameter or 8mm – 40mm in length is greatly facilitated due to less space requirements and a clearly arranged operating panel. As there is no elaborate cabling between the units, the risk of error and the susceptibility to damage are significantly minimised. Additional performance features of the HesoMatic-9 include: • No cumbersome and time-consuming manual feed. • It requires 50% less space owing to a compact design in a single housing. • Maximum operating comfort and significant time savings. • Large diameter feeder bowl of 300mm for long studs and large filling capacities. • Trouble free transport due to stud feed via steps and low noise operation. • Long service life due to high grade, hardened and ground mechanical components. • One-piece casing as a protection against welding spatters, dirt and noise. • Accessories for above mentioned stud diameters are included as standard. www.soyer.com

RIV-ELIT® – providing an alternative The RIV-ELIT® brand was created in 2006 when Caroline Fodor, CEO of TITANOX Group – one of the main French distributors of technical fasteners and assembly solutions – acquired ELITE Assemblage, a French engineering company specialised in riveting solutions.

aroline’s vision was to build, under its own RIV-ELIT® brand, a full range of high added value blind rivets, and to provide high-quality, cost efficient products, with technical expertise and a fast and reliable service. With its strong engineering skills, resulting in 60 years of experience in the market of technical fasteners, TITANOX designed and produced the RIV-ELIT® range, which meets the ISO 9001 V2008 standard. The RIV-ELIT® product range covers all systems of blind fastening solutions including: Speed rivets – a semi-automatic fastening system designed to increase productivity – blind breakstem rivets, high strength structural rivets and bolting systems suitable for assemblies subjected to high-tensile and shear strengths, blind nuts for resistant threads in thin sheet materials, installation tools, as well as pneumatic or hydro-pneumatic. All the products in the range meet the specific requirements of TITANOX’s customers – from low frequency use to high frequency, as well as fully automated assembly lines. “Assembling different materials and thicknesses with access from one side is a fairly common problem in industries such as lighting, telecoms, sheet metal, automotive, electronic sub-assemblies, railway, and trucks. The RIV-ELIT® range offers the highest quality to ensure high clamping and secure joints.” www.rivetlit.com

32 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

13.E01

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EUROBLECH 2014

Innovative technologies The Nord-Lock Group is a world leader in bolt securing systems, offering a unique combination of innovative products and expertise.

ord-Lock states that its mission is to safeguard human lives and customer investments by securing the world’s most demanding applications. Nord-Lock bolting solutions include multifunctional wedge-locking technology, 27.J81 Superbolt tensioners and expansion bolts. These products have documented success in every major industry and hold several certificates from independent institutes including AbP, DIBt, DNV and TÜV. “Through a combination of expertise and our innovative products we are able solve the toughest bolting challenges and help our customers achieve outstanding results. The Nord-Lock Group looks forward to being your partner in bolt optimisation.”

Sala Punzoni – high-quality tools The Italian company Sala Punzoni Srl has been manufacturing high-quality tools for more than 40 years.

13.G67

ala Punzoni specialises in the production of special punches according to customers’ drawing in high speed steel and carbide for sheet metal piercing, forming and cupping, and for wire deformation. Over the years the company has evolved both from a technological and a technical point of view. The technological development comes from its long experience and from its constant skill in researching new raw materials, new and better heat treatments and in developing more and more suitable TiN coatings in order to improve its products’ quality.

High precision key Schmeck Verbindungstechnik GmbH, based in Lüdenscheid, Germany, manufactures screws and studs for a wide range of applications and technologies.

chmeck says that the highest precision and profitability are determining factors in the manufacture of its products, which include:

13.F20

• Welding studs (capacitor discharge, short cycle welding, drawn arc welding). • Weld screws. • Friction welding studs. • Special cold-formed parts to customers’ specifications. Schmeck’s customers include manufacturers of prototypes, machines and electrical equipment, automotive suppliers, as well as major commercial enterprises dealing with connectors. “Whether for prototypes, large or small series – we are the right contact partner for you in all cases.”

34 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

Specialist fastening solutions

13.B68

HEYMAN®, a specialist in the field of access and fastening solutions, says that its mission is to improve the competitive position of its customers by means of using its knowledge, service and creativity in order to improve the quality of customers’ products and/or improve the efficiency of their production and assembly processes.

hroughout the years HEYMAN ® says it has established an excellent reputation for high-quality fastening and access systems, which are sourced from the world market leaders. Its product range includes latches, hinges, handles, telescopic slides, gas springs, blind rivet nuts and studs, rivets, tools, as well as cable accessories.

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EUROBLECH 2014

POP® and Avdel® create fastening solutions At EuroBLECH 2014 Stanley Engineered Fastening will introduce a comprehensive portfolio of blind riveting, lockbolt and Speed Fastening® systems.

OP ® and Avdel ®, widely recognised brands throughout the world, have come together to create a broad range of fastening solutions for the most complex technical challenges that Stanley Engineered Fastening’s customers face today. An example is the NeoSpeed ®, which Stanley says is the first Multi-Grip Speed Fastening ® system – replacing several standard grip fasteners. Maintaining the complete systems philosophy the POP ® Avdel ® product portfolio encompasses both engineered fasteners and installation systems ranging from manual/pneumatic hand tools to more complex automated systems. “POP ® Avdel ® branded products are used in major industries where quality and technical support is of the utmost importance, such as the automotive, electronics, domestic appliances, as well as a multitude of industrial segments.”

13.A18

Unifast’s FAST turn Unifast Srl manufactures captive nuts and quick acting fasteners, in addition to a vast range of special bespoke products, all of which are produced for the needs of the customers and provide cost savings.

he quick acting fasteners are widely used where rapid assembly and disassembly of units is vital or where service access is required such as electrical cabinets, air conditioning units, compressors, and inspection panels on engine covers. Unifast points out that the automotive industry is a major user of this product – the noise shields under motorcars being a prime example. FAST turn quick acting fasteners are designed to be rapid and economic to use whilst maintaining reliability. Their slip-on receptacle means employing fewer tools and a variety of styles and finishes for the studs enable them to be ideally suited for many applications. The studs are cold-headed and rolled in Unifast’s production line based in Settimo Torinese, Italy. Manufactured from case hardened steel and now from stainless steel, the parts may be supplied with various head styles including wing, slotted and Phillips.

17.B122

Full line of insertion machines Haeger Europe BV manufactures hardware insertion machines, and says it is a leading developer of innovative fastener insertion technology.

aeger has a full line of insertion machines, which all include Haeger’s SingleTouch Part Handling technology. These machines enable the insertion of up to four different fasteners in a single handling of a part – which Haeger says provides the most significant boost to hardware insertion productivity since the introduction of automatic tooling systems. Haeger explains that its machines create Hardware Insertion Profit Centres™ by optimising labour, improving quality, and increasing productivity through the use of technology.

36 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

12.D26

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TECHNICAL

An insight into DIN 7500 standard Peter Witzke, vice president engineering/quality, Bossard AG The DIN 7500 standard was first published in the late seventies and has been updated a number of times since. Simultaneously with the publication of DIN 7500-2 “guideline values for hole diameters” the standard for screws was named DIN 7500-1. However, most often the screws are just referred to as DIN 7500.

IN 7500 screws are thread rolling screws for metals that form an ISO metric thread upon installation. For a great number of applications the total in-place costs and joint performance can be optimised at the same time. This is the reason why DIN 7500 screws have greatly increased in popularity over the years and continue to be the first choice fastener for many situations. Unlike most fastener standards, DIN 7500-1 does not specify the geometry of the threaded part. It specifies what the screws must comply with in terms of performance and leaves it up to the manufacturer to decide the threaded shape. This is to encourage technical development, however in reality two basic thread shapes are commercially available worldwide.

Trilobular thread forming systems The screw thread has the characteristic trilobular cross section along its entire length. They have the same diameter in the threaded section, irrespective of the orientation. During thread forming the compressive strains are concentrated on the 3 ‘edges’. The mating material is more easily deformed this way. Compressive strains in the flat areas of the trilobular thread cross section are very low. The material of the workpiece can relax into these and the risk of bursting is low, even in thin walled internally threaded joint members. The friction between screw thread and mating material is limited to the 3 ‘edges’. The screws are coated with an invisible dry lubricant and installation torque is very low compared to other thread forming screws. DIN 7500 trilobular screws are often referred to as ‘Taptite’ which is a registered trademark. Several brands and names can be found for this type of screw, but they are all based on the same principles and they all meet the requirements of DIN 7500-1.

Spiralform® Looking at worldwide usage, the Spiralform ® screw is of lesser significance compared to the trilobular thread forming systems. The four lobes, positioned at 90° around the diameter of the screw and running spirally along the length of the thread, enable thread forming when the Spiralform ® screw is driven into the mating part.

Technical information and benefits Basic function As noted by the title of DIN 7500-1, the screws are thread rolled. This means that chips are not produced during the forming of the mating thread. This is especially important in

38 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

the production of electrical and electronic equipment. In comparison to a tapped thread a formed thread has greater strength due to work hardening of the material. Stripping resistance of the joint can be improved depending on the hardenability of the type of material that is used. The costs of tapping operation and related processes can also be eliminated. One feature that is important to notice is that the formed female thread is a nut thread with 6H tolerance. This facilitates a normal metric screw being fit into the formed female thread should the DIN 7500 screw be replaced.

Vibration resistance Another important feature regarding the thread is that the play-free thread engagement of the screws and their friction secure assembled screws against rotational loosening. Locking elements such as those sometimes required for normal screws are not necessary when using DIN 7500 screws. Fastened joints are very cost-effective, with no procurement and assembly costs for spring lock washers, serrated lock washers, or locking adhesives.

Mechanical properties DIN 7500 screws are made from case-hardening steel. During heat treatment they obtain a minimum hardness of 450HV on the surface. The core is softer with a hardness of 290HV – 370HV to keep the screws relatively ductile. The hard surface is necessary for forming the thread in the mating part, and the screws can be installed into all malleable metals up to a maximum hardness of 135HB (tensile strength Rm = 450N/mm2 ~ 65,000 psi). The tensile strength of these screws is not defined by the standard as they are case hardened. However, when tested the tensile strength is roughly the same as for property class 8.8 screws, although it is important to recall that their toughness is lower due to the case hardened surface. DIN 7500 screws made of a strain-hardened austenitic A2 or A4 steel are also available. However, they can only be used in soft aluminium alloys.

Strength of the assembly Pullout resistance of the screws is determined amongst other things by their thread engagement length. For normal screws, nuts usually have a height of 0.8 times the nominal thread diameter (d). This height is sufficient to prevent the nut threads from being stripped off. Theoretically and under similar conditions the pullout resistance of a DIN 7500 screw is the same as that of

conventional screws in tapped threads. The fact is, the pullout resistance of DIN 7500 screws is higher than that of regular screws. Reasons for the higher pullout resistance are: • The outside thread diameter is larger than for regular screws. Thus, the circumferential virtual cylinder around the engaged thread (shear-off surface in the clamped part) is larger than that for a regular screw. • No thread play (more engaged material). • The grain structure in the material of the mating part is not interrupted. • The material of the mating part is compressed and work hardened during thread forming.

Pilot holes for counter threads DIN 7500 screws are designed for multiple purposes. This is evident looking at the possible pilot hole configurations that are suitable for the screws(1). In the case of a punched hole the punching direction should correspond to the installation direction. Tolerance of hole diameter H11.

defined preload in the fastened joint. In the case of thread forming screws, the driving torque increases with increasing thread engagement. They too are finally tightened. However, no defined preload can be achieved. The goal is only to sufficiently tighten them to keep the clamped parts in place. For the same reason these kinds of screws are not usually used in safety-critical applications that need verification by calculations. Assembly guidelines recommend the size of the pilot hole and the amount of thread engagement (penetration depth of the screw) in the mating part(1). These recommendations must be checked and optimised through practical application testing. The applied tightening torque (3. MA) should be between the maximum necessary thread forming torque (2. Me) and the minimum thread stripping torque or screw breaking torque, whichever happens to be lower (4. Mu).

By using extruded holes thinner sheets can be used(2).

Thread forming displaces material, so a small bulge is produced at the hole’s entrance. This may prevent parts from being tightly fastened but a slight chamfer can prevent it. Tolerance of hole diameter H11.

Die casting holes can be made as blind holes or through holes.

Design considerations regarding the thread end DIN 7500 screws have a slightly cone shaped thread end for insertion. Its length must not exceed 4 times the thread pitch (P). Designers must not consider this portion of the screw as load carrying. To ensure a full grip, e.g. in thinner metal sheets, the thread end must protrude.

Assembly parameters Thread forming screws have different driving torque characteristics than regular screws have in tapped internal threads. Conventional screws drive in freely until their heads seat against the clamped part. From there, the torque increases to a certain calculated tightening torque. The goal is to induce a

1. Thread forming 2. Thread forming torque Me (surface contact between screw head and component) 3. Assembly torque MA 4. Stripping/breaking torque Mu The determined assembly torque MA for a given DIN 7500 screw mainly depends on: • Hardness of the material of the mating part. • Material thickness when assembled in a through hole. • Engagement depth when installed in a blind hole. • Diameter of the pilot hole that the screw is assembled into. • Friction conditions. An assembly speed of a maximum 1,000rpm is recommended. For some applications simple tools can determine the installation parameters. For others, more advanced and precise equipment is needed. Such equipment is available from Bossard.

Standard screws and special developments A wide range of DIN 7500 screws is defined by the standard. However, a number of special developments are also available. One example is a special design for electrical devices where conductivity is required. Instead of having to use a toothed washer, small nibs are integrated underneath the head of the screw. This way only one fastener is needed and costs are optimised. www.bossard.com/ffm Footnotes: (1) For detailed recommendations please see Bossard's Catalogue, Technical section or Bossard DIN 7500 brochure. (2) Special information regarding extrusion is available – contact Bossard Engineering for more information.

www.fastfixtechnology.com

TECHNICAL

Calculating endplay take-up for beveled retaining rings By Jeffrey Finkernagel, technical sales engineer, Rotor Clip Company Inc In many assemblies, dimensional tolerances in ring thickness, groove location or the overall length of the components being retained add up to a degree of clearance, or endplay between the abutting surfaces of the ring and retained part.

n some cases, the endplay can be eliminated by shims, washers and similar devices or by ‘selective assembly’ in which parts with plus or minus tolerances are matched carefully to provide the desired tight fit. But in high-speed production these alternatives can be prohibitively expensive both for materials and assembly labour. Manufacturers have benefitted from substituting beveled retaining rings for these other alternatives. Beveled rings provide all of the cost savings benefits of conventional rings with an added advantage – they compensate for accumulated tolerances or wear in the retained parts and provide rigid endplay take-up in the assembly. This permits manufacturers to work with larger tolerances in the parts being assembled and still achieve required performance characteristics.

Design features: Rigid endplay take-up Beveled retaining rings are similar in construction to the standard internal and external types. They differ from the standard rings in that the groove engaging edge is beveled to a 15° angle (the bevel is located around the outer circumference of the internal rings, around the inner circumference of the external rings). The rings are designed to be used in grooves having a corresponding 15° bevel on the load bearing groove wall. The ring should be seated at least halfway down into the groove to provide sufficient contact area with the load-bearing groove wall. When a beveled ring is installed in its groove, it acts as a wedge between the outer groove wall and the part being retained. When there is endplay between the ring and the abutting face of the retained part the ring’s spring action causes the fastener to seat more deeply in the groove, compensating for the endplay. Beveled grooves differ from standard ring grooves in two important respects. As indicated previously, they have a 15° angle on the outer wall of the groove and they are considerably deeper than standard ring grooves. The beveled wall matching the beveled edge of the ring is necessary for maximum ring effectiveness. The groove loads listed in the manufacturer’s data charts are based upon minimum ring engagement; i.e., with the ring seated halfway into the groove. For this reason, the groove loads are somewhat less than the maximum loads for equivalent sizes of flat rings.

40 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

If the ‘A’ dimension is maintained and the cut is made accurately from the fixed shoulder to where the beveled portion of the groove intersects the housing or shaft diameter, the listed plus tolerance for groove width ‘W’ may be held or increased as required. If the beveled edge of the groove is located by establishing the ‘A’ dimension from the fixed shoulder to the straight wall of the groove, the listed plus tolerance for ‘W’ must be reduced (See Figure 1c) and will be referred to as the ‘F’ dimension (Figure 2). Note: It is not recommended to locate a groove using the ‘F’ dimension as it introduces extraneous tolerances. In order to determine if a beveled ring will be functional in an assembly, a comparison must be made between the total tolerance of the assembly and the capability of the ring to fulfil this requirement. This fulfillment is achieved when the ring seats anywhere between halfway down to all the way down in the groove depending on the tolerance build up in a particular assembly. This is shown in Figures 1a and 1b and may be expressed as follows: d

Ring Take-up = 2 tan 15° ≥ ∆A + ∆B + ∆U

Figure 1a – Ring seated at maximum depth (near groove bottom)

Figure 1b – Ring seated at minimum depth

Figure 1c

Calculation of groove location and analysis of end-play take-up The recommended procedure for calculating the groove location is: A1 ≥ B max + Umax + 2 tan 15° A 2 ≤ B min + Umin + d tan 15°

Example of calculation technique Determining the location of a groove for an 80mm (VHO-315) internal beveled ring, which will retain a 6208 ball bearing against a shoulder. The width of a 6208 bearing is 0.704 – 0.709 inches and we will assume a standard machine tolerance of ± 0.001 inches for groove location. B max – B min = ∆B 0.709 – 0.704 = 0.005

TECHNICAL Minimum desired tolerance on groove location is: ∆A = 0.002mm Umax – Umin = ∆U 0.0845 – 0.0795 = 0.005 inches Total assembly tolerance ∆A + ∆B +∆U = 0.012 inches

The take-up of this ring is 0.006 inches as shown previously. Then we may safely conclude that in 997 cases out of 1,000 this ring will adequately retain the application rigidly. The three remaining extreme cases can be overcome merely by the substitution of any other corresponding machined part taken from stock. To determine location of groove: A1 ≥ = 0.592 + 0.041 + tan (15°) = 0.639 inches A 2 ≤ 0.588 + 0.039 + 0.042 tan (15°) = 0.638 inches A= ± 0.01 = ± 0.001 = 0.6385 ± 0.001 inches

Take-up of VHO-315 ring: tan 15° = Take-up tan 15° = 0.016 inches Even under extreme conditions this ring will maintain a rigid assembly. To determine location of groove: A1 ≥ B max + Umax + tan 15° A 2 ≤ B min + Umin + d tan 15° tan (15°) = 0.809 inches A1 ≥ 0.709 + 0.0845 + A 2 ≤ 0.704 + 0.0795 + .116 tan (15°) = 0.815 inches A= ± .001 = ± 0.001 = 0.812 ± 0.001 inches

Inspection of ring beveled edge (‘U’ dimension) As is noted on the manufacturer’s data sheets for both internal and external beveled rings, the beveled edge width, designated as the ‘U’ dimension (see Figure 3) should only be used for calculating the groove location and take-up requirement as was illustrated in the previous section. No attempt should be made to directly measure this dimension since the point at which the measurement should be taken is not clearly defined due to the blanking crown and die clearance taper on the ring edge. During the manufacture of these rings, techniques other than the direct measurement of this dimension are utilised to be sure that the dimensional integrity of the parts has been maintained.

Figure 3 Checking ring installation: Dimensions ‘G’ and ‘Gd’

Figure 2

To determine the location of a groove from a 1.25 inches external beveled ring, which will retain against a shoulder part whose width is equal to 0.590 ± 0.002 inches and whose minimum desired groove location tolerance is 0.003 inches. B max – B min = 0.592 – 0.588 = 0.004 inches A max – A min = 0.003 inches Umax – Umin = 0.041 – 0.039 = 0.002 inches

As indicated previously, beveled rings must be seated at least halfway in the groove to provide sufficient contact area with the load-bearing groove wall. The dimensions for minimum gap width ‘G’ (internal rings – see Figure 4) and maximum gauging diameter ‘Gd’ (external rings – see Figure 4) provide a quick means to determine if beveled rings are seated at least half way in their grooves. If the gap measured on an installed internal ring is less than the listed dimension, the ring is not seated properly and may fail. If the maximum gauging diameter measured on an installed external ring is greater than the listed dimension, once again the ring is seated improperly and may fail. In either case, the ring should be removed and another installed. If the condition persists, the entire assembly should be checked for excessive tolerances on the retained parts.

Total assembly tolerance = 0.009 inches Take up of VSH-125 =

tan 15° =

Figure 4

tan (15°) = 0.006 inches

It may be concluded that an external beveled ring, under the extreme conditions illustrated above, will not sufficiently take up the endplay in this application. However, based on accepted probability statistics such extreme conditions may be counted on to occur three times in 1,000 random assemblies. Therefore, the ring take-up need not be larger than the square root of the sum of the squares of the tolerances. Total range of tolerances according to probability is: ∆A 2 + ∆B2 + ∆U2 = 0.0042+0.02 2+0.0032 = 0.005 inches

42 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

Internal ring

External ring

Today’s demands for reduced costs extend to every component of an assembly. Fastening methods that require multiple components like shims and washers should be re-evaluated to determine feasible alternatives. Beveled retaining rings are a clear option paving the way for effective retention with a minimum cost in materials and labour. Following the guidelines above can help customers determine if this fastening method is right for their application. www.rotorclip.com

screw bolt rivet nut

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FASTENER + FIXING TECHNOLOGY

OTTO ROTH – tolerances have top priority This year OTTO ROTH GmbH & Co KG celebrates its 100th anniversary as a manufacturer of precision turning and finishing parts. Through a combination of products, experience and services – across its eight sites, including its plant in Buchen, Odenwald, Germany – the company has become a well known and sought after partner for a variety of industries.

olfgang Dambach (pictured above), authorised representative of the company and manager of the Buchen plant, comments: “Our industrial customers come to us with requests for ever more sophisticated and technically complex turned parts. This means we need to develop and improve our production equipment and train our employees on an ongoing basis.” The Buchen plant was opened in 1980 and since then has made significant technological advancements and can now produce everything from simple turned parts, such as shafts and pistons, to more complicated parts (these parts are turned, milled and drilled, many of them then being hardened, ground and polished). The plant even handles the assembly of highly complex assemblies, for example, valve components. Also, every single part is thoroughly tested to make sure it meets customers’ requirements for functionality. Dambach has even identified a trend towards customers requesting OTTO ROTH to provide ever more sophisticated services and products, such as entire machine assemblies.

“This is the greatest opportunity our manufacturing plant has to extend our range of added value services.” The ability to make such significant technological advances is all down to the company’s manufacturing expertise and its highly qualified staff – also not forgetting the added advantage of being a single point of contact for the customer. “Every machine in our 5,500m2 of manufacturing halls has been carefully sited to optimise each step in production – ensuring every process runs safely and effectively, both for us and our customers. This is an important hallmark of quality,” adds Dambach. “At Otto Roth, ‘manufacturing based on drawings’ our production specialists are always looking for ways in which we can improve things.” Next OTTO ROTH’s cutting machine specialists are able to apply their production experience to offer the best possible manufacturing strategies, at the best possible price. “Our wealth of in-house manufacturing expertise really pays off in production planning, says Dambach. “Every work step can be exactly tailored to suit the next.”

100 machine tools, 1,000 test devices Using cutting edge machining technology, the Buchen plant produces highly precise ready to install, rotationally symmetrical parts. This is achieved by approximately 100 machine tools, the majority of which are CNC controlled units, as well as a small number of mechanically controlled automatic lathes. The CNC controlled grinding and honing machines make it possible to achieve production tolerances of up to 2µm. The grinding machines operate in climate controlled rooms, to reduce variations in workpiece dimensions. “We make complying with tolerances our top priority,” states Dambach. In addition to extensive manufacturing know how, the demand for quality is a key

44 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

“ …we can manufacture anything from a few hundred up to tens of thousands of components.” priority for OTTO ROTH. In many cases, working to the most stringent tolerances is absolutely essential as OTTO ROTH believes that quality is often the key foundation of a product’s functionality. To ensure the highest quality spectral analysis is used to inspect incoming goods, to guarantee that the raw materials are as specified. Also, regular interim inspections at the machines and in the QA laboratory accompany every stage of the manufacturing process. Experienced QA employees analyse strength, shape, position, contour and layer thickness, among other characteristics, using cutting edge testing methods and more than 1,000 optical and tactile measuring and testing instruments. The quality of the entire production process is monitored at all times – which OTTO ROTH says helps to ensure an impressively high delivery quality of almost 100%. Customers can also be supplied with test reports if required including traceability right back to the base material. “We are completely flexible in terms of batch size – we can manufacture anything from a few hundred up to tens of thousands of components,” explains Dambach. “If deadlines are pressing, we can also operate multiple shifts. Our high bay warehouse is well stocked with raw material, which means we can also respond to requests at short notice.” The high bay warehouse, which was constructed in 2008, was a quantum leap forward for OTTO ROTH and the production at the Buchen site in terms of workflow organisation and raw material management. The high bay warehouse also makes stock management and work processes easier (store, remove, re-store) – ensuring quality, process reliability and traceability. www.ottoroth.de

1 9 1 4

2 0 1 4

SU CCE SSF U L

Y E A R S Times are changing, but values remain the same. Variety, expertise and reliability – this is what we have stood for over a century.

// Wholesale trade

// Production

// Customised solutions

// C-parts management

Otto Roth GmbH & Co KG, Rutesheimer Str. 22, 70499 Stuttgart, Germany Phone: +49 711 1388 0, Web: www.ottoroth.de

EXHIBITIONS

New technology on display at Fastener Fair Hannover The second Fastener Fair Hannover took place from 8th – 10th April at the Hannover Exhibition Grounds, once again co-located with Hannover Messe, with organisers – Mack Brooks Exhibitions – reporting a positive response from visitors and exhibitors.

ltogether 5,441 visitors from 73 countries came to Fastener Fair Hannover to discover the latest products and services, make business contacts, and build international trade networks. The exhibition attracted fastener and fixing specialists at all levels, with the majority in business management (35%), followed by purchasing (20%), research/(product) development/ construction (20%) and manufacturing/production (11%). “We are delighted with the good response to the second Fastener Fair Hannover. Compared to the first event in 2012, Fastener Fair Hannover 2014 recorded a visitor increase of 20%. The new combi-ticket, which allowed entry to the Hannover Messe, built on the visitor momentum,” states David Tellett, managing director at Mack Brooks Exhibitions. The exhibition also moved to Hall 22, which was closer to the main halls of Hannover Messe. This meant that the hall was on the Blue and Red bus routes around the Hannover Exhibition Grounds – making it easier for visitors to reach the hall. A total of 234 exhibitors from 29 countries exhibited at the show, displaying a wide range of new fastening technology and capabilities. There was a wide variety of new products including Rivit Srl’s new vertical RIV949 hydropneumatic tool; HEICO Befestigungstechnik’s HEICO-LOCK® Wedge Lock Nut and HEICO ® Wheel Nut; Celsus Fasteners’ new ‘Human Driven’ quality label; as well as Lubotechnic’s Lubocoating. Peter De Brune, CEO at Lubotechnic, reported a very successful show with lots of visitors stopping to view the numerous demonstrations of the company’s Lubocoating – a coating for stainless steel screw thread connections that offers strong corrosion protection and has a low and constant coefficient of friction. Those stands demonstrating new technology definitely attracted a lot of attention during the show. GESIPA® Blind Riveting Group had a host of product demonstrations on its stand and was busy throughout the show with the company running low on brochures and business cards by the end of the three days. One of the products on display was the new TAURUS ® 1 Speed Rivet. The lightweight construction of the TAURUS ® 1 Speed Rivet, and the automatic rivet feed, means that users always

46 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

have a free hand and therefore a secure hold on the work piece. The large diameter of the device base also guarantees secure standing. A first time exhibitor was pgb-Europe NV, who shared a stand with its production branch – pgb-Polska. “Our goal was to present some new products and of course attract new customers,” explained Johannes Heyes, marketing manager at pgb-Europe. The company showcased its newly developed universal plugs and hammer nail plugs with different collars. It also focused on the upgrades to its existing ETAs, new additions to its anchor programme, and its vast range of pfs+ wood screws. The organiser’s exhibitor survey showed that the vast majority of exhibitors were satisfied with the overall result of the show. Two thirds of exhibitors rated Fastener Fair Hannover 2014 as good or very good. 89% of exhibitors claimed to have reached their objectives and praised the highly qualified trade audience. Pravin Malhotra, managing director at Nipman Automotive Fasteners, reported having a positive show. “This was our first time at Fastener Fair Hannover and we had lots of visitors to our stand throughout the first two days of the show, who were interested in the products we could offer.” Pravin added: “If we were to exhibit again at Fastener Fair Hannover we would make sure that our technical manager is on the stand, as we had a lot of visitors who brought drawings and wanted to know what we could offer. By having a technical manager on the stand we could give visitors an answer straight away rather than taking enquiries back to the office and having to follow up at a later date.” Stafa Group had a large stand at the show and was promoting its complete range of structural bolts (SB bolts) according to EN 15048, with the company able to supply a full range, from stock, either zinc plated or hot dip galvanised. Speaking after the show, Ivo van Gool, sales manager at Stafa Group, reported a positive experience. “We found Fastener Fair Hannover to be a successful show. The first two days were good for us, with a good number of quality visitors. The last day was quite slow though, and could be changed into half a day. Overall, we met many customers and have already received orders from new leads.” Federico Sarti, export manager at Specialinsert Srl, was also happy with how the show had gone. “We met new potential customers and received several new enquiries. We also had the opportunity to strengthen partnerships with existing customers. In total we made approximately 60 contacts and all of them were professionals of the fastener world – mainly from Europe but also a few international visitors from Brazil and the USA.” Specialinsert used Fastener Fair Hannover to display its new Keep-Nut – a self-anchoring insert for stone and compact materials – as well as its new Master-plate – threaded studs and bushes for bonding or moulding applications.

www.fastfixtechnology.com

PRODUCTS

GESIPA® Speed Rivet Technology GESIPA® has added a new member to its vast product range – GESIPA® Speed Rivet Technology.

peed rivets are the ideal connectors for all applications with low strength requirements and fast rates. They are used in the switch cabinet building, lighting, electrical engineering, household appliance building and lightweight constructions industries, among others. Alongside the cost-efficiency achieved through the use of the tried and tested GESIPA® TAURUS ® modular system, GESIPA focused on user safety and convenient working. The standard safety lock relieves tension on the chuck jaws, allowing mandrels to be replaced safely. GESIPA points out that the optional cut off valve and tool-less access to the chuck jaws also makes maintenance and repairs especially fast and convenient. The extremely lightweight construction of the TAURUS 1 Speed Rivet (pictured right) – the device weighs just 1,800g – and the automatic rivet feed means that the worker always has a free hand and therefore a secure hold on the work piece. The large diameter of the device base also guarantees secure standing.

The TAURUS 1 Speed Rivet offers low vibration and is sound insulated. Its ergonomic construction and comfortable softgrip areas also make working pleasant and fatigue free even for longer periods. All mandrels, speed rivets and nosepieces common on the market can be easily adapted to the GESIPA TAURUS 1 Speed Rivet. However, with occupational safety and process reliability in mind, GESIPA recommends using GESIPA speed rivets and GESIPA disposable mandrels. www.gesipa.com

MacDermid’s zinc nickel coatings MacDermid say that engineers choose zinc-nickel in automotive and aerospace applications due to its excellent corrosion and abrasion resistance. Meaning the coating retains its corrosion protection even after handling and assembly operations. Zinc-nickel coatings demonstrate the following features: • Exceptional corrosion resistance for relatively thin coatings. • Hard coating, good for mechanical resistance properties. • Good grounding properties for electronic applications. • Galvanic compatibility with aluminium. • Lubricated to modify friction properties. MacDermid says that it leads the way in electroplated zinc-nickel technology with the Enviralloy and Kenlevel Ni range of products. These are suitable for all applications including bulk fasteners and post plate deformed tubing. The range of Enviralloy and Kenlevel Ni range includes: Enviralloy NiSpeed – High speed alkaline zinc-nickel process, particularly recommended for rack applications. Enviralloy NiSpeed delivers both with a bright deposit, coupled with even alloy and deposit distributions. By using new polymer technology, combined with inexpensive steel anodes, Enviralloy NiSpeed delivers fast plating rates for improved productivity. Enviralloy Ni 12-15 – Alkaline zinc-nickel process, recommended for barrel applications where process consistency and ease of use are key processing criteria. Production proven and automotive approved for over 10 years now, Enviralloy Ni 12-15 provides zinc-nickel coatings for global manufacturers such as Ford, GM, Renault, PSA and VW-Audi. Enviralloy NiFlex 12 – Alkaline zinc-nickel process specifically for applications where the plated layer is post-plate deformed. Enviralloy NiFlex 12 produces a unique deposit morphology that allows the coating to react dynamically and in sympathy with the substrate. This low stress structure means parts can be manipulated, formed, bent and swaged with minimal loss of corrosion. Kenlevel Ni 12-15 – Acid zinc-nickel process for cast iron applications. Kenlevel Ni 12-15 combines the benefits of acid zinc electrolytes with zinc-nickel alloy deposits. This allows the rapid covering of components such as brake callipers.

48 Fastener + Fixing Te chnology • Issue 14 Jul – Sep 2014

SINARD prioritises the customer Spanish based S.A SINARD says that the key to its success over the past 65 years has been based on its relationship with customers and potential customers.

hrough its daily work actions, commercial visits across the world by its team in Sabadell, Barcelona, and by its commercial agents in different countries, SINARD has been able to establish long-term relationships with customers. The company exhibits at a variety of exhibitions each year and presents its wide range of products and manufacturing capabilities. At the recent Fastener Fair Hannover the company presented its SINARD Quick Attachment Devices 2014 catalogue. Quick Attachment Devices are pieces specially designed to install and fasten all type of electric material including cables, pipes, trays, and specially, false ceilings with metal or concrete structures. In addition to Quick Attachment Devices, SINARD also specialises in heat treated spring steel stamping. Its wide range of products includes standard pieces according to Norms (spring pins ISO 8752, disc springs DIN 2093, aranlocks, rings and washers DIN 137, 6798, 6799), production of special pieces from design, and production of tools for the stamped piece. “You can only create long lasting relationships with customers if you are able to provide the correct product range, along with quality, service, and competitive prices.”

New products from Lee Spring Lee Spring UK has launched two new springs, adding to its range of approximately 20,000 spring products.

he first new addition is a line of high-pressure compression springs, which are suitable for applications with small spaces – requiring firm, but not rigid, slender springs. They can be used in a variety of applications including switches, ball plungers, safety relief valves, quick change tools and vice clamps. The Lee Spring engineering team has designed an offering of 144 slender parts packed with high load capacities, rated to pressures of 300psi, 400psi, and 500psi. High pressure series compression springs in 17-7PH stainless steel are passivated, shot peened, and preset, to provide a balance of corrosion resistance, high strength, and toughness. Lee Spring has also introduced the new Metric Bantam™ Mini Compression Springs – powerful springs designed to operate in small spaces that can be used in various applications, including in medical instruments and surgical tools, firearms, communication devices and hardware, as well as in the aerospace, automotive and marine sectors. The new metric range of Bantam™ compression springs starts at 0.01mm, with outside diameters from 0.81mm to 1.65mm and free lengths from 1mm to 14mm. The existing imperial (inches) range of Bantam springs ranges from a 0.004 inch to 0.0055 inch wire diameter, with outside diameters of 0.025 inches to 0.057 inches. Made using Elgiloy™, a high temperature resistant, non-magnetic nickel alloy that is 10% stronger than Type 316 stainless steel, these miniature stock springs offer a combination of strength and corrosion resistance. www.leespring.co.uk

SKINNY& STRONG NEW! High Pressure Compression Springs Very high spring rates without the bulk. Conventional Spring with Similar Pressure

High Pressure Narrow Profile

Same Pressure in a Narrow Profile

These slender, low index, High Pressure Compression Springs are manufactured in passivated and shotpeened 17-17 Stainless Steel to provide a great balance of corrosion resistance, high strength and toughness in a reduced footprint. This line is ideal for anyone in need of firm but not rigid springs with thinner profiles, suitable for small spaces. New Series 20 Catalogue

leespring.co.uk

Over 200 pages of Stock springs, including • New High Pressure Compression Springs, • Metric Bantam™ Mini Compression Springs • Expanded Heavy Duty Die Spring line. Call or email us today for your FREE copy.

Call: +44 (0)118 978 1800 | Fax: +44 (0)118 977 4832 | www.leespring.co.uk Lee Spring HalfPage IPE Mar14.indd 1

09/05/2014 09:59

S R N E O N I E T T C S FA P RO T E

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

ADVERTISERS INDEX Adolf Pühl GmbH & Co KG........................................................ 7 Albert Pasvahl GmbH & Co KG................................................ 35 Alcoa Fastening Systems..........................................................15 Baker & Finnemore Ltd..............................................................23 Berardi Bullonerie......................................................................13 Bokers Inc.................................................................................37 Bonfatti Filettature Srl................................................................28 Bossard Ltd................................................................................ 9 Bülte Plastiques SA................................................................... 50 DIV d.o.o................................................................................... 1 ETMA.........................................................................................51 EuroBLECH................................................................................31 Fastener + Fixing Search......................................................... 43 Fastener Fair Russia................................................................. 29 Ferdinand Gross GmbH & Co KG.............................................19 Fixi Srl....................................................................................... 35 GESIPA Blindniettechnik GmbH.................................................37 HEICO Befestigungstechnik GmbH...........................................21 Heinz Soyer Bolzenschweisstechnik GmbH............................... 33 Kettling Verbindungselemente GmbH......................................23 Lederer GmbH.......................................................................... 17 Lee Spring................................................................................49 Lesjöfors AB................................................................................ 6 Mavita......................................................................................37 Micrometal.............................................................................. 35 NOF METAL COATINGS EUROPE..................................................27 NORMA Group..........................................................................25 OTTO ROTH GmbH & Co KG..................................................... 45 Peter Schröder GmbH...............................................................13 Precision Technology Supplies Ltd............................................52 Reyher......................................................................................13 Rivelit......................................................................................... 5 Rivit........................................................................................... 2 Rotor Clip Ltd............................................................................41 Roy Hopwood Fasteners...........................................................28 Specialinsert Srl....................................................................... 29 Top Screw Metal Corp............................................................. 50 Walter Stauffenberg GmbH & Co KG........................................23 Würth Industrie Service GmbH & Co KG..................................... 8