Fastener + Fixing Technology #15

Connecting with engineers

Our Promise:

Proven Productivity

www.bossard.com

I ss u e 1 5 O ctob e r – D e ce mbe r 2 0 1 4

www.fastf ixtech n olo g y.co m

Fastening solutions?

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BECAUSE WE ARE ALWAYS AHEAD OF THE MARKET Rivit is a leading company in design and production of fastening systems and tools for sheet metal assembly.

This is because we provide a very wide range of products for all your fastening needs, taking care of the customer from the big picture to the detail.

RIVIT SRL FASTENERS & TOOLS SINCE 1973 Via Marconi, 20 loc. Ponte Rizzoli, 40064 Ozzano dell'Emilia (BO), Italy T. +39 051 4171111 | F. +39 051 4171129 | rivit@rivit.it | www.rivit.it

EDITORIAL

Creating partnerships Part of the Mack Brooks Group Romeland House, Romeland Hill, 4423.1_BigHead St Albans, Herts, AL3 4ET, UK Tel: +44 (0) 1727 814 400 Fax: +44 (0) 1727 831 033

A theme running throughout this issue is the importance of close working partnerships and the numerous benefits that are possible when fastening technology Press Ad 28/4/10 14:56 Page 1 companies work with customers on applications.

I

Will Lowry – Editor

had the pleasure of interviewing Jean-Luc Kirmann, director of application engineering – EMEA at NORMA Group, about the steps that NORMA takes when working with its customers and the benefits of a close partnership. The result is a unique insight into a recent project that involved NORMA working with a customer to design a new solution that reduced weight, improved usability and enhanced functionality.

Group Publishing Director A recent visit to Alcoa Fastening Systems (AFS) in Telford, UK, further underlined the Jamie Mitchell advantages of collaborating on fastening installations. I spoke to Jonathan Craven, operations info@fastfixtechnology.com director at AFS industrial operations UK, about AFS’ capabilities within the structural and civil Editor engineering market – including its DIBt approved Huck ® BobTail ® and Magna-Lok ® ranges.

Will Lowry Jonathan also emphasised the importance of having a regular dialogue with customers editor@fastfixtechnology.com and the benefits of designing and developing successful fastening technology together.

Executive Editor For over 40 years bigHead’s design and Stevens, managing director at bigHead ® Bonding Fasteners For the Cover Story, Matthew Phil Matten manufacturing has been trusted by Ltd (a Bossard company), industry. looks at the growth of composite materials in applications and Deputy Editor the challenges faced by fastening companies to find the right solution.

Versatile and strong, embedded or surface Claire Edwards Continuing thecan focus on Plastics + Composites, we also have articles on the newly bonded, bigHead fasteners simplify Senior Advertising Executive ® developed product assembly and ONSERT save time.technology – an innovative joining method that combines bonding Harry Whyte and screwing – as well as new wing body additions to Bülte Plastiques’ Plastimont range. harry.whyte@fastenerandfixing.com Further articles include Bill Eccles of Bolt Science explaining his new ‘on-off-on’ tightening Senior Advertising Executive sequence for bolts and how it improves upon the present tightness checking methods Tom Allen Visit our website: used; Dipl-Ing (FH) Elmar Kampmann, technical sales director at Rotor Clip, looking at how tom.allen@fastenerandfixing.com to prevent ring failures due to rotational movement in wind turbine gearboxes; as well as Advertising Executive a preview of the upcoming Advanced Engineering shows – taking place from 11th – 12th Emiliano Pagliaroli November, in Hall 5 of the National Exhibition Centre, Birmingham, UK. emiliano.pagliaroli@fastenerandfixing.com My colleagues Claire Edwards, deputy editor, and Tom Allen, senior advertising executive, Production Manager will be at the Advanced Engineering shows on stand I56, so make sure you stop by to say hello.

Andy Clow andy.clow@fastenerandfixing.com www.fastfixtechnology.com

How will you use yours?

www.bighead.co.uk

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.

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Contents Industry news Latest fastener industry news..................................4-8 Cover Story Fastener solutions for composites....................... 10-11 Plastics + Composites NORMA Group – creating a close working partnership...12-13 New wing body versions for Plastimont range....... 14 Joining lightweight materials with ONSERT®.......... 14 Bespoke designs from Veck....................................... 16 Features Clevedon – British manufacturing at its best........... 18 A new approach to the tightness checking of bolts... 20-22 Preventing ring failures in wind turbine gearboxes...38-39

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.

bigHead – the original bonding fastener.

24-26

+44 (0)1202 574 601

Structural Fixings...........................................................

Structural bolts conforming to EN 15048................. 23 Structured solutions from Alcoa.......................... 24-26 The finish of choice: Ensuring structural reliability... 28-29 Exhibitions......................................................................

Advanced Engineering UK preview.....................30-34 InnoTrans report......................................................... 36 Product news.........................................................40-42 Advertisers Index....................................................... 42

www.fastfixtechnology.com

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FASTENER INDUSTRY NEWS

NORMA Group recognised as top supplier by General Motors General Motors Company has presented NORMA GROUP in Germany with its 2013/2014 Supplier Quality Excellence Award for outstanding performance.

F

ollowing the recent recognition of the manufacturing plants in Monterrey, Mexico, and Qingdao, China, the US vehicle manufacturer now also recognises NORMA Group in Germany for its efficient processes, strong product quality and superior services.

The Supplier Quality Excellence Award was handed to NORMA Group at the Adam Opel AG headquarters in Rüsselsheim at the end of September. “This award by GM makes us particularly proud. It confirms that our approach of continual improvement ensures sustainably high product quality and reliable supply for our clients. It is attributed to the outstanding commitment of our employees in Germany”, says Werner Deggim, CEO of NORMA Group.

Eligible candidates for the GM Supplier Quality Excellence Award must meet numerous rigorous criteria including timely delivery of top quality products, seamless production processes, innovative strength and quality systems for instance according to ISO TS 16949.

In Germany, NORMA Group manufactures metal and plastic joining products in Maintal and Gerbershausen.

Its engineered joining technology is used globally, among other things in the automotive and agricultural industry, in aerospace and marine applications, as well as in infrastructure projects. www.normagroup.com

Lesjöfors supplying Volvo Polestar Lesjöfors Fjädrar AB has been chosen to be a supplier of chassis springs to Volvo S60/V60 Polestar, a high performance car focused on the driving experience.

4 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

Photo © Volvo Car Group

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olestar introduced the concept car as a further development of the standard version of the Volvo S60 and V60 where great efforts have been made on improving the genuine driving experience combined with a high-level of performance and aerodynamics. The target group has very high demands on the car features, where the suspension is a central part.

The development process of the chassis springs was characterised by a close cooperation between the development engineers and operators of Lesjöfors and Volvo Polestar – with quality as a main parameter. The final product was an optimal spring of very high-quality that opens up for other future collaborations.

“We are very pleased and proud to have been selected as spring supplier to Volvo. This is the first step in what we hope in the future is a close and successful relationship for both parties,” says Mats Blåder, managing director of Lesjöfors Fjädrar. www.lesjoforsab.com

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FASTENER INDUSTRY NEWS

Barton introduces 3D printing service UK manufacturer of bespoke critical fastenings and special cold forging, Barton Coldform (UK) Ltd, has launched a 3D printing service to dramatically reduce product launch timelines.

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ollowing over a year of research and development with a leading UK university, Barton says the service will complement its existing product launch process in the design and development of fasteners.

Barton points out that analysis of initial results have shown that the rapid, almost instant, 3D printing process allows for a much faster, therefore less costly, development phase. Typical turnaround can be 4 – 5 days rather than the several weeks normally expected for ‘off tool’ parts.

The 3D service allows engineers to gain a better understanding of their component or product before and during the tooling design and development phase, and enables them to review their products and undertake multiple iterations in the same time it would previously have taken to produce the first ‘off-tool’ parts. All that is required to take advantage of this service is a copy of 2D or 3D design drawings from which the 3D part can be created.

Barton’s first 3D customer said: “The ability to see and touch a part that was previously just a CAD design really helped me to understand and communicate the changes that needed to be made, which ended up cutting both costs and development time.”

Nedschroef takes to the skies Nedschroef Aviation Fasteners, based at Altena, Germany, has been certified as a manufacturer of fasteners for the aviation industry.

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n the 24th April Nedschroef Aviation Fasteners GmbH officially achieved a key milestone in aviation business development for 2014 by successfully passing the EN 9100 audit. With this certification the company is allowed to directly supply fasteners into the aviation and aerospace industry on a global level. It is also able to source products from internal EN 9100 audited plants.

The first steps towards achieving the challenge of stepping into the aviation industry were taken in March 2013. The aviation industry is very different, explains Nedschroef, from the automotive industry, with which it has long been familiar, because of its special material performance sheets, technical process parameters and surface procedures.

Nedshroef sees this achievement as an important milestone in the history of the company and the next step of its long-term growth plans.

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

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

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

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

The highlight of GESIPA® – fast, reliable and cost-efficient!

FireRex – The new blind rivet nut setting device of GESIPA® Discover it at the EuroBlech 2014 hall 13 / stand F40

The experts in blind riveting

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The highlight at this year’s EuroBlech will be the presentation of the new fully-automatic GESIPA® blind rivet nut setting device. Connected to a robot application, the modified GESIPA® FireFox® 2 is able to fit blind rivet nuts, including hexagonal headed ones, reliably at every imaginable angle in industrial production.

Of particular economic interest, innovative and fast, the new GESIPA® technology will revolutionise blind rivet nut processing.

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

FASTENER INDUSTRY NEWS

Innovation Begins Here… …was the theme for Anixter’s Customer Appreciation and Open Day, held at its Wood Dale manufacturing facility located near Chicago O’Hare International Airport.

Marc Abbagnaro, senior vice president sales, Americas

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Chris Sloncen, director of manufacturing

8 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

n 22nd August the OEM Supply – Fastener division of Anixter celebrated the completion of its phase one investment and wide-ranging improvements at its Wood Dale plant by inviting more than fifty local, regional and global key customer representatives from thirty market segments.

“With the energising theme of ‘Innovation Begins Here’, we invited guests to explore the history of our only manufacturing facility, to provide a platform for working together towards successful future partnerships,” explained Marc Abbagnaro, senior vice president sales, Americas. Marc acted as master of ceremonies and joined with Ian Clarke, executive vice president, OEM Supply – Fasteners, in welcoming Anixter’s guests.

Other keynote speakers included Anixter chief financial officer, Ted Dosch, who discussed the company’s overall service and quality goals across segments. Special guest Andrew Kalnow, CEO of National Machinery, brought to life the importance of cold forming technology in today’s lean manufacturing environment. He was presented at the event with a purchase order for phase two investments at the Wood Dale facility.

Chris Sloncen, director of manufacturing at Wood Dale, delivered the story of the company’s successful entry into manufacturing. To provide a complete Anixter perspective, Eric Bulington, vice president inventory management and purchasing, wire and cable, and Randy Mortensen, vice president marketing, enterprise cabling and security systems, introduced their divisions’ capabilities and highlighted the value of ‘One Anixter’, which includes, not least, an unparalleled physical presence in markets throughout the world.

After the presentations, guests were treated to a tour of the Wood Dale facility, to see first-hand the wide spectrum of manufacturing technology, as well as the comprehensively equipped Quality Engineering laboratory. Together with a highly skilled and experienced work force and management team, these provide technical expertise and supply chain assurance to Anixter customers, both in North America and across global markets.

One important measure of the success of the Open Day was the general agreement amongst attendees that real value was gained from meeting Anixter senior leadership and exploring first-hand the capabilities and talent of the Wood Dale facility.

One customer commented that the “excellent event” helped him gain a better perspective on “the progress and continuous improvement” at the Wood Dale facility. Another said: “The meeting helped to solidify Anixter as the leading candidate to support [us] globally” and added that they “found the meeting content very compelling and helpful.” Another particularly expressed the value of gaining a broader perspective of ‘One Anixter’ and its “divisions outside of fasteners.”

Anixter is now planning similar Open Days at its UK and Italian locations during 2015.

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COVER STORY

Fastener solutions for composites As composite materials grow both in range and volume of applications, the challenge to find the right fastening solution continues to grow. Here, Matthew Stevens, managing director at bigHead® Bonding Fasteners Ltd (a Bossard company), explores some trusted fastening solutions within this fast growing market.

What is a composite?

The fastening challenge in composites

Composites are materials engineered from two or more constituent materials with different physical or chemical properties. The two main categories of constituent materials making up the composite are the matrix and the reinforcement.

Examples of matrices are resins, ceramics, polymers or cements, with examples of reinforcements including fibres, sandwich cores or aggregate. The matrix material surrounds and supports the reinforcement material and the reinforcement material imparts its special mechanical and physical properties to enhance the matrix properties.

Composite materials are formed into a shape during their manufacture, typically in a mould cavity or on a mould surface.

The synergy between the two materials results in a composite material with properties unavailable from the individual constituent materials. The wide variety of matrix materials that are available provide engineers with significant design freedom and greater potential to optimise their product’s form and function.

The ability to combine different constituent materials to create superior new composite materials allows engineers to target improvements in cost, weight, strength and handling as their product applications and manufacturing processes demand.

The expansion of lightweight composite materials presents challenges as well as opportunities. One of the key challenges is how to securely fasten to such materials. Traditional fastening systems designed for sheet metal, such as rivets, bolts and clinched fixings are often incompatible with composites or require too many compromises to work. For example, weld studs designed for metal cannot be effectively welded to plastic.

Lightweight panel composites need to be kept thin and not thickened to hold a traditional fastener in position. Thin carbon panels do not improve with piercing or drilling. In short, design and process engineers liberated by composite materials do not want to be limited by fastening solutions that are not designed for use with composites.

The growth of composites The development of composites and plastics and their migration into applications habitually dominated by traditional materials such as wood and metal is a significant trend. Lighter, stronger, versatile and more mechanically stable, modern composite materials have found a home in almost every industrial sector. The issue of reducing weight or ‘lightweighting’ has become central to innovation in the automotive sector, accentuated by high oil prices and regulatory pressure to reduce carbon emissions.

Initially, lightweight composite materials such as carbon fibre were only used in very high-end applications such as aerospace and super cars, as costs were very high and production processes slow. Increasingly, major car makers are introducing carbon fibre into their luxury models and many are examining ways to replace structural elements traditionally made in heavier metal. As the volumes of carbon fibre production increases, the costs will fall and the number of applications in premium and standard car models will increase.

10 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

bigHead – the original bonding fastener. +44 (0)1202 574 601

Fasteners embedded in composites Embedding fasteners in composites is a common requirement and can provide a secure and discrete fastening solution. Integrated into the composite manufacturing process the fasteners become integral to the composite product, which supports efficient final assembly. The embedded fasteners can be integrated within the composite mould tool, there is no secondary work required, and the fastener is fully integrated in the composite product – making it very discrete and stable.

However, embedding a fastener that has not been designed to be embedded can lead to design compromises and process inefficiencies. These compromises can weaken the composite product or increase its thickness and weight. The example below shows how plastic is built up on this floor pan around a traditional bolt for no other reason than to hold it securely in position.

Seen in cross section (right) you can see how the traditional bolt requires significant composite material to anchor it securely in position.

Alternatively, a bonding fastener such as a bigHead ® can be used, which is designed to be embedded in the composite material without the need for the material to be thickened. The thin flat head (shown in cross section below) which is perforated to allow the flow of composite material, helps transfer the load efficiently into the composite structure. The same threaded stud fastening is provided with potentially higher tensile and torsional strengths.

Different levels of tensile and torsional strengths can be achieved by using different size and shape heads.

In summary, these are some of the key benefits of using a fastener designed to be embedded in composites: • Space saving, as no additional composite material needs to be built up to anchor the bolt.

• Weight saving, as less composite material is used.

• Reduced composite curing times, as less composite material is used.

• Higher tensile and torsional loads can be withstood with bigHead designs.

• Design optimisation with the fastener designed around the composite product.

Surface bonding on composites Many composite applications rely on the use of thin structures – carbon fibre reinforced plastics used for automotive body panels are a good example of this. Such composite panels are often only a few millimetres thick.

In these cases, without sufficient material to embed a fastener, a surface bonded fastener can be a very effective and discrete solution. Bonded to the surface with adhesive, a bonding fastener can provide a secure fixing that does not pierce or damage the composite panel.

The example below shows a carbon fibre diffuser for a

Carbon fibre composite diffuser held on with nine bigHead®s

car, attached with bigHead bonding fasteners. Discrete and very strong, the bigHead fasteners are surface bonded on the inside of the diffuser with a structural adhesive. This bonded solution is completely invisible from the ‘A-side’ as there are no rivets, drill holes or visible ‘shadows’. The structural integrity of the single composite panel is fully maintained. Due to the unique design of the perforated ‘head’, the glue flows through the holes and locks the fastener into position, achieving high stability and strength. Bonded in position by the Tier 1 supplier, the diffuser is ready for final assembly at the OEM. Depending on the application, various bonding fastener designs are possible to compliment rather than compromise the final design and function of the composite part.

Alternative fasteners requiring a hole to be drilled or pierced through the panel can weaken the panel. Piercing a carbon fibre reinforced panel will break or damage the reinforcing carbon fibres which are, by definition, there to provide reinforcement and structural integrity. Depending on the position, size and quantity, the holes in the panel may lead to degradation and failure of the composite under stress. Composites can fail on the microscopic or macroscopic scale. Compression failures can occur at both the macro scale or at each individual reinforcing fibre in compression buckling. Tension failures can be net section failures of the part or degradation of the composite at a microscopic scale where one or more of the layers in the composite fail in tension of the matrix or failure of the bond between the matrix and fibres. Due to the complexity and variation of composite materials it would therefore be necessary to include the piercing or drilling of holes into any pre-construction strength testing and analysis of the behaviour of a composite panel so fastened.

The surface bonded solution does rely on the adhesive for the critical bond between composite structure and fastener.

The performance and reliability of adhesives has continued to grow and they are now commonly used and relied upon in numerous applications. The range of adhesives is very large, but almost any structural adhesive will be compatible with a bonding fastener such as the bigHead. There is also a significant range of adhesive curing speeds available on the market, from several seconds to hours, to ensure compatibility with the assembly process. Much work is also being done on the efficiency of adhesive delivery, from hand-held devices to fully automated robot cells.

It is no longer necessary for design engineers working in composites to compromise their product design or function by using fasteners designed for non-composite applications. In doing so, they risk their product quality and customer satisfaction.

Excellent fastening solutions designed for composites, offering design flexibility and functional reliability, have become well established over many years in applications across a wide range of industries. The quality of these solutions has been fully tested by world leading companies in the automotive, marine, construction, energy and general manufacturing industries.

To find out how these tried and tested solutions can work for you, and to receive assistance in optimising your composite fastening solution, contact Bossard. www.bossard.com/ffm

www.fastfixtechnology.com

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PLASTICS + COMPOSITES

NORMA Group – creating a close working partnership NORMA Group prides itself on its ability to work with customers to create engineered joining technology for applications in a host of industries. Will Lowry spoke to Jean-Luc Kirmann, director of application engineering – EMEA, about the steps involved in working with customers and the benefits of a close partnership.

NORMA Group is able to supply a wide range of engineered joining technology.

What type of plastic solutions can it offer?

“NORMA Group has a large product portfolio of approximately 30,000 engineering joining technology solutions – supplying components for different applications in vehicles, aircraft, trains, ships, washing machines, water pipelines, and for applications for the pharmaceutical and biotechnology industry.

In this portfolio we can supply a variety of plastic products, with our key range being Quick Connectors – which can be used in cooling water systems, emissions reduction systems, as well as charged air systems – mainly in the automotive, truck and off road industries. We can supply a unique selection of Quick Connectors including NORMAQUICK® S, NORMAQUICK ® PS3, NORMAQUICK ® V2, NORMAQUICK ® MK, as well as a broad variety of versions and sizes that meet European and US standard.

We can also design and provide Quick Connectors that include function such as valves, sensors, or heating elements.

We can do this because of the manufacturing capabilities within the Group. We offer full production capabilities for multi-material, multi-component, and multi-layered products. Overall, 200 NORMA engineers globally combine a unique know-how in metal and plastics technology.”

Can you give us an example of NORMA working with a customer to create a solution? What steps were involved in the development process?

“We recently had a project with a customer that makes agriculture vehicles such as tractors and harvesters. We already supplied a range of Quick Connectors and fluid pipes to the customer for numerous applications. During one of the meetings with the customer, our application engineer noted that one of our Quick Connectors was being used in a complicated system – made of plastic and metal – for the closing of the fuel line when draining water from the fuel tank. The

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customer explained that they had to assemble the components for the complicated system themselves, and that the components were heavy, expensive and not very user-friendly.

To create a solution we worked with the customer to understand the critical functions of the system. Only then could we redesign the system to optimise these functions, as well as reduce weight and installation time.

Our solution involved designing a system that was fully plastic – using the minimum number of components – helping to reduce weight and make it easier to install. As part of the process we designed a sample using 3D printing. Whilst the 3D printed part was not fully functional the customer could see and hold the part to see its shape and how it would work.

This helped us finalise the design and make sure the customer was happy with the results we could offer.

Once the customer was happy with the design the next step was to create the tooling for the moulds in the plastic injection process to make the components.

We are now at the stage where the tooling has been launched and in the next few weeks we should get the final components to make the first prototype system. We can then start to test the solution with the customer to make sure that it is suitable for the application and meets all the requirements. Once the prototype has been validated the customer will be able to start production of the components.

By working with us the customer can now buy the components for the whole system from one supplier. We have also optimised the design and been able to improve the system by reducing weight, making it user-friendly, as well as enhancing the functionality.”

How does NORMA Group ensure it is supplying engineered joining technology according to its customer’s needs?

“The key success point in making sure we are providing the right solutions is to work very closely with our customers.

We believe it essential to have a close working relationship with the customer, as this enables us to identify all the potential solutions we are able to offer for applications. We have technical meetings with customers where we are constantly looking at ways in which we can work together to help improve the functionality of applications, as well as if there is any weight or costs that can be saved. Through our engineering department we can provide optimal solutions. Our application engineers identify and propose new ideas and our specialist product engineers create the products and technology. This structure within the engineering department is global and we can work with customers and OEMs around the world, whether it is Europe, Asia-Pacific or the Americas.

An additional benefit is that we often find that customers do not necessarily know what we are able to supply and don’t realise our capabilities. It is only by visiting customers and interacting with them, and seeing the applications for ourselves, that we are able to ensure that the most optimised solution is proposed.

Looking to the future, having a close relationship with customers will become even more important, especially with

“ Through our engineering department we can provide optimal solutions.” the growing trend for replacing metal and rubber components with plastic components. At NORMA we have introduced new plastic components that are able to withstand even higher temperatures, meaning customers can now replace metallic or rubber components. This helps the customer improve recyclability and reduce weight, which is especially important in the automotive market in relation to emission reductions and the new Euro-6 standard.” 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

PLASTICS + COMPOSITES

New wing body versions for Plastimont range

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Bülte Plastiques France SA has introduced new CO 251 and CO 252 wing body versions for its Plastimont range.

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he CO 251 and CO 252 are plastic knobs in kit form that enable users to insert their own hex screw or nut made from steel, stainless steel, brass, nylon or other materials.

For CO 251 the Plastimont is available in M4 and M5 x 28mm and for CO 252 it is available in M5 and M6 x 31mm. The Plastimont body’s ergonomic shape and use of small grooves enables a good grip, with the bodies also stain resistant, light and insulating, as well as offering a good alternative to over moulded products.

The standard material is polyamide (nylon), which is resistant to various chemical products. It also has excellent mechanical properties including wear resistance, low friction coefficient, a high melting point, good impact resistance, as well as being very light. The working temperature range is -30°C to +100°C. Thanks to its special properties nylon is also suitable for a wide variety of industries including: Military, medical, aerospace, railway, toy, food, chemicals, electronics, electrical and building.

“A significant finished products’ stock, efficient production process, and reliable logistics, allow Bülte to deliver these products in small quantities and in competitive lead times.”

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CO 251

3 28

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CO 252

3,8 34

Joining lightweight materials with ONSERT® DELO Industrial Adhesives LLC says it has developed ONSERT® technology, an innovative joining method developed alongside assembly specialist Böllhoff, for fast curing in a variety of materials.

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ELO says that ONSERT® technology, based on stud welding, combines bonding and screwing by equipping fastening elements, such as threaded metal bolts, with a transparent plastic base and bonding it to fibre composite materials. The threaded rod of the ONSERT can be screwed and – when necessary – removed again.

With ONSERT, composites, thin sheet metals, plastics and other materials are equipped with a multi-purpose connection element. Composite materials, such as CFRP and GFRP, take established joining technologies including welding, screwing and riveting to their limits.

The special feature of the ONSERT technique is its speed as the adhesive is cured within approximately 4 seconds using an LED lamp. It is also possible to fully automate this process and the bonded connection can be loaded immediately. Bonded bolts with a base diameter of 25mm achieve a pull-off strength up to 2,000N on CFRP. When applying higher forces, a predetermined breaking point in the base ensures that the laminate of the composite material remains intact and no fibres are torn out. Nevertheless, the ONSERT is robust as shown by salt spray and VDA climate tests.

In addition, ONSERT excels due to its flexibility in design and production. First, the structural shape can be defined by the user to a great extent, particularly in terms of rod length and base diameter. Second, they provide much freedom in production as bonded bolts can be attached to the raw body and prior to final assembly of lacquered elements.

Böllhoff and DELO have tested this technology in a series of pilot projects including fixing of cables, claddings and other components of the BMW i3.

ONSERTs are suitable for a broad variety of applications including cable harnesses, control units, sensor retainers, brake lines, claddings or exterior attachment components, cover plates, insulating materials, floor panels in airplanes, and white goods.

14 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

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PLASTICS + COMPOSITES

Bespoke designs from Veck Bonding fastener manufacturer and supplier, Veck Composite Fasteners Ltd, is widening the potential applications for its range of fasteners by offering more bespoke designs to its customers.

V

eck explains that features that may not be available in the existing standard range of bonding fasteners can now be included in custom versions, designed and produced specifically to customer requirements. This may include more than one fastener within an assembly, producing many important benefits as a result, such as a simplified moulding process – helping to reduce costs and improve the final product.

One project that Veck recently undertook that demonstrates these advantages involved combining three female threaded collars with one non-standard base plate for use as a fixing point within the hulls of a catamaran. By using one large fastener assembly, compared to three smaller ones, it was easier to fit within a mould – thereby saving time by simplifying the customer’s manufacturing process. In addition, by increasing the overall base plate area by more than three times the combined size of the previous bases, load distribution and strength were increased markedly, thereby significantly improving the strength of the final moulded assembly. A 10% cost saving was also made as a result of the change because of the relative ease of manufacture compared to producing one assembly instead of three.

“At Veck we prefer to offer solutions rather than simply products and it is often only through a bespoke service that compromises in design and cost can be minimised or removed altogether.

A standard product range works very well for many customers but it is recognised that others have more specific needs that can only be satisfied by a custom solution, which is available quickly and easily.”

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FASTENER + FIXING TECHNOLOGY

Clevedon – British manufacturing at its best Who? You may ask. Clevedon is quite a well kept manufacturing secret that goes against the usually accepted wisdom that British owned fastener manufacturing in the UK is dead.

N

ext time you look in your rear view mirror, the chances are that the truck behind you has Clevedon rivets holding vital parts of its braking system and body parts together. When you get home and open your double glazed doors or windows, Clevedon rivets are probably holding them together as well. Clevedon supplies fasteners to all kinds of industries both in the UK and worldwide.

Based in Sutton Coldfield in the West Midlands, Clevedon manufactures 22 million parts per month; mainly solid, semi tubular and fully tubular rivets, plus a significant number of specialist cold forged components. The company has successfully weathered numerous downturns, recessions and every other economic and regulatory malady that has been thrown at UK manufacturing. Not only is it still here and thriving, but Clevedon’s largest export market, wait for it, is the Far East.

Steve Hardeman, Clevedon’s managing director, attributes the company’s survival to its hardworking work force and a sales ethos that demands that any prospective customer is seen face-to-face, no matter where they are in the world.

Clevedon Fasteners began manufacturing in Clevedon Street, Birmingham, in 1939, supplying the Spitfire factories in Castle Bromwich with aircraft rivets. It went through numerous ownership changes – small groups, mini conglomerates, whatever was the prevailing trend at the time.

In 2000, the present management team of Steve Hardeman and Charles Hopkins took the opportunity to buy the company, backed by Langham Industries – a privately owned group mainly involved in engineering and marine services.

In 2001, following the 9/11 attacks, British Aerospace closed part of its Regional Jetliner business. This resulted in Clevedon’s turnover reducing by one third. With the help of the government’s ‘Passport to Export’ scheme, Clevedon went to its first exhibition – at Automechanika in Frankfurt.

The reaction from potential overseas customers was overwhelming. In the space of three months the shortfall was replaced. Clevedon now supplies 47 countries and exports account for 29% of turnover.

“Exports saved the day,” comments Steve Hardeman.

“I had believed the hype that UK manufacturing companies were lame ducks as far as the rest of the world is concerned. It was refreshing to find this was not the case: UK manufactured parts are highly regarded globally. If a UK based rivet maker can make a success of exporting, any British company can.”

Recognising the need to balance the company following the 2008 recession, Clevtec was created as a wholly owned subsidiary in 2010. Clevtec is a distributor specialising in niche areas such as commercial vehicle brake shoes, rivet setting

18 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

machinery and tooling – as well as fasteners that Clevedon does not make, such as rivet nuts and clinch nuts.

“Our product range is constantly evolving,” says Karl Love, Clevtec’s general manager. “We are currently working on a number of customer specific products and services, which will lead to significant, rapid growth over the next 12 months.”

Karl is also general manager of Clevedon’s latest acquisition, Blakeacre. Clevedon purchased Blakeacre Ltd in 2013 in order to consolidate its UK manufacturing base. Blakeacre manufactures mainly threaded products from its factory in Great Barr, Birmingham. Whereas Clevedon makes to order, and sell predominantly to the OEM market, Blakeacre has a well developed product range of threaded fasteners, which it sells from stock, predominantly to the distributor trade.

“The Blakeacre range of clinch studs, capacitor discharge and weld studs, cup square, spline and silo bolts, and Bolt Lok products are well known in the UK but the plan is to develop the export market for these products in a similar way to Clevedon.”

Clevedon/Clevtec and Blakeacre’s long-term planning and development of niche marketing opportunities certainly look set to ensure they will be around for years to come. www.clevedon-fasteners.co.uk

Friction Lining Rivets OEM Aftermarket Machines & Tooling Riv Nuts Clinch Nuts Supply Chain Solutions Clevtec is the Distributors, distributor.

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T H E C L E V E D O N G RO U P Clevedon. Reddicap Trading Estate, Sutton Coldfield, West Midlands B75 7DG. Tel: 44(0)121 378 0619. Fax: 44(0)121 378 3186. Email: sales@clevedon-fasteners.co.uk www.clevedon-fasteners.co.uk Clevtec. The Courtyard, Reddicap Trading Estate, Sutton Coldfield, West Midlands B75 7BU. Tel: 44(0)121 378 5960. Fax: 44(0)121 378 4291. Email: karl@clevtec.com www.clevtec.com Blakeacre. Austin Way, Birmingham, West Midlands B42 1DU. Tel: 44(0)121 358 5066. Fax: 44(0)121 358 1721. Email: sales@blakeacre.co.uk www.blakeacre.co.uk

TECHNICAL

A new approach to the tightness checking of bolts Bill Eccles, Bolt Science A frequent question that is asked relating to bolting is: ‘We’ve just checked a nut that we tightened and it’s well below what we tightened it to just minutes earlier – what’s wrong?’

I

t’s not widely known that the torque for a newly tightened nut or threaded fastener, in general, is different depending upon whether you attempt to untighten it or tighten it a bit more. Typically the torque needed to untighten a newly tightened fastener is around 10% to 30% less than the torque to tighten it further.

When you are tightening a threaded fastener a significant amount of torque is needed to overcome friction in the threads and under the nut face (or the bolt head, if the bolt is rotated).

The proportion of the torque that is used to overcome friction depends upon the friction value but is typically in the 85% to 90% region. This is illustrated in Figure one, which shows that when tightening a nut/bolt with a coefficient of friction of 0.12, only about 14% of the torque is used to stretch the fastener producing the clamp load with 86% of the torque being lost overcoming friction. The torque needed to stretch the fastener always acts in the untightening direction and it’s for this reason that the untightening torque is less than the tightening torque.

Figure two shows what happens when you tighten, and then untighten, a threaded fastener. The tightening torque TOn produces a certain clamp force (F), it then takes a torque TOff to untighten it. For a newly tightened fastener, TOn is greater than TOff. If the fastener is left for a prolonged period, changes in friction can result in the untightening torque TOff becoming greater than the original tightening torque TOn.

20 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

Figure two In many applications the clamping force provided by tightening fasteners is of critical importance in determining the success, or otherwise, of the structural integrity of an assembly. A great deal of attention is often placed on ensuring that bolted connections are installed in a controlled manner so that a predictable clamping force is achieved. The most popular controlled method of tightening a threaded fastener is by applying a specific tightening torque. Below the yield point of the fastener, the relationship between the applied torque and the clamp force provided by the fastener, is linear. That is, double the torque and you double the clamp force. Once tightened, the clamp force provided by a bolted connection can decrease. The decrease can occur without any rotation of the thread, as in the case of stress relaxation, embedding, creep and similar effects, or, the bolt or nut may rotate decreasing the clamp force as in the case of self-loosening. Subsequently, concern over the loosening of bolts, in many applications, necessitates quality control measures to check their tightness.

Tightness is usually assumed to be the measured torque value

but in the majority of applications, it is the clamp force rather than the torque that is the critical factor. The problem is that there is no low cost method of assessing the clamp force provided by a previously tightened fastener.

Currently, the tightness of a bolt/nut assembly is usually assessed by a torque based method, the approach is referred to as torque auditing. Torque auditing is usually completed by one of three torque methods: 1. On-torque method: Measuring the torque needed to rotate the bolt/nut by a small angle (typically 2 to 10 degrees) in the tightening direction. This is the most frequently used method of torque auditing.

2. Off-torque method: Measuring the torque needed to rotate the bolt/nut in the untightening direction (which will normally be less than the tightening torque).

3. Marked fastener method: Marking the position of the bolt/nut relative to the joint, untightening it by an angle of approximately 30 degrees, then measuring the torque needed to tighten the bolt back to the marked position.

“ In many applications the clamping force provided by tightening fasteners is of critical importance in determining the success, or otherwise, of the structural integrity of an assembly.”

Each of these three methods have their deficiencies.

The key assumption in each method is that the torque value measured is a true assessment of the tightness of the connection. The critical flaw in each of these methods is the assumption that the coefficient of friction has not changed between the tightening of the bolt/nut and the completion of the checking process. Changes in temperature, humidity and the effects of corrosion after the bolt/nut was originally tightened will affect the friction value and subsequently the torque value but not necessarily the clamp force. A change in the friction condition can make invalid the assumption that the torque value is a true assessment of the bolt’s tightness.

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TECHNICAL The method described in this article is an attempt to improve upon the present tightness checking methods to allow the clamp force being provided by a previously bolted connection to be assessed and, potentially, corrected. This is achieved by performing a tightening-untightening-retightening sequence (referred to as the ‘On-Off-On’ method) on the bolt/nut involving the measurement of torque. The ‘On-Off-On’ tightening sequence can provide information as to the clamp force provided by the bolt, which allows a better indication of the structural integrity of the joint than existing methods.

By studying the underlying relationships between the tightening and untightening torques, a simple formula can be derived relating the tightening torque TOn and untightening torque TOff to the clamp force (F) present in the fastener. This relationship is shown in Figure three, the p in the equation is the pitch of the thread1. So for example if on a previously tightened M12 nut/bolt (pitch p = 1.75mm), a torque TOn of 80Nm was measured and the TOff value was 60Nm, the clamp force would be estimated as being 36kN. Essentially the larger the difference between the on and off torque values, the larger was the force present in the bolt.

To apply the ‘On-Off-On’ method to establish the tightness of the bolted connection, the torque needed to incrementally rotate the nut in the tightening direction is measured, then measured in the untightening direction, before final retightening. A series of images illustrating this approach is given in Figure four.

Figure four A large number of tests have been conducted by the author to assess the validity of the ‘On-Off-On’ method. The tests conducted indicate that when the fastener coefficient of friction is low (<=0.08), the ‘On-Off-On’ tightness auditing method is an accurate prediction of the load in the bolt. With fasteners displaying typical values of the coefficient of friction (0.08 to 0.18), the tests indicate that the method is a good indicator of the bolt load.

At high friction values (>0.25), such as may be displayed by galvanised bolts tightened without a lubricant, the approach has limited potential.

The ‘On-Off-On’ tightness auditing method is more accurate when: • Well lubricated fasteners are used that have inherently low friction values.

• The auditing process is conducted after a relatively short period of time after the fastener installation.

The ‘On-Off-On’ tightness auditing method would tend to be less accurate when: • The fasteners are not lubricated and have an inherently high friction, for example, a galvanised finish without a lubricant being used.

• A significant period of time has elapsed since the fastener installation and the operating environment is such that corrosion is likely to occur.

Depending upon the method of applying the torque and knowledge of the friction conditions, the scatter in the bolt load can vary between +/-17% to +/-33%. The variation in bolt load is largely due to the variation in the fastener friction rather than the accuracy of the applied torque value. The typical accuracy of the ‘On-Off-On’ tightness auditing method is well within these limits.

Establishing what load/torque that the bolts in a joint should be tightened to can be problematic for some maintenance activities. The ‘On-Off-On’ method could, potentially, provide important information about the load that the existing bolts are sustaining – allowing the torque that a new bolt should be tightened to be better estimated.

Measuring the on-torque alone can be a poor indicator of the retained clamp force of the joint. It is frequently used since usually there is no practical alternative. In short, for most applications the conventional torque auditing approach can be effectively used (that is, measuring the torque needed to fractionally rotate the fastener in the tightening direction), the ‘On-Off-On’ tightness auditing method can also be implemented. A major advantage of the ‘On-Off-On’ tightness auditing approach is that additional information can be derived regarding the integrity of the joint without a significant change being made to existing working practices.

Establishing the likely retained clamp force present in a joint can be a crucial factor in determining whether the structural integrity of the assembly is likely to be satisfactory, or likely to be impaired.

As such, this new approach can be a useful tool in helping to ensure product safety and reliability. There are limitations to this new approach to fastener tightness checking, principally its accuracy in high friction conditions, but it is a useful indicator as to the retained fastener clamp force in many circumstances. www.boltscience.com

About Bill Eccles Bill Eccles is a chartered engineer and has a Doctorate in Engineering on the self-loosening of threaded fasteners.

In 1992 he set up Bolt Science, which is a company that provides independent technical expertise in bolted joint technology. Bill also delivers training courses around the world on the analysis of bolted joints and bolting technology.

1 More details of how this relationship is derived is presented in the paper: ‘A new approach to the checking of the tightness of bolted connections’ presented at the LUBMAT 2014 conference in Manchester in June 2014.

22 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

STRUCTURAL FIXINGS

Structural bolts conforming to EN 15048 As of 1st July 2014 it has been a legal requirement under EN 1090-1 for all parts of a bearing steel structure to have CE marking. Non-preloaded structural bolts have to meet all of the regulations under EN 15048. That is why Stafa Group has made sure its entire range in stock meets the regulation – meaning customers can be assured of European quality.

T

he CE marking requirement is set by the Construction Products Regulation (CPR) and the European standard EN 1090-1.

This standard sets the requirements for CE marking for steel and aluminium bearing construction parts with references for implementation to EN 1090-2 and EN 1090-3. EN 1090-2 describes the bolt connectors in which reference is made to standard EN 15048 for non-preloaded structural bolts and EN 14399 for preloaded bolts.

EN 15048 contains regulations governing products used for the design, calculation and manufacture of non-preloaded bolt connections for steel structures. Stafa guarantees that all of the structural bolts in its range meet these requirements.

“Most steel structures use non-preloaded structural bolts. For that reason we keep a complete range of structural bolts that conform to EN 15048. This assures customers of competitive conditions and fast delivery. We can also supply preloaded bolts conforming to EN 14399 on request. If you have been using non-certified nuts and bolts for steel structures since 1st July 2014 you are violating European law with all the consequences that entails. Stafa Group offers you all the expertise in the field of this new legislation so that you are assured of the right products.” www.stafa.nl

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STRUCTURAL FIXINGS

Structured approach from Alcoa Alcoa Fastening Systems (AFS) is a leader in developing fastening technology and providing safety critical solutions for a variety of installations. Through its commitment to quality and innovation, it has established itself in key markets, including commercial transportation, automotive and rail.

Now the company is looking to do the same in the structural and civil engineering market.

A

FS has been involved in the civil engineering market for over 40 years. However, it is only recently that the company has looked to further develop the products and range it can supply to the market. A key achievement was the Deutsches Institut für Bautechnik (DIBt) approval for its structural fasteners, both Huck ® BobTail ® lockbolts – the advanced two-piece fastener – and also blind fasteners.

“In the structural market you are dealing with engineers who want absolute confidence in what they do,” explains Jonathan Craven, operations director, AFS industrial operations UK. “We are talking about large civil engineering structures that involve safety critical applications. This means, we have to operate within the DIBt standard to meet the needs of that market. Achieving the DIBt standard gives us the possibility to market authoritatively.”

A leading product in the AFS product range that received DIBt approval was the Huck BobTail – a lockbolt system that is entirely vibration resistant and has an extraordinary fatigue life – with the product achieving DIBt approval for static and dynamic structures. “That approval goes to the extent that it gives functional performance, but it also makes the statement that the installed joint is maintenance free,” proudly states Jonathan. “That creates an opportunity because one of the limiting factors and cost of conventional nuts and bolts is the ongoing need for regular inspection and retightening. By proving that the BobTail lockbolt is vibration resistant and maintenance free – in addition to offering high clamp retention and joint integrity for the life of the product – it makes the BobTail lockbolt an attractive proposition for companies.”

“ Achieving the DIBt standard gives us the possibility to market authoritatively.”

24 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

Compared with conventional lockbolt technology, the BobTail lockbolt design doesn’t involve a pin break. Normally the clamp to install a standard lockbolt is created by pre-tensioning of the pin; an anvil then slides over the collar to swage it and at that point, when it is engaged fully with the collar, the pressure rises and the pin snaps off. With the BobTail lockbolt, there is no pin break. The pin is simply pulled, the collar is installed, and then it retracts. This means that the customer is left with an intact pin and an intact collar. A key benefit of not having a pin break is that the assembly is even more corrosion resistant.

“Our coatings for the BobTail lockbolts are compliant to the DIBt and to ISO 12944 standards up to C5M high, which includes offshore external joints,” mentions Jonathan.

“To reach the ISO 12944 standard requirements, it is necessary to test the fasteners for 1,440 hours (approximately two months) in a salt spray corrosion cabinet. In order for us to be confident that we could reach C5M high, we went to 2,160 hours in the salt spray corrosion cabinet. This meant the product had to be below the first signs of red rust, whilst installed for almost 3 months in a salt spray corrosion cabinet.

This is quite a big test, but by completing these types of tests it gives the product extra credibility.”

From the way in which he talks, it is clear that Jonathan is passionate about the BobTail lockbolt and its unique features.

“Overall I am biased because I know that it is a great technology,” says Jonathan with a wry smile. “What I would say is that it’s an evolutionary step forward from conventional lockbolts.

If you compare a BobTail lockbolt with an equivalent sized nut and bolt, the fatigue life of the BobTail lockbolt is approximately 5 times greater. If an engineer is working with a dynamic application, then obviously this is a critical benefit.”

From feedback AFS has received from the market, it is looking to further develop its service, by extending the

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STRUCTURAL FIXINGS also gives us a unique level of accreditation because to my knowledge, we are the only manufacturer of 12.7mm DIBt blind fasteners approved for dynamic structures.”

Jonathan enthuses: “The Magna-Lok blind fastener is a fantastic, robust, versatile fastener. It has a great grip range, enormous strength and it is superb at closing gaps – making it ideally suited to joining a wide range of materials. It also offers speed of assembly and functional performance improvements, which make it the perfect product for racking housing, steel construction and modular building applications.”

BobTail lockbolt diameter range available with DIBt approval.

“We have spoken to some of the larger civil engineering companies in continental Europe and they are all interested in large diameter lockbolts,” explains Jonathan. “We are therefore going through a process of developing large diameter BobTail lockbolts. Once they are ready, they will go through an extension of the DIBt approval process, which will enable us to offer customers an expanded range of fully approved products.”

In addition to the BobTail, AFS also developed a DIBt standard for its Huck ® Magna-Lok ® structural blind fastener – a sleeve-expanding product that offers single sided joining and rapid installation. The Magna-Lok blind fastener has a wide grip range and the pin lock is inside the sleeve, so it can be used in large joints. Installation can be done on-site using portable power rigs or small hydraulic units, and requires minimum operator expertise.

The DIBt approval for the Magna-Lok blind fastener came up for renewal in 2012, and AFS took the opportunity to not only extend the range, but also the scope of the DIBt approval to include both static and dynamic structures.

“The original DIBt approval was for the Magna-Lok fastener and another product – Magna-Bulb ® blind fastener – and was only for static structures. However, when we renewed the standard we decided to focus on the Magna-Lok fastener because it is a more popular product for steel construction,” says Jonathan. “By extending the scope of the approval it

26 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

Thanks to its DIBt approved products, AFS is attracting interest from across Europe, as well as North America. “Whilst the DIBt is essentially a German standard, it is internationally recognised. The performance benefits our products deliver – and the fact that there is a definition within the civil engineering approval that states that our BobTail fasteners are maintenance free – has generated a lot of market interest,” says Jonathan.

“We are already seeing projects where counterparts in Europe and North America are working in parallel, but on separate projects, and require the same technology. Customers are becoming more aware of our capabilities and products, and then from there it evolves.”

Through the BobTail and Magna-Lok, AFS is able to provide customers with high-quality, approved products that have distinctive benefits, depending on the structural and civil engineering installations they are used. To ensure customers are aware of what each product can deliver, AFS works closely in partnership with the customer to find the ideal solution.

“It is very important that as a company we have a dialogue with our customers so that we can work with them on finding the right product for their application,” states Jonathan. “By working closely with these companies, we can propose the right fastening solutions for their design technologies. We are also happy to bring a product to market while partnering with a key customer. I believe that you cannot design and develop really successful fastening technology in isolation from the market. You can, however, go on that journey with a customer and both benefit at the end of it.”

Jonathan concludes: “At AFS we are in a continuous cycle of looking to increase functionality and add new performance criteria to our products, as well as increase product awareness.

For us, it is about looking at the bigger picture. It is about establishing ourselves in a market where we are not historically well established. We have built the products, the range and the approvals, so the next stage is to continue to engage with customers and take our engineering to them, and wave the flag for our best in class fastener technology.” www.afshuck.net

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STRUCTURAL FIXINGS

The finish of choice: Ensuring structural reliability Malcom Wright, director at B.E Wedge, Wedge Group Galvanizing’s dedicated spin galvanising division and recognised European Centre of Excellence for centrifuge galvanising, looks at the process of galvanising and explains why it’s one of the most reliable processes for treating fastenings and threaded components to ensure their structural reliability. He also identifies some of the issues that may occur if the wrong finish is used, which could potentially pose a risk to the overall structural reliability of a project.

G

alvanising is the finish of choice for many industries, not only for the long-term protection it provides against various types of corrosion including weathering and rust, but for the ease of application and fast turnaround time it offers.

Galvanising can be used for a wide range of projects from large-scale structures right through to sculptures and artwork, however one of the most vital – yet often overlooked aspects – is ensuring the structural reliability of the project. Nuts, bolts and other fastenings are vital for reinforcing and securing steel projects, so it’s essential they are treated appropriately.

For the vast majority of steel related projects, hot-dip galvanising is simply the most effective method to provide a long-lasting protective coating against rust and corrosion.

Because it forms a series of alloy layers with the steel, it is much more robust than other coatings that only bond chemically or mechanically, and it also has the added advantage of fully coating the steel – both inside and out. Galvanising is long-lasting and can protect an item for up to 60 maintenance free years (or longer) depending on where it is located. It is environmentally friendly with low whole life costs. It’s these qualities plus its flexibility across a whole range of projects that makes it a popular choice throughout the construction process.

28 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

Although larger steel components significantly benefit from galvanising, perhaps one of the most vital aspects to consider during construction is protecting the fasteners such as bolts, nuts, and screws that hold the core structural components together. If fasteners fail, the integrity of the entire structure is at risk, and corrosion can essentially cause this.

Threaded components form a key element in construction projects such as bridges, stadiums, and tunnels which wholly rely on the resilience and durability of the fixtures to reinforce them and maintain their stability.

Centrifuge galvanising differs from the conventional hot-dip galvanising, which is used to treat larger steel components.

Leading facilities follow the BS ISO 10684 industry standard, which is directed at hot-dip galvanising fasteners and specifies alternative material, process and some performance requirements for centrifuged hot-dip galvanised. It’s not recommended for hot-dip galvanising of threaded fasteners smaller than 8mm in diameter, and states 10.9mm fasteners may be hot-dip galvanised providing a certificate of compliance is issued by the galvaniser stating that the galvanising has been carried out in terms of the recognised standard.

Galvanising threaded parts also requires a slightly alternative process compared to larger components, primarily due to

the size of the fasteners and their end requirements. Prior to galvanising, the surface of the steel must be clean from light grease, scale and dirt. However, the technique of acid pickling used to clean larger steel components can cause embrittlement in smaller parts, which can damage the mechanical properties and compromise its performance. Hydrogen embrittlement may occur when atomic hydrogen is absorbed by the steel during the acid pickling process. This embrittlement can potentially lead to the loss or partial loss of ductility in the steel and consequently result in the premature failure of the fastener in the field.

Small components that are 10.9mm or less should be shotblasted, which ensures the steel product isn’t damaged prior to treatment. At B.E.Wedge the Galblast 450 process is used, which is designed to meet the requirements of the fastener industry for reliable, long-life, high strength nuts and bolts, typically grade 8.8mm to 10.9mm.

Spin galvanising is used for products that cannot be conventionally treated, primarily small parts, as it ensures any excess zinc is removed ensuring a smooth surface and preventing items sticking together. The process sees the threaded components and other small parts immersed in molten zinc in a perforated basket which, after the coating has formed, is spun at high-speed – it’s this spinning action that removes any surplus zinc and ensures a clean finish.

After centrifuging, the contents of the basket are immersed in a quench tank where the steel is allowed to cool.

Similarly to standard galvanising, smaller components can

be hot-dipped at conventional temperatures that provide a robust outer layer that can cushion the component against direct blows and help resist abrasion.

In recent years, high temperature galvanising (HTV) has been used across Asia as an alternative to conventional galvanising and sees steel treated at temperatures between 560ºC and 633ºC. Although some believe the process is more suitable for smaller components due to its thinner outer layer, in reality this decreases the products strength and doesn’t provide the protection of conventional galvanising, as it doesn’t provide an additional protective outer zinc layer. So, although the process provides a thinner coating, there are a number of risks that could essentially compromise the strength of the fastening.

It is commonly assumed once fasteners have been galvanised they will no longer fit the previous size. This can be overcome through the process of over-tapping, a procedure that sees the fastener manufacturer make the nut threads slightly larger to accommodate the slight dimensional increase in the bold thread that can result from galvanising. Following galvanising treatment if the thread is still not large enough, it can be re-tapped. Re-tapping will not necessitate re-galvanising because of the cathodic properties and the zinc coating will continue to protect re-tapped fasteners, an ideal process for bolts kept in stock.

Wedge Group Galvanising has 14 plants strategically located across the UK offering a national galvanising service ranging from centrifuge galvanising of small components, such as bolts and washers, right the way up to 29 metre steel beams.

Achilles Seibert GmbH

classic · system · automotive

Achilles Seibert GmbH Germany

Philipp-Reis-Straße 3 D-24558 Henstedt-Ulzburg

Fon: +49 4193 89 55 Fax: +49 4193 89 56 99

sales@achill-fasteners.com www.achill-fasteners.com

EXHIBITIONS

Special features at Advanced Engineering The Advanced Engineering shows will once again be taking place from 11th – 12th November, in Hall 5 of the National Exhibition Centre in Birmingham, UK, with over 650 specialist exhibitors covering 20,000m2 of floor space.

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lready established as valuable events in their own rights, show organisers are confident visitor numbers will also surpass the 12,000 of last year. Ian Stone, managing director of UK Tech Events, said: “This year’s Advanced Engineering is already shaping up as the biggest and best yet, which is quite an achievement for an event that has grown over six years and one that showcases the UK’s burgeoning engineering, manufacturing, technology, innovation and supply chain capability.”

The co-located events – Aero Engineering Show 2014, Composites Engineering Show 2014, Automotive Engineering Show 2014, Auto Electronics 2014, and new for this year, Performance Metals Engineering Show 2014, provide focused individual environments for the latest technologies and solutions; product and process innovation; and industry supply chain capability – supporting current and future market requirements.

Ian Stone explained: “The combination of such highly synergetic show elements under one roof provides a hugely exciting integrated experience for supply chain sourcing, technology transfer and business development. The assembly of multi-sector knowledge, skills and capabilities also generates a unique dynamic for visitors, exhibitors and partners alike, allowing the drawing of ideas and possibilities beyond already quite defined groups.”

The Aero Engineering Show 2014 provides an open conference for the aero structures, power plant and aero systems engineering communities. It is a unique annual showcase of technology and engineering suppliers supporting the UK’s critically important aero engineering supply chain – the second largest in the world.

Reflecting the UK industry’s increasing demand across diverse sectors for harnessing the benefits of composites materials, the Composites Engineering Show 2014 is a showcase of the very latest in composites materials, composites processing equipment, tooling and technologies, related design and simulation technology, specialist composites processing services, as well as composites test and inspection technologies.

The Automotive Engineering Show 2014 provides a showcase of specialist UK and international engineering services, as well as technology and supply chain partners, supporting the UK’s multiple vehicle engineering programmes – from passenger cars to performance vehicles; from commercial vehicles to motorcycles, plus specialist low carbon vehicles and the engine sector.

In addition, the Auto Electronics 2014 event supports the drive to new levels of vehicle functionality, safety and efficiency – including exciting developments in infotainment and telematics.

New for this year is the Performance Metals Engineering Show 2014 – in response to increasing demands for higher performance from metallic materials in a range of capabilities vital to tomorrow’s engineering programmes, including greater strength, lighter weight and extended functionality with processing efficiency.

In addition to this, there will also be six show floor based open conference auditoriums offering more than 200 expert technical and strategic speaker presentations throughout the duration of the shows.

The shows will be open from 9:00 – 17:00 on 11th November and 9:00 – 16:00 on 12th November. Visitors can pre-register now for a free entry badge, which covers all five show streams and linked open conference programmes. www.advancedengineeringuk.com

30 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

PRE-REGISTER TODAY - VISIT WWW.ADVANCEDENGINEERINGUK.COM

Join us where the UK advanced engineering sectors come together

Five key engineering events converge in one hall: Advanced Engineering UK 2014

Once again, the Advanced Engineering UK group of events brings together OEMs, primes and all supply chain tiers, to meet and do business across some of the UK's highest-growth advanced engineering sectors.

Whether attending as an exhibitor or a visitor, each of the 5 co locating advanced engineering shows provides you with a business forum and supply chain showcase within its own sector, and those of its co-locating sister events.

Automotive – Aerospace – Composites – Motorsport – Marine – Consumer – Energy – Electronics and more . . .

Hall 5 of the NEC this 11/12 November.

Register now for your FREE entry badge at: NEW FOR

2014

Media and industry Partners include

www.advancedengineeringuk.com

EXHIBITIONS

Reusable fire retardant fastener system

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Binder Fastener Systems has introduced a new fire retardant self-adhesive version of its Duotec® fastener system, which it says is capable of passing the very stringent requirements of mass transport flammability certification.

ollowing the success that Binder enjoyed with its original Duotec ® – a very strong, interlocking mushroom, single component fastener system – it was challenged by companies in the aerospace and transportation sectors to develop a fully fire retardant version. The new self-adhesive Duotec is capable of passing FAR 25.853 (a) Appendix F, part 1, (a) (1) (ii) and DIN ISO 6941, as well as the toxicity requirements of ABD 0031.

Duotec can now be specified without restriction in areas such as aircraft interiors. Binder Fastener Systems points out that the new product helps remove the hesitation designers and engineers have when replacing unsightly nuts, bolts and screws – thanks to the Duotec being strong, lightweight, reusable and a re-closeable fastener system – without compromising safety legislation.

No special tools are needed to apply the product and along with its multi-directional engagement and uniform performance, panel fixing and alignment is a very fast and simple procedure.

“By utilising our fasteners you can speed up production, reduce weight, stockholdings and costs. This item adds to our great range of products specifically for the interiors market.”

Expert advice from TFC D93

TFC Ltd will have engineers on its stand to discuss specific applications and offer expert advice at Advanced Engineering 2014, and will also be exhibiting its exclusive range of space saving Smalley® wave springs, Spirolox® retaining rings and Laminar sealing ring solutions.

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FC employs over 100 people and has been supplying a wide ranging industrial customer base with technical fastening solutions for over 50 years, enabling designers and buyers to improve their product range and generate bigger profits.

Working throughout a national and European network of logistic service centres, TFC is able to offer a truly local level of support to customers at their manufacturing plants – wherever in the world.

“Our supply chain expertise provides significant benefits to customers by reducing costs associated with the purchase, stockholding and handling of a wide range of low cost fastening and ancillary items. With a reduced supplier base, minimal inventory, and ‘direct to the line’ quality approved products immediately at hand, customers are able to remove a whole variety of hidden administration and transaction costs.” www.tfc.eu.com

32 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

Tape solutions at Advanced Engineering

3rd International Exhibition for Fastener and Fixing Technology

Stokvis Tapes will be showcasing its comprehensive range of high-quality tapes for the automotive industry at this year’s Advanced Engineering shows.

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he company says its exclusive range of bonding, sealing, protection and noise suppression products can be converted and customised to meet specific application requirements.

For instance, to eliminate noise, vibration and harshness within the car interior, Stokvis Tapes has developed a wide range of tapes, including velour, felt, non-woven, PTFE and UHMW-PE. With computer aided design, Stokvis can convert raw materials into effective solutions including: polyurethane, polyethylene, EPDM, neoprene, NBR, PVC foams, non-wovens, felts, carpets, synthetic or natural leathers, protection masks and plastic sheets – all with or without adhesives.

Stokvis Tapes also offers a wide range of protection films that can be used to protect the interior and exterior of a vehicle temporarily during production or transit.

I24

D93

FASTENER FAIR RUSSIA • ST PETERSBURG

Your path to the Russian market

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

Crest-to-Crest Springs

Spirolox Rings Laminar Seals

Innovative solutions to simple problems Wave Spring and Retaining Ring specialists call now to speak to our expert team

+44 (0)1435 860333 www.tfc.eu.com

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

EXHIBITIONS

Improving product design with bigHead®

F150

At this year’s Advanced Engineering shows bigHead® Bonding Fasteners Ltd will be highlighting its integrated fastener solutions for composite manufacturing.

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elping manufacturers avoid secondary processes, bigHead ® works with companies to integrate fasteners in the moulding process, saving process time and improving product design and quality. A recent project with a customer using an SMC process significantly improved a product’s performance, eliminated a secondary manual process and reduced processing time from 5 minutes to 5 seconds. This was all achieved without any significant tooling costs or tooling changes.

Also at the shows will be bigHead’s product solutions now specified for carbon fibre applications by leading automotive manufacturers such as Lamborghini and Porsche.

“As a UK manufacturer with a long established reputation for quality, bigHead continues to innovate and develop new solutions. We look forward to helping customers with their composite design and process challenges.”

Detectable cable ties from Hellermann Tyton Hellermann Tyton has added metal detectable cable tie mounts to its product range, which allow easy detection in the food and pharmaceutical industry.

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lue in colour for easy visual detection, the mounts are screw fixing bases that can be secured to any surface in order to hold a cable tie in place. This screw fixing element means that the product does not require any self-adhesive, removing the risk of the adhesive becoming detached from the base and entering the manufacturing process undetected. The mounts also boast a high metal pigment, meaning that even small ‘cut-off’ pieces are detectable and they can be used as part of the HACCP process.

Richard Rands, product manager for fastenings and fixing at Hellermann Tyton, said: “Plastic contamination is a major issue that can cause problems through the supply chain. If undetected before the products reach the consumer, plastic fragments could at best cause distress and have the potential to present a choking or laceration hazard. To avoid this, it is essential that cable management solutions comply with industry standards stating that any plastic component used around food or pharmaceutical production lines should have a detectable metal content. However, this is not a statutory requirement and there are no established standards.

The cable mounts reflect the next stage of development here at Hellermann Tyton and provide a safe, reliable and low risk solution.”

34 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

There will be a time when you need to join ‘A to B’…

Know your options.

ONLINE The new knowledge hub for fastening innovations, news, technology, and applications across every industry.

www.fastfixtechnology.com

EXHIBITIONS

Fastening technology attracts interest at InnoTrans 2014

After four successful days InnoTrans 2014 came to an end on 26th September – achieving record exhibitor and trade visitor numbers: 140 world premieres, 145 vehicles on the outdoor display and an even greater number of satisfied visitors.

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his year’s show saw 2,758 exhibitors from 55 countries present their innovative products and services in Berlin, Germany, with around 139,000 international trade visitors from over 100 countries attending the show.

“Once again, InnoTrans was able to build on its undisputed standing as the leading innovation platform and the world’s largest marketplace for rail technology,“ said Dr Christian Göke, CEO of Messe Berlin. “With a 10% increase in exhibitor and visitor numbers this event continues to grow consistently in every important area.”

The majority of fastener related exhibitors were based in Halls 8.2, including Nord-Lock GmbH, Keller & Kalmbach GmbH, Bufab Industries SAS, Gally SpA, Otto Fuchs KG, Adolf Würth GmbH & Co KG, Growermetal Srl and J.Lanfranco & Cie. HEICO Befestigungstechnik GmbH was also situated in Hall 8.2 and was displaying its range of products including HEICO-LOCK® Ring Lock Washers and the HEICO-LOCK® Wedge Lock Nut. The company reported a successful show with lots of visitors interested in its products’ capabilities.

Also in Hall 8.2 was Lederer GmbH, exhibiting at InnoTrans to further strengthen its reputation as a specialised supplier for rail fasteners. Lederer is able to offer a full range of products for a variety of rail applications including track and overhead, contact line construction, rolling stocks, bogies and rail automation.

Markus Gebehenne, marketing manager at Lederer, commented: “At the show we were able to present our capabilities to new customers, as well as take care of customer contracts that we have developed over the years through a close working relationship. We had some intensive dialogues with interested parties, buyers, and engineers, throughout the show.”

Markus added: “The number of international visitors is of special value for us and shrinks the gigantic world of trains, trams and rails into one location. There is no way to travel around the world faster to meet all our customers and partners.”

36 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

Another company situated in Hall 8.2 was Bossard AG focusing on lightweight materials and its leading edge logistics system – SmartBin. At the show Bossard launched the new SmartLabel system to be used for the semi-automatic material management of C-Parts in storage, production and directly at the workplace.

SmartLabel uses an E-paper display on the front of the box, which shows an image of the product and the item number – ruling out any confusion when handling the parts. The order status and delivery date are also shown, with the user simply pressing a single button on the SmartLabel to reorder the product. Users can apply SmartLabel to any standard box and at any storage site, enabling the existing infrastructure to be used without the need for any conversion.

Talking at the show, Bernardo Egli – marketing communications manager at Bossard – said that it had been a successful show with the company’s ‘light and lean in fastening technology’ theme attracted a lot of visitors to the stand – interested in the fastening systems Bossard could provide for lightweight construction materials.

Other fastener related exhibitors at InnoTrans included Walter Stauffenberg GmbH & Co KG – showcasing its clamping components and systems – and Ferdinand Gross GmbH & Co KG – promoting its Kanban visualisation software FALCON – both located in Hall 10.2.

In Hall 26 there was also Croatian based DIV d.o.o with a two-tier stand that included numerous flat screen TVs showing the vast array of products that the company can supply the rail industry, as well as Staytite Ltd promoting its new Shakeproof ™ Thread – a locking fastener that integrates a curved thread feature that creates a mechanical interface with the mating internal threads to ensure the fastener stays tight.

The next InnoTrans will take place once again at the Berlin Exhibition Grounds from 20 th – 23rd September 2016.

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

TECHNICAL

Preventing ring failures due to rotational movement in wind turbine gearboxes

By Dipl-Ing (FH) Elmar Kampmann, technical sales manager, Rotor Clip According to Sandy Butterfield at the National Renewable Energy Laboratory (NREL) today’s gearboxes last 7 years – 11 years versus the 20 years expected from the average wind turbine.

Extending gearbox life is therefore critical to current and future wind energy projects.

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normous axial loads impact the gearbox assembly, including bearings and planet gears in both directions.

The bearing race wears; the resulting metal debris leads to bearing failure. These bearings are typically secured via retaining rings designed to eliminate such movement; though analysis shows this is not always successful. The rotational movement spins the ring in the groove, leading to failure of the ring and gearbox.

The reasons for this unwanted movement are: • Bearings fit relatively loose in the bore: This guarantees easy assembly of large components typically used for wind turbines and balances possible thermal radial expansion during operation of the gearbox. Such will not prevent rotational movements of the bearing because there isn’t sufficient friction between the outer race of the bearing and surface of the housing. A retaining ring’s axial contact with the bearing causes the rotational movement of the ring, resulting in the failure.

• A rotating gear is fixed by a retaining ring: As the axial friction between the gear wheel and the retaining ring is greater than the radial load of the ring and the friction between it and the groove, the ring will rotate.

“ Improving the performance of wind turbines is an important industry objective as the market grows.”

38 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

• Rotational movements can be caused by high dynamic torsional loads in an axial direction: As components in a turbine gearbox are fixed by a retaining ring, and dynamic punctual axial loads are introduced, the ring rotates in the groove. This is not caused by the rotation of a retained component but by the dynamic punctual axial loads exerted on the ring.

Fortunately, there are various retaining ring types designed to eliminate the movements described above; thereby increasing bearing life and improving performance.

Preventing rotating of outer races of bearings If the application does not generate enough radial friction between the outer race and the surface of the housing, it should receive an axial load to prevent the race from rotating.

A single-turn wave spring with a specific axial load will hinder the tendencies of the outer race and the retaining ring to rotate. A very precise load should be generated to guarantee non-destructive levels of force. A spiral-wound flat wire single-turn wave spring can generate such a load.

Alternatively, single-turn or two-turn wave springs can replace the retaining ring. These retain and pre-load the outer race of the bearing, streamlining the assembly process.

Rotating gear and retaining ring Instead of a conventional retaining ring, a modified retaining ring can be used to solve the problem. A keystone assembled in the gap of the snap ring with an L-profile similar to the following prevents the ring from rotating:

The bent end offers a â&#x20AC;&#x2DC;noseâ&#x20AC;&#x2122; which hinders the rotation.

No additional keystone needs to be handled in the assembly process. Time and costs for machining the additional groove is comparatively less.

High dynamical punctual loads in axial direction A spiral-wound constant section or multiple-turn retaining ring offers an elastic effect in an axial direction. As this is a coiled part, it eliminates damaging sharp corners. Thus, the ring can withstand higher dynamic axial loads and not rotate in the groove.

Improving the performance of wind turbines is an important industry objective as the market grows. Eliminating damaging movement through the prudent selection of a retaining ring is an important step in achieving that objective. www.rotorclip.com

PRODUCTS

GESIPA: Competent, innovative and reliable GESIPA Blindniettechnik GmbH will be presenting the new GESIPA® FireFox® 2 – a new fully automatic GESIPA® blind rivet nut setting device – and its range of speed riveting technology at EuroBLECH in Hanover, Germany, from 21st – 25th October.

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onnected to a robot application, GESIPA says its modified GESIPA® FireFox ® 2 is able to fit blind rivet nuts, including hexagonal headed ones, reliably at every imaginable angle in industrial production.

Also on display at EuroBLECH will be GESIPA’s wide range of blind riveting machines, including GAV 8000 eco, GAV 8000 electronic and GAV HF. Whether operator-controlled, robot-controlled or in plant operation, GESIPA says its automatic blind riveting machines are flexible and can be used almost anywhere. Their modular design and their application range for diameters between 2.4mm – 8mm allows them to be configured for individual customer requirements. Each machine also has over 40 riveting processes per minute.

GESIPA says it has also revolutionised its flexible, battery operated blind rivet setting devices, AccuBird ® and PowerBird ®.

The new Bird generation now use brushless technology, making them extremely low wearing. With a capacity of 20kN the new PowerBird ® Pro Gold Edition is especially powerful – with the new AccuBird ® Pro almost as fast as blind rivet setting devices operated on compressed air.

“The service life of the removable battery is increased efficiently by recovering the brake energy. The quick charging function and ergonomic shape of the tried and tested TAURUS ® series offers the user real added value, further complemented by its low weight. Poor lighting conditions can also be solved by the LEDs aligned precisely to the workpiece.” www.gesipa.com

Fastenright’s new Tricone® security bolt Fastenright Ltd, a specialist in the supply of security fasteners, has launched the Tricone® – a patented premium security bolt that has been developed specifically for end users.

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he Tricone ® security bolt features three equally spaced blind holes that are formed into the head, with a cone projection protruding from each of the holes.

This patented design makes removal of the fastener extremely difficult without the dedicated unlocking tool.

Whilst security of the bolt has always been the company’s number one priority, Fastenright has also ensured that the look of applications aren’t compromised, with each bolt featuring a polished head offering a unique aesthetic appearance.

The security bolts are manufactured from high-quality A2 stainless steel and stocked in M6, M8 and M10, in lengths ranging up to 100mm and other sizes available on request. The bolts and tools are only available from Fastenright and are not permitted for resale.

Dave Wright, managing director of Fastenright, says: “Each Tricone tool is fully traceable through the use of a unique laser number that is registered to each customer. Combined with the fact that the bolts and tools are only supplied to end users with resale prohibited, we are confident that the Tricone offers one of the securest fasteners on the market.”

HoleMaker Technology launches the Speedtap® Manufacturer and distributor of innovative cutting tools for the UK and Ireland, HoleMaker Technology, has launched Speedtap® – designed for use with an impact wrench or impact driver.

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specially hardened to avoid breakage, with a hexagon socket head, HoleMaker Technology says the Speedtap ®’s patent pending design uses the consistent torque of an impact tool to cut perfect threads in seconds. When combined with a cordless impact wrench or impact driver, the Speedtap can be used anywhere with virtually no set-up time, saving time and money on the production line or the job site.

Speedtaps are currently available in metric coarse M6, M8, M10, and M12 with other sizes in progress, and are recommended for metal thicknesses up to 75% of diameter.

40 Fastener + Fixing Te chnology • Issue 15 Oct – Dec 2014

Piers Crane, marketing manager at HoleMaker Technology said: “We have customers reporting 10 – 15 times quicker tapping compared to hand taps and in some situations over 300 holes tapped with each Speedtap – it’s a genuine revolution in tapping.”

HoleMaker Technology based in Kent, UK, holds a unique range of innovative cutting tool solutions for specialist applications including reamers, taps, and Carbidemax broaching cutters. There is also an advanced specials department for producing impact taps for larger size holes (up to M30), thick and specialist materials, and non-standard threads.

ONTOOL’s alternative to rivet nuts ONTOOL has announced THERMDRILL® – an alternative method to producing solid and wobble free bushings even in thin walled materials.

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ddressing the problem metal workers face when using rivet nuts for connections with dynamic load or vibrations, ONTOOL says its THERMDRILL® is a cost-effective alternative, providing wobble free bushings, starting with a wall thickness of 1mm,

which can save up to 50% of working time and 90% of material costs in comparison to rivet nuts, depending on the application.

Applicable on almost every pillar drill press (ca. 1.5kW motor capacity, speed range 1,500rpm – 3,000rpm) the THERMDRILL starts to generate friction heat once the rotating drill is pressed onto the material. ONTOOL explains that due to THERMDRILL’s special geometry, metallic materials such as aluminium, brass, copper, steel, stainless steel and many other alloys turn ‘plastic’. Meaning that within seconds the so-called thermal drill is ‘drilling’ chipless through the wall thickness. While doing this it is forming a bushing from the displaced material that is three times more than the original material thickness and gives enough space for the threads.

“Without additional material the final bushing is made with a thread former. In only two steps the THERMDRILL threaded bushing is made out of one piece with no twist, is wobble free, and has enormous resistance to dynamic load.”

Tools are available direct from ONTOOL or through authorised dealers all over the word. The standard product range starts from metric M3 to M20. Metric-fine, pipe thread, UNC, UNF and customised tools are also available on request.

Stand:

C53

SouthWind International

Tel: +55 (11) 3165-9991 www.southwind.com.br

PRODUCTS

ADVERTISERS INDEX

Thread repair tool now available from Damar

Achilles Seibert GmbH............................................................. 29 Advanced Engineering UK........................................................31 Albert Pasvahl GmbH + Co....................................................... 5 Alcoa Fastening Systems Ltd....................................................25 APM-Hexseal............................................................................. 9 Baker & Finnemore Ltd............................................................... 7 Bokers Inc.................................................................................25 Bonfatti Filettature Srl................................................................. 5 Bossard Ltd................................................................................ 1 Bülte Plastiques SA.................................................................... 17 Clevedon Rivets & Tools............................................................19 EFC International..................................................................... 43 Fastener + Fixing Search..........................................................27 Fastener Fair Russia................................................................. 33 GESIPA Blindniettechnik GmbH.................................................. 7 Kettling Verbindungselemente GmbH......................................25 Lederer.....................................................................................37 Lesjöfors AB................................................................................ 6 Mubea Tellerfedern GmbH........................................................ 5 NORMA Group..........................................................................13 OTTO ROTH GmbH & Co KG....................................................... 9 Peter Schröder GmbH................................................................ 9 Precision Technology Supplies Ltd........................................... 44 Reyher......................................................................................21 Rivit........................................................................................... 2 Rotor Clip Ltd............................................................................39 Roy Hopwood Fasteners...........................................................16 Specialinsert Srl........................................................................ 17 Stafa Group..............................................................................23 TFC Ltd..................................................................................... 33 Top Screw.................................................................................42 TR Fastenings Ltd......................................................................16 Volt Industrial Plastics Inc..........................................................15 Walter Stauffenberg GmbH & Co KG........................................ 17 WPI Services B.V........................................................................41

In a UK exclusive agreement with NES, Damar International has announced it is now selling the NES Thread Repair Tool.

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he NES Thread Repair Tool is an internal and external tool able to slide into a thread and adjust to the correct diameter and pitch automatically. Damar says the tools help to save costs by being quick and easy to use and help to avoid spending on large quantities of taps and dies or power tools.

The NES tool can be used for the maintenance of large diameter threads, which can often be challenging and costly as their large size and weight often mean repairs cannot be done at a workbench, instead they need to be done on the spot. Damar explains that the NES Thread Repair Tool slides into the thread and adjusts the diameter and pitch easily and quickly, and after a couple of rotations the thread is fixed with barely any effort.

The thread repair tool can also repair threads where ordinary taps and dies would fail; automatically adjust to any thread diameter and pitch; can be used on left hand and right hand threads (both imperial and metric); and needs no prior measurement of the thread.

Brian Martin, Damar’s managing director, explains: “Minimising expensive maintenance downtime is essential for all plant and equipment users in all types of industry. There is nothing more annoying than a damaged threaded fastener. The NES internal and external tools make short work of fixing these problems to keep productivity high at all times and are a small investment that easily pay for themselves many times over.”