Fastener + Fixing Technology #16

Connecting with engineers Customer Value through Innovation

To meet future emission targets, a lot of separate parts will have to come together.

Who’s going to connect them?

We are. NORMA Group’s Engineered Joining Technologies and applications know-how provide cleaner, more efficient use of precious energy sources.

Using our extensive knowledge of legislation and global market trends, we offer custom solutions for a range of areas such as Cooling Systems, Air Intake & Induction, Emission Control and Ancillary Systems.

www.normagroup.com

I ss u e 1 6 Ja nua ry – Ma rc h 2 0 1 5

www.fastf ixtech n olo g y.co m

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

EDITORIAL

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

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

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

The opinions expressed are not necessarily those of the Editor or Fastener Fairs Limited.

Copyright Entire contents copyright © Fastener Fairs Limited 2015.

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.

Innovations are a key part of every industry, involving a new method, idea or product that can help save time, money, offer a better solution or give a company a competitive advantage.

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Will Lowry – Editor

ne of the key visitor attractions of Fastener Fair Stuttgart has always been the opportunity to discover and evaluate innovations in fastening technologies.

Once again we will be sponsoring the Fastener Technology Innovator Competition and have a preview in this issue of all the entrants’ innovations – providing a great opportunity to learn more about the products and what stands to visit during the show.

Our Cover Story focuses on NORMA UK Ltd and how its innovations, technology and investments has enabled it, as part of NORMA Group, to become one of the world’s leading manufacturers of clamps, connectors and fluid systems.

To add to this we also have an article from DEPRAG SCHULZ GmbH u. Co that focuses on innovative screw driving systems for vehicle bodywork production; as well as Enthone GmbH looking at the benefits of zinc-alloy corrosion protection for threaded fasteners.

Other articles include an insight into Baker & Finnemore Ltd as it continues to invest in machinery and infrastructure; Christian Bauer explaining how disc springs are not just a simple product, but highly complex; as well as the latest news and reports on fastening technology.

We are innovating

We launched Fastener + Fixing Technology to provide a unique platform for engineers, designers and production managers, which was solely focused on fastener technology.

From the response and interest we have received from readers, we have undoubtedly achieved this goal and more. Alongside the magazine we also launched www.fastfixtechnology.com as an online fastener news source. Over the past twelve months the visitor numbers to the website have increased exponentially – underlining the desire from engineers to find the latest fastener news as and when they need it.

The immediacy of news online, compared to a quarterly magazine, enables us to provide a wider range of engineers – across a multitude of industries – with up to date product innovations, fastening technology application case studies and white papers – which can be searched by industry and are available at a click of a button. All the time whilst reinforcing how the right fastening solutions can improve applications, reduce costs and enhance safety and performance.

Therefore from now on we will be exclusively focused online and ensuring we provide the very latest fastening technology developments as and when they happen.

In addition to www.fastfixtechnology.com, Fastener + Fixing Technology also has a strong presence on social media sites including Twitter, Facebook and LinkedIn – where we will continue to proactively targeting relevant industry groups and post market specific articles. This makes it even easier to keep up to date with the latest innovations in the fastener industry and how these innovations can benefit you. www.fastfixtechnology.com

Contents Industry news Latest fastener industry news.........................................................................................4-6 Cover Story NORMA Group – a leading manufacturer of clamps, connectors and fluid systems..... 8-9 Automotive Innovative screw driving system for vehicle bodywork production........................ 10-12 Corrosion Zinc-alloy corrosion protection for threaded fasteners............................................ 14-18 Features The fascination of advanced technology........................................................................ 19 Baker & Finnemore continues to invest........................................................................... 20 Lesjöfors invests in laser technology.............................................................................. 22 Exhibitions Fastener Technology Innovator competition.............................................................24-34 Advertisers Index.............................................................................................................. 34

www.fastfixtechnology.com

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FASTENER INDUSTRY NEWS

30 years of integrity

A large wind tunnel fan that uses RotaBolt® measurement fasteners to secure its main rotor blades to a central hub has clocked up nearly 30 years of trouble-free service at an automotive vehicle testing centre in Russia.

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onstructed in 1984 the fan entered full service in 1986.

However, it wasn’t until this year that the centre re-contacted RotaBolt ® to enquire about specialist lubrication greases, and to also report that the fasteners were still operating trouble-free in monitoring and maintaining the correct bolt load.

The fan has a rotor diameter of 7.5m and operates at a speed of 350rpm in a closed metal channel, creating an airflow of 55m/s.

There are eight blades that are 3m long and are each fastened to the main hub by ten M24 x 3 x 100mm RotaBolts, which were installed with a pre-set load of 22 tonnes.

The original specification of using RotaBolts over 30 years ago was made by the company that constructed the handcrafted wooden blades – Permali Gloucester Ltd. Although it no longer manufactures these blades, it was able to confirm the original design parameters and detail of the fan’s construction.

Wind tunnel fan blades were generally constructed from laminations of selected spruce and birch woods. The aerofoil shape of the blades was handcrafted and each blade was attached into a forged machined steel adaptor using a custom tapered threaded root. The blades were then attached to the hub using the RotaBolts.

The use of an adaptor allowed the blade pitch to be adjusted to alter the flow in the tunnel, unlike the fixed pitch blades, which were simply sandwiched between two hub plates.

“The main characteristics of laminated wood blade construction are high structural integrity and resilience to operating stresses.

Another key benefit is the freedom from fatigue – a quality also found in bolted joints that use RotaBolt measurement technology to successfully achieve and maintain the correct tension throughout their life… even if that is 30 years.”

Tentec fulfils major bolt tensioning order for wind turbines Working together with its distributor in China, HTS Engineering and Equipment Corp Ltd, Tentec has sealed a major order for its bolt tensioning equipment from a leading international wind turbine manufacturer.

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he order involves the supply of 50 specially designed WTB blade bolt tensioners for the new G114 wind turbines.

Tentec’s standard Aero WTB series is a purpose designed range of hydraulic bolt tensioning tools to suit most wind turbine bolting applications. All WTB tensioning tools have the capacity to achieve the specified proof load requirements as detailed in EN ISO 898-1:1999 and ASTM A490M for grade 10.9 bolts.

Tentec explains that these feature packed tensioners have been designed with rapid tensioning in mind and offer a safe, reliable and consistent method to simultaneously tension many bolts.

The tools that have been delivered to China have been modified in line with the customers’ specifications. All work was carried out by Tentec’s in-house engineering team, enabling the customisation costs to be kept to a minimum.

“Thanks to the excellent local support from HTS in China, all orders for this customer will now be handled directly in China.”

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Bringing together the advanced engineering supply chain

The Advanced Engineering UK group of events held on the 11th – 12th November 2014 – at the NEC Birmingham – saw a record 13,000 visitors from all parts of the advanced engineering supply chain.

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ore than 700 exhibitors (650 in 2013) showcased the latest technologies and a diverse range of technology, capability and engineering services – many within the fastener industry including: 3M, Anochrome Technologies Ltd, bigHead Bonding Fasteners Ltd, Binder Fastener Systems (UK) Ltd, DELO Industrial Adhesives, Ellsworth Adhesives Europe, HellermannTyton Ltd, NORMA UK Ltd, Permabond Engineering Adhesives, Specialty Fasteners & Components and TFC Fastening Solutions.

Visitors from a wide range of industries were brought together over the two-day event for the five co-exhibiting shows: Aero Engineering Show, Composites Engineering Show, Automotive Engineering Show, Auto Electronics and – new for 2014 – Performance Metals Engineering Show.

Ian Stone, managing director of show organisers UK Tech Events, commented: “The continuing maturity of the event and its growing pivotal position on the industry calendar is evidenced by a number of key indicators this year, notably the increasing diversity of international companies. Yet again we

have seen the immense value of bringing together multiple high value sectors into a dynamic integrated environment.”

As well as the five shows, a comprehensive presentation schedule took place during the two days to give a coordinated view of the current landscape for the advanced engineering sector in the UK. The 2014 open conference programmes included a record volume of content sessions from leading industry bodies and leading OEMs and Tier 1 contributors including Airbus UK, BAE Systems, British Institute of Non Destructive Testing (BiNDT), Institute of Materials Finishing (IMF), Jaguar Land Rover, Motorsport Industry Association (MIA), Rolls-Royce plc and Rubber & Plastics Research Association (RAPRA).

The schedule also included a seminar on the ‘Process with a twist: DELTA-eLACK’ in the automotive forum from Chris Gorvin, business development director at Anochrome Technologies and Hans-Jörg Minas, applied technology – process engineering at Dörken MKS-Systeme GmbH & Co KG. The Advanced Engineering UK group of events will once again take place at Birmingham’s NEC arena on 4th – 5th November 2015. www.advancedengineeringuk.com

Repairing pinholes in sheet metal Techsil Ltd says that it has found great success with its UV repair system for repairing pinholes in laser welds and brazes for automotive applications on doors, bonnets, and trunk joints, in both aluminium and steel.

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he system combines Vitralit ® 4282 Mod II UV-curing adhesive and the Bluepoint LED light curing equipment.

Cell integrators installed seven Techsil repair stations at three UK car manufacturing plants in 2014, with another one to be added in the UK soon. The company has also sold its first system to a Chinese assembly plant.

Techsil explains that the process only takes a few seconds.

The robot on the inspection line carries out an in-process inspection and if it identifies a pinhole it rejects the panel out of the line. The operator either repairs it locally or takes the panel to a re-work station. The whole repair takes less than

30 seconds, with the adhesive cured in place by a dual system of UV light to fix it and then an anaerobic cure as the adhesive is starved of oxygen. The repair creates a seal and eliminates a leak path before the panel goes to the paint shop. This system also eliminates porosity in the visual surface of the brazed seam and repairs cracks that could propagate further across the panel.

The maximum quantity of pinholes repaired in one panel is four and the scope of pinhole that can be filled is from 0.3mm to 3mm diameter. Deep holes can be filled in sandwich fashion by building up two layers of adhesive.

www.fastfixtechnology.com

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FASTENER INDUSTRY NEWS

TR Fastenings invests in 3D printing

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TR Fastenings Ltd has invested in a highly sophisticated 3D printer for the purpose of creating, testing and prototyping parts, predominantly for the automotive industry.

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ased at the company’s headquarters in East Sussex, UK, the 3D printer will use molten plastic to produce the prototypes, which will enable customers to see what a particular part might look like before they commit to ordering a large quantity.

The investment underpins the company’s commitment to the latest technology processes – particularly those that support continuous improvement and innovation in customer care.

TR Fastenings’ core business is aimed at being the principle provider of assembly components to a fast growing range of high volume multinational OEMs, whereby global consistency of price, quality and delivery is a minimum requirement for being nominated as a preferred strategic supplier. With more than 90% of TR Fastenings’ revenue

deriving from non-standard components to customer specification, engineering product development is a key group activity – often demanding design and pre-production component prototyping.

“In the past, not only did the manufacturing of component parts take an average of two weeks to complete but the costs exceeded thousands of dollars, thus prompting a reassessment of optimal prototyping for customer product development,” commented Malcolm Diamond, chairman of TR Fastenings. “Extensive research by my colleagues in our marketing and IT system teams into US and UK based 3D printing manufacturers has led to our first investment in a highly sophisticated industry standard printer and we are delighted by the response from our customers.”

Locking system IstLock® extended to trucks According to Ferodom s.r.o, nearly 60% of the 30 – 70 year old drivers surveyed confirmed that wheel nuts on a car or lorry had loosened at some stage in their driving career. 28% of respondents stated they had discovered one or more nuts missing at the end of a drive. The worst recorded cases resulted in tragic consequences.

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free rolling wheel on the road cannot only inflict damage it can kill. Such cases are not as rare as might be thought. The greatest period of risk is in the first 50km – 100km after wheels have been fitted.

Ferodom has therefore extended the application of the well established and certified locking system IstLock ® to wheel nuts for trucks and lorries. This system provides effective protection against vibration, as well as dynamic stress in the axial and radial direction.

One example is the use of M22 x 1.5, Class 10, phosphate IstLocks on the Renault Magnum truck. This vehicle has been test driven over difficult terrain without loss of preload of the bolted joints on the wheels.

IstLock nuts are also suitable for other marks of trucks, including MAN, DAF, Scania, IVECO and Volvo – with the only condition being that the wheel rims are flat.

6 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

The main advantages of the IstLock system include: • Safety during the drive.

• Almost unlimited lifetime as the locking plastic ring on the IstLock can easily be replaced by hand with a new one with the same original characteristics, which means IstLock nuts have a high repeatability of usage.

• Low dependence on the friction coefficient.

• Independence from the material or type of nut thread (metric or inch).

• No damage or marking of the contact surface.

• Free turn during assembly/disassembly so no heat is generated from friction.

The IstLock system already has wider utilisation in the automotive industry and is generally suitable in applications of dynamic loads or vibration.

Ferodom s.r.o is based in Žilina, Slovakia. Established in 2000 the company prides itself on delivering “just the best” solutions for which customers pay in the hardest currency in the world – Trust.

Increased productivity with new automated setting tools for speed rivets

®

Blind Assembly Solutions

• Automatic setting of speed rivets • Low investment • Lightweight • High productivity

For further information:

service@rivelit.com www.rivelit.com

• Gentle riveting • Reduced setting time • Reduce operator fatigue • Ease maintenance • Intensifier made integral to the hand tool

• Mistral-1 sets rivets up to 4,0 mm all materials • Mistral-2 sets rivets up to 6,0 mm all materials • Available in fixed under or above workstation versions

Fastener Fair Stuttgart 10- 12 March 2015 Hall 8, stand R25

COVER STORY

One of the world’s leading 4.D140 manufacturers of clamps, connectors and fluid systems Not a claim to be made lightly but one that NORMA UK Ltd is justifiably proud to make, being the UK arm of the NORMA Group – one of the biggest manufacturers and suppliers of connecting products worldwide.

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ORMA UK Ltd has been established in the UK for over 30 years now and since 2006 has been providing its market leading range of engineered joining technology solutions from its Greenham Business Park headquarters in Newbury.

As a key member of NORMA Group, the company acts as both a strategic manufacturing centre – specialising in the design and production of the NORMACONNECT® V range of precision engineered profile clamps, which are predominantly used in the automotive industry – as well as a national distribution centre for more than 35,000 products that are also produced within the Group.

The hose clamps, pipe connections, retaining products, quick connectors, fluid systems and plastic connectors of NORMA Group are accredited to all leading European and international quality standards and are vital parts of for instance vehicles, aircraft, trains, ships, water pipelines, and of applications for the pharmaceutical and biotechnology industry. This combination of experience and market leading product portfolio, has enabled NORMA UK to maintain its position as a primary supplier to businesses ranging from large-scale multinationals through to local independent resellers.

A technological focus on automotive solutions With its many years of experience in manufacturing and developing a comprehensive range of engineering joining technologies in the clamp, connect and fluid sectors,

8 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

the automotive industry is a key market for NORMA. As such, providing solutions that integrate stringent emission regulations, rapid installation times, consistent performance at temperature extremes and ever tightening space envelopes, is a discipline in which NORMA Group combines its expertise in both metal and plastic materials. One such product manufactured by NORMA that encompasses all these criteria is the VPP profile clamp.

VPP (V-Pressed Profile) clamps have been produced at the NORMA UK facility since 2005 and through their innovative design, consistently high performance, and engineering development, have now become a product of choice for many leading vehicle manufacturers, with demand for these clamps rising significantly to many millions of parts per year.

To satisfy both current and future production requirements, 2014 saw NORMA UK take delivery and commission its latest technology to this business – two Aida 250 tonne ‘C’ frame presses with integrated transfer mechanism. Key to the success of the VPP production process is the transfer mechanism that is integrated into the new press machinery. This mechanism enables parts in the VPP manufacturing flow to be moved from one step to the next, in a sequential and automated process, until the finished forming has been achieved. This not only achieves the high volume production runs required, but crucially allows tool changing time to be drastically reduced, thus keeping down time to an absolute minimum. The Aida 250 tonne transfer presses, weighing approximately 29 tonnes and with an overall size of nearly 90 cubic metres each, represent a significant investment and milestone for NORMA UK. Commenting on the success of the new manufacturing capabilities, Mark Burnett, managing director at NORMA UK, said: “With this facility now in place, NORMA UK has considerably increased its competitive advantage. Through the efforts of many departments and people here, we now have a significantly enhanced ability to surpass the exacting specification, quality, deadline and volume requirements that our customers demand.”

Innovation is the key Innovation is also a vital element in all the solutions that NORMA provides, an aspect that is very well illustrated by the BREEZE Constant Torque hose clamps that the Group manufactures. Constant Torque clamps or CT clamps, as they are often referred to, are used throughout the automotive, general industrial and marine industries and include a Belleville spring mechanism fitted to the clamp that enables it to maintain a constant seal, even when subjected to fluctuations in temperature.

These Belleville springs are specially shaped components that whilst resembling a washer, feature a spring characteristic, and when a series or stack of these are fitted to the clamp, it is allowed to thermally expand or contract without adversely affecting sealing performance. This unique design means that BREEZE Constant Torque clamps eliminate the problems of ‘cold flow’ and through their dynamic action, are ideal for applications involving a thermal cycle.

The marine industry is also one of the many environments, where another well established NORMA connecting solution can be found, namely the FGR pipe coupling. The DIN 86128 accredited FGR range – thus called as it combines the FLEX, GRIP and REPAIR clamp solutions – offers a compact, economical and reliable means for connecting plain-ended pipes. The different combinations of anchoring ring, protection ring and seal material that is integrated into each clamp, means that FGR couplings are ideal for joining both plastic and metal pipes, especially stainless steel, throughout the mechanical engineering, construction, shipbuilding and hydro-technology industries. Key to the technical superiority of FGR pipe couplings however, is its patented double lip sealing system.

Firstly, the seal of each clamp – which could be either an EPDM or NBR rubber material – features a design that enables two sealing lips to be in contact with the pipe application at the same time. This double safety feature means that a highly reliable seal is delivered for each application, be it low pressure, vacuum or extreme load. Secondly, sealing performance is

further enhanced by the profiled shape of the rubber material.

This profile means that when internal pipe pressure increases, the double lip seal is compressed even further onto the pipe surface, thus delivering an even stronger sealing force.

Investments securing the future Significant investment in service levels and product development, such as the examples previously mentioned, have led to many large-scale, long-term contract wins for NORMA UK. These successes in the manufacturing and distribution industries, plus an on-going commitment to providing the very best in engineered joining technology solutions, are the key steps in satisfying the product demands forecasted for 2015 and beyond.

“2013 and 2014 have seen major developments and investment in the future of NORMA UK,” commented Mark Burnett. “We have expanded again with the opening of a new 1,850m2 building alongside the current 5,000m2 premises, which has enabled further manufacturing, warehousing and distribution amenities for the company. Our workforce has grown to the largest it has ever been – over 250 people are now directly employed by the company – and a highly successful apprenticeship scheme to accommodate future demand has also been implemented.”

Mark continued: “Annual sales, workforce numbers, product ranges and production capabilities have all seen significant increases this year, and everyone within NORMA UK has contributed to the success and growth of the company. However, the opportunities ahead of us are even greater. 2015 will see a major roll out of the Nagara manufacturing principles we have already implemented, along with several other benchmark projects that will support our growth. We’re incredibly proud of our achievements and we plan a great many more of them in 2015.” www.normagroup.com

“ The DIN 86128 accredited FGR range – thus called as it combines the FLEX, GRIP and REPAIR clamp solutions – offers a compact, economical and reliable means for connecting plain-ended pipes.” www.fastfixtechnology.com

9

AUTOMOTIVE

Innovative screw driving system for vehicle bodywork production Whereas in the past, steel sheets were easy to join by spot welding or resistance welding, today this is no longer economical due to the modern material mix. The automotive industry is under pressure from legal requirements to reduce CO2 emissions, use lightweight construction and consequently to find alternative joining methods.

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here access to both sides of the connection point is available this can be done using rivets. If however only one side is accessible then the well established direct screw driving flow form principle comes into use. A flow form screw is positioned on an aluminium or steel sheet without pre-drilled holes and the screw driving process begins. The screw is applied with a high-pressure down-force and rotates at high-speed, generating a frictional heat that forms a crater through which the screw’s thread passes under reduced pressure. A machined thread is created and a normal screw can also pass through in the case of repairs.

After the flow passage has been formed the speed is reduced and the screw is tightened to the head connecting surface and then the final tightening of the fastener to the pre-determined parameters of torque and angle takes place. The entire procedure usually takes less than two seconds. Additional fastening elements such as nut and bolts are not required as the assembly has been optimally adjusted to the passage and thread of the screw. The screw is fixed. There is no need for preparatory drilling or punching of the component.

DEPRAG SCHULZ GmbH u. Co, the screw driving specialist, will present a live show on the topic of flow form screw driving (FFS) at the Automotive Engineering Expo: The exhibition for the car body process chain – from concept to final assembly, which will take place from 9th – 10th June 2015 in Nuremberg, Germany. Development, product and processing engineers from vehicle bodywork construction departments, as well as many other branches in which sheet metal is assembled such as white goods, will be able to gain first-hand information about the next generation of FFS.

What is new?

DEPRAG engineers have successfully developed a freely programmable gearbox for a torque range of up to 15Nm and speed range of up to 8,000rpm from two gears – with 15Nm at 6,000rpm and 12Nm at 8,000rpm.

As well as reduced investment costs this also means a reduction in processing costs, as replacement expenses do not apply. DEPRAG explains that the currently established FFS units usually shoot the flow drill screws tip first through the mouthpiece. Damage to the screw tip geometry is inevitable and can have devastating consequences. The required frictional heat that is necessary to penetrate the material cannot be generated. However, DEPRAG says that this is not the case with its innovative FFS driving unit. Here the screw is shot in headfirst and an integrated revolver separator positions the screw so that its position is secured even for overhead assemblies. The next screw is already reloaded as the first screw is being seated – providing a decisive benefit in optimising the cycle time.

In developing this new generation further, years of operating experience have been incorporated. Jürgen Hierold, sales manager at DEPRAG, comments: “Due to the complex geometry of bodywork the highest requirements for mobility of robots and the FFS unit are set. Combined rotation and pivoting movements of the robots are required in order to reach the screw assembly positions. Often the feed hose used can bend or twist so the screws get stuck during loading. Massive disruptions to the assembly process, high risk to the processing reliability of the complete system and extensive fault clearance are the inevitable consequences. We were

10 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

The DEPRAG FFS system for direct screw assembly into sheet metal

Joining sheet metal - direct, quick and simple.

The DEPRAG FlowFormScrewdriving System n Integrated revolver separator n Magazine system to avoid feedhoses n Intuitive setting of the screwdriving process and its parameters n Mouthpiece exchange device n Active nosepiece jaws

DEPRAG SCHULZ GMBH u. CO. Carl-Schulz-Platz 1 • D-92224 Amberg Phone +49 9621 371-0 • Fax +49 9621 371-120 www.deprag.com • info@deprag.de

AUTOMOTIVE recently approached by one of the largest internationally active companies in the automotive industry with the demand for a system that presented screws without a feed hose. We therefore developed a magazine system for our customer, which is based on three basic elements – the screw magazine, the magazine exchange station and the screw feeder.”

Jürgen Hierold explains that whilst one magazine is in operation, docked on the FFS unit systematically presenting 31 fasteners, the second magazine is being filled at the exchange station by the screw feeder. The screw feeder is outside the activity range of the robot, refilling screws without interference in the danger zone. If the first magazine is empty then a robot on the exchange station removes it to be refilled and replaces it with an already filled magazine so that assembly may continue. Thereby the best possible processing times are achieved with guaranteed processing reliability.

“We now have this exchange magazine available as a standard solution. Even existing FFS systems can be simply and easily upgraded to include it,” adds Jürgen Hierold.

Another aim of the developers for the new generation of FFS systems was the

parameterisation of the screw driving procedure for the operator so that it is as intuitive and simple as possible to use, with system adjustment automatic.

The operator must only enter the screw geometry (shaft diameter and length), information relevant to the part (quantity, material and strength of the sheet, with/without drill hole) and the tightening parameters onto the clear HMI panel.

Of course each screw assembly is individually analysed and displayed.

Additionally the software provides comprehensive documentation and archiving options not only for individual screw assemblies but also for different sets of parameters. Another plus point is

12 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

the mouthpiece exchange device for the application. The adjustment to a different screw type or fault clearance is taken care of at the touch of a button. The lock is loosened and the mouthpiece can simply be exchanged. Usually the holding function of the nosepieces is based on spring-loaded pressure. The disadvantage here is that the screws open the jaws against spring pressure and mechanical load through friction can occur. This is not the case on the new DEPRAG flow form unit, here the cylinder controlled nosepieces control the release of the screws as soon as the screw begins to form the passage, therefore friction between the screw head and nosepiece is greatly reduced.

“There are a number of advantages as a result of the improvements to the FFS unit such as increased user friendliness, reduction of maintenance, varied user options and simplified system integration.

Above all the processing reliability of the flow form procedure has been decisively increased,” concludes Jürgen Hierold.

Under the slogan ‘Sheet Metal – Direct – Screw Assembly’ visitors can experience each of these improvements on the demo unit at Automotive Engineering Expo. DEPRAG will be exhibiting the complete flow form process on its stand using various material pairings.

DEPRAG SCHULZ GmbH u. Co employs 600 staff in over 50 countries and is based in Amberg, Germany. It has made its name as a full service provider in the field of screw driving automation. The company’s core competencies include high-quality EC servo screwdrivers and EC screwdrivers, sophisticated measurement technology and first class screw feeders, which makes it a much sought-after partner in the field of automated assembly. www.deprag.com

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Directly from Stock DIN 125, 912, 931, 933, 934, 976, 7991, 9021 aND more

Rudolf-Diesel-Str. 8 D-74613 Ă–hringen T: +49 (0) 7941 6073-0 F: +49 (0) 7941 6073-500 info@tobsteel.com www.tobsteel.com

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There are literally hundreds of different screws but they are not all of the same quality. adverse conditions take their toll. a challenging climate, the huge forces experienced in buildings and special hygiene requirements – the products have to withstand all these extremes, and the selected material and quality must be just right. It’s a huge responsibility.

We are the specialist in high-quality fasteners made from stainless high-grade steel and special materials.

We are used to extreme conditions and face the toughest challenges on a daily basis. We never lose sight of our aim to give the customer just what they want. and we always offer that little bit extra.

So, why not contact us?

CORROSION

Cost efficient and high performing: Zinc-alloy corrosion protection for threaded fasteners Dr Björn Dingwerth – global product line manager, corrosion resistant coatings, Enthone GmbH Rene van Schaik, industry manager, functional coatings Europe, Enthone GmbH Keeping it all together is what fasteners are all about. At first, some may consider this a simple objective to achieve given what appears to be a relatively basic component. However, the ever increasing demands for higher durability, enhanced decorative appearance, extended warranty life, as well as meeting OEM design requirements and consumer preferences, have made ‘keeping it all together’, more than mechanical. Defined friction properties that are of paramount importance for reliable automatic assembly in manufacturing and safe re-assembly in maintenance procedures, OEMs and their tier suppliers have established comprehensive specifications to ensure exacting performance requirements are consistently achieved and maintained.

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o address these challenges, a new generation of zinc-nickel corrosion protection coating systems have been introduced that reliably deliver durable, highly functional and appealing coatings for safely fixing components together. Currently being used by major plating facilities worldwide, the OEM approved coatings withstand exposure to a diverse range of global environmental conditions.

Over the last few years, new car warranties have evolved to go well beyond the standard five year anti-corrosion guarantee. Such extended warranty times call for improved corrosion protection on numerous automotive components. Within those components that contribute to the structural stability and functionality of a car, fasteners play a dominant role. Sufficient fastener quality throughout the service life is a crucial pre-requisite to be met in order to achieve the required high overall stringent OEM quality standards of today’s automotive production.

This need for higher quality throughout the in-service life finds itself expressed in an ongoing change in the surface finishing industry from pure zinc layers towards zinc-alloy based sacrificial coatings. This transition is due to the ability of zinc-alloy coatings to generate higher corrosion protection. More specifically the zinc-nickel alloy provides the maximum protection to corrosion as the so called zinc-nickel gamma-phase (γ-phase) alloy can be achieved with a 12% – 16%-wt nickel alloy content from qualified plating solutions. The γ-phase describes a specific crystal structure of this intermetallic phase, which has proven to be highly beneficial for the highest performance cathodic corrosion protection coatings.

A major advantage of zinc-nickel alloys over pure zinc coatings or other alloy coatings like zinc-iron is the high corrosion resistance from the plated alloy material without taking an additional post-treatment into account. Figure 1 shows the dependency of the neutral spray corrosion protection (ISO 9227 NSS) from the nickel alloy concentration without any post-treatment. An alloy composition of approximately 14% by weight nickel yields 700 – 800 hours to red corrosion as demonstrated in the testing. Industrial experience proves that >720 hours to red corrosion is safely met by this type of coating. This high corrosion protection together with less voluminous white corrosion products is a unique feature of the 12% – 16% γ-phase zinc-nickel alloy (Figure 2).

Zn with passivate. No sealant

ZnNi with passivate. No sealant Figure 2: The difference between pure zinc and γ-phase zinc-nickel alloy without a sealant (only passivation applied), hours given are time in ISO 9227 NSS test. The zinc plated fastener shows voluminous white corrosion at 480h, whereas only a thin layer of white haze forms on the zinc-nickel coated fasteners (all 8µm – 12µm Zn resp. ZnNi, thick film passivate)

Figure 1: A diagram showing the basis material corrosion resistance to red rust in the neutral salt spray test versus the nickel incorporation rate in the plated zinc-nickel alloy layer (8µm) without any post-treatment (no passivation, no sealant) applied. The protection peaks with a maximum at 14% w/w Ni, best performance in the range of 12% – 16%-wt Ni.

14 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

Through the additional application of high performance sealants on top of the passivated surface, the corrosion resistance is significantly reinforced as well as other functional properties such as adjusted coefficient of friction, improved decorative appearance, etc. Reinforced by such sealants, zinc-iron (0.5% – 1% Fe) alloy or even pure zinc coatings show excellent corrosion protection results (Figure 3 – see next page).

Figure 4: Plating rates obtained from an acidic zinc-nickel electrolyte (red) and from an standard alkaline zinc-nickel electrolyte (blue) as well as from a new generation alkaline ZnNi electrolyte (green) plotted vs current density

Figure 3: 720h ISO 9227 NSS exposure to zinc (top), zinc-iron (middle) and zinc-nickel (bottom) plated, passivated and sealed (ENSEAL 26) fasteners. Application of a sealant significantly increases the fasteners corrosion protection

The major advantage of the zinc-nickel coating is that it provides superior corrosion protection from the bare zinc-nickel layer, independent of the chosen post-treatment.

The protection of zinc or zinc-iron coatings strongly depends on the post-treatment, most importantly the sealant applied. Once this post-treatment layer is damaged, corrosion will proceed at an accelerated pace and also create more voluminous white corrosion products. Harm to these layers can be due to any mechanical impact in assembly (tools) or service life (stone chipping, etc). In addition to the low corrosion rate of the zinc-nickel alloy in comparison to zinc and zinc-iron layers, the γ-phase zinc-nickel alloy features increased wear resistance, due to its high hardness of 500HV – 550HV (14% Ni) compared to lower hardness of zinc (approximately 100HV) and zinc-iron (0.5% – 1% Fe) layers (150HV – 250HV).

High strength fasteners of >1,000N/mm² tensile strength (property class 10.9 and higher) suffer a risk of hydrogen embrittlement. With increasing tensile strengths being used in fastener technology, this is a critical factor.

Very long experience in industrial zinc-nickel fastener finishing and scientific investigations have shown that the zinc-nickel alloy is unique in terms of its dramatically reduced risk for hydrogen embrittlement1. Pure zinc coatings or other zinc alloy coatings bear a significantly higher risk to cause hydrogen embrittlement. This very advantageous property of the zinc-nickel alloy has made it a prime selection for cadmium substitution in the aviation industry, even on very high strength steel materials of >1,400N/mm² and therefore should always be taken into consideration for finishing of even very high strength fasteners.

Last but not least, zinc-nickel coatings are the preferred choice where thermal resistance of the layer is needed, due to the coating’s ability to maintain the corrosion protection, even after being subjected to elevated temperature. This makes zinc-nickel coatings the preferred choice, for example for automotive applications – such as brake components or engine compartment parts.

The application of zinc-nickel alloys is widely conducted using alkaline electrolytes for the finishing of fasteners and many other steel based automotive components. Alkaline ZnNi plating solutions offer an excellent thickness distribution even on 1

complex formed parts and are a well suited process for example on rack plating of complex formed stamped steel parts.

Alkaline plating solutions are also widely employed for barrel application of bulk parts. Here, the advantage of an excellent thickness distribution over the part is less relevant than in rack plating operations. Due to the nature of the barrel plating application, the different thickness distribution of the electrolytic process has only a minor impact on fastener plating.

Technically, a good thickness distribution translates into a lower cathodic current efficiency at higher current densities (Figure 4). Therefore to enjoy a good thickness distribution one trades off some plating efficiency on certain areas of a workpiece for a more even plated layer thickness.

An attractive alternative to the well known alkaline zinc-nickel electrolytes is the acidic zinc-nickel electrolytes of the latest generation. An outstanding feature of the latest generation of acidic zinc-nickel electrolytes such as the newly developed ZINCROLYTE ® KCl-Ni IV is the very high efficiency of >90% which is consistently maintained over the entire bath life.

With approximately 30% higher current efficiency than conventional alkaline zinc-nickel electrolytes have, the latest generation of alkaline ZnNi plating solutions provides an additional alternative where the highest performance from alkaline plating solution is needed.

The nickel incorporation is of paramount importance to achieve the desired high corrosion protection. Strict control of 12% – 16% of Ni in the alloy is crucial to obtain the optimum corrosion protection of zinc-nickel alloy coatings.

With the latest generation of acidic zinc-nickel electrolytes a constant and narrow ranged nickel incorporation rate is achieved in rack and barrel application on the same level as obtained from alkaline electrolytes. This makes acidic zinc-nickel an application alternative for the same purpose: Yielding exactly the same kind of layer is of paramount importance to ensure the same performance of the finished component.

The crystal structure and orientation of the zinc-nickel layer are both highly important to achieve the desired physical and chemical properties of the coating and can be taken as a critical indicator to characterise the layers.

The structure and the orientation of the electroplated layer from either electrolyte can best be assessed by X-ray diffractometry (XRD). The diagrams obtained for layers from conventional alkaline zinc-nickel ZINCROLYTE NCZ 315 Plus, from the acidic ZnNi ZINCROLYTE KCl-Ni and from the new alkaline ZnNi electrolyte ZINCROLYTE Sprint™ do not show significant differences (Figure 5 – see next page). Thus the resulting zinc-nickel layer is the same zinc-nickel material showing the same crystallographic structure and texture, independent from choosing an acidic or alkaline electrolyte.

W. Paatsch, R. Landgrebe, M. M. Lohrengel, Mat. Sci & Eng. Tech., 2008, Vol 39, Issue 1, 75-78

www.fastfixtechnology.com

15

CORROSION

Intensity in CPS

Intensity in CPS

Another important advantage in the new alkaline process is that the high plating performance is achieved consistently without the use of any auxiliary equipment.

Figure 6: M8 x 40 bolt plated to the same thickness on the head (11.6µm – 11.9µm) in the three different zinc-nickel electrolytes: A conventional alkaline plating solution (left, ZINCROLYTE NCZ 315 Plus, 75 min plating time), newest development alkaline plating electrolyte ZINCROLYTE Sprint™ (middle, 50 min plating time) and the new generation acidic electrolyte ZINCROLYTE KCl-Ni IV (right, plating time 42 min). Minor differences in thickness distribution The clear advantage from choosing an acidic electrolyte for barrel application is the higher plating speed resulting in shorter plating times and higher throughput making the process economically well suited for a bulk application Additionally, the excellent initiation behaviour of the electrolyte allows for very fast coverage even on materials with a low hydrogen over potential such as particular case-hardened, carburised fasteners.

Figure 5: XRD diagrams (Cu Kα-radiation) of ZnNi on mild steel from conventional alkaline ZINCROLYTE NCZ 315 Plus (top), acidic ZINCROLYTE KCl-Ni electrolyte (middle) and new generation alkaline ZINCROLYTE Sprint (bottom) all plated at 15% Ni. All layers bear the same texture, preferred (330), (600) orientation indicating same columnar γ-Ni2Zn11 phases Therefore, the choice for the best suited electrolyte for the application in question can technically be met based on performance preference. Significantly reduced plating time does not only contribute to cost savings, but also reduces the mechanical stress to the fastener during the plating sequence and supports perfect thread appearance with low mechanical damage.

Comparing M8 x 40 fastener plating in barrel application using an acidic versus the alkaline electrolyte set up to yield the same thickness in the head area results in the situation as shown in Figure 6. With virtually the same thickness being achieved on the fasteners head, the difference in thickness in the middle of the fastener is minor.

The differences in plating times are major as shown in the example given. Application of a conventional alkaline zinc-nickel electrolyte requires plating for 75 minutes until the desired thickness is achieved. Using the latest generation of alkaline ZnNi electrolytes (ZINCROLYTE Sprint), the same result is achieved in approximately 50 minutes. The highest plating rate is provided by the acidic ZnNi electrolyte, which needs only 42 minutes to achieve the demanded thickness.

16 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

Figure 7: Bottom section of screw threads showing a fine grained deposit on the top image from the acidic ZnNi electrolyte and a more coarse grained morphology with more nodules on the bottom image (conventional alkaline electrolyte) Acidic ZnNi, as well as the new alkaline ZINCROLYTE Sprint electrolyte, already provide smoother surfaces (Figure 7): An excellent pre-condition for good control of friction properties.

Combined with well matched post-treatment processes such as PERMA PASS ® trivalent chromium passivations and ENSEAL® lubricated sealants, such smoother surfaces are the perfect pre-requisite for consistently meeting narrow ranged coefficients of friction, resulting in constant clamping forces achieved in torque controlled automatic assembly applications (Table 1 – see next page).

Enthone Zinc-Nickel for Fasteners

Perma SHIELD™ 1000 ZINCROLYTE® PERMA PASS® ENSEAL® Technology. Quality. Performance.

Perma SHIELD™ 1000 systems create value throughout the entire supply chain and feature patented ZINCROLYTE® KCI-Ni acid or an NCZ alkaline zinc-nickel process production-proven to extend product life, increase yields and reduce rejects. Each ELV compliant process is followed by a PERMA PASS® passivate and an ENSEAL® sealant.

Perma SHIELD 1000 acid systems deliver high deposition rates and ensure control of the nickel. Easy to waste treat, the systems are engineered to provide uniform coverage of case hardened, carburized materials. Alkaline systems offer superior ductility with compressively stressed deposits that provide enhanced alloy uniformity in LCD and HCD areas.

Perma SHIELD 1000 systems ensure process stability, while decreasing metal and chemical consumption at the lowest cost of ownership. Substantial productivity gains have been achieved as a result of dramatically reduced plating times on high hardness parts due to the systems’ exceptional initiation and efficiency.

Learn more. Please contact auto@enthone.com.

enthone

®

Automotive Solutions

Enthone GmbH, Elisabeth-Selbert-Straße 4, 40764 Langenfeld, Deutschland• Tel: 49-2173-8490-0

an Alent plc Company

CORROSION µtot vs steel

µtot vs aluminium

Conventional alkaline ZnNi

0.12

0.21

New ZnNi electrolyte (acidic)

0.12

0.18

Table 1: Coefficient of friction measured according to ISO 16047 of M10 fasteners plated in alkaline zinc-nickel from conventional alkaline ZnNi and acidic zinc-nickel. Post-treatment in both cases trivalent passivate (PERMA PASS® Ultra III) and a sealant with integrated lubricants (ENSEAL 21) Choosing the right lubricated sealant process, depending on OEM demands, allows for excellent control of the coefficient of friction of the fastener in different ranges as required by the OEMs (Table 2). µtot ENSEAL 21

0.09 – 0.14

ENSEAL 1303

0.10 – 0.16

ENSEAL® 26

0.12 – 0.18

® ®

Table 2: Coefficient of friction ranges matching different automotive OEM requirements. Measurement according to ISO 16047

Conclusion

Applications of zinc-nickel for cathodically protecting sacrificial coatings are increasing over the recent years, particularly in the automotive industry, and this process is gaining more and more pace. This is clearly as a result of the many benefits of this coating:

• Highest corrosion protection already from the plated zinc-nickel layer.

• Increased wear resistance.

• Dramatically lower risk for hydrogen embrittlement compared to pure zinc or zinc-iron.

• Excellent thermal stability of the coating.

• Improved friction properties with appropriate post-treatment processes.

Resulting from this list of important benefits, the increased efficiency and productivity of the zinc-nickel plating process for high-throughput applications is a strong argument to best utilise existing production lines. The latest generations of acidic plating solutions (ZINCROLYTE KCl-Ni IV) and the alkaline process (ZINCROLYTE Sprint) open up the possibility to choose the best suited ZnNi plating electrolyte technically based just on the type of application and delivery specification demands. Excellent control of the nickel incorporation in the zinc-nickel gamma-phase region is crucial and is achieved with all discussed electrolytes.

Improved morphological features of the new generation electrolytes ZINCROLYTE Sprint and ZINCROLYTE KCl Ni IV provide excellent pre-conditions for fastener finishing with highest performance, in terms of surface properties as well as optimised productivity. ® ZINCROLYTE, PERMA PASS, and ENSEAL are registrated trademarks of Enthone Inc. Sprint™ is a trademark of Enthone Inc auto@enthone.com

Special Screws Fit bolts, plugs, knurled thumb screws, square head bolts, flat headed screws, hexagon set screws, brass screws and specials.

directly from stock!

< PLUGS

according to DIN 906,907, 908, 909, 910, 5586, 7604

10.-12.03 2015 Halle 4 Stand D 04

Fon +49 (0) 40 532 852-0 Fax +49 (0) 40 532 852-52

141227_FF_E2_Verschluss_190x135.indd 1

info@pasvahl.de www.pasvahl.de

26.12.14 10:34

FASTENER + FIXING TECHNOLOGY

D

The fascination of advanced technology

tolerance can be reduced down At first glance they appear to isc springs have a vast amount potential, obtaining force deflection to +/-2% – and this can be be of a simple product, but they achieved in a production run in fact highly complex: curves, which are impossible are with other springs.

In fact, the same disc springs. They have a vast of just one spring, or several million. Good disc force can be obtained at two amount deflection points.

Alternatively, a springs are of potential, obtaining hard to manufacture, howevforce deflection curves which decreasing force or a force that changes in steps, is also possible. er, and tribology is a complex are quite impossible with topic,isespecially fretting In fact, the same Christian Bauer points out other thatsprings. the DIN 2093 Norm a wellwhere known fatigue is concerned. cb has force can be obtained at two standard in the disc spring industry, and thedefltolerances and lifecycle estimates ection points. Alternatively, mastered these challenges, and has successfully a decreasing force, a force tolerance based on it form the basis of numerous calculations.

Theor force can increased which changes in steps, is also the number of lifecycles up to actually be reduced down to +/-2% – and this can be achieved in a production 10x times without changing possible. the number of springs, force or run of just one spring or several million. spring dimensions. This means The DIN 2093 norm is a well“Good disc springs are hard to manufacture and tribology is a complex that a current topic, disc spring stack known standard in the disc can be changedmastered without any spring industry, and the tolerespecially where fretting fatigue is concerned. At Christian Bauer we have adjustment to the rest of the ances and lifecycle estimates these challenges and have successfully increased number lifecycles up far – enabling based on it the form the basis of of construction longer service life. calculations.

Fewor spring to 10 times – without changing the numbernumerous of springs, force dimensions. people realise that the force

4.D120

typical spring disc sp spring

displacement

spring force

At first glance they appear to be a simple product, but Christian Bauer GmbH & Co KG explains that disc springs are in fact highly complex.

spring force

The fascination of advanced technology

This means that a current disc spring stack can be changed without any adjustment Christian Bauer GmbH + Co. KG to the rest of the construction – enabling far longer service life.”

Schorndorfer Straße 49 · 73642 Welzheim, Germany sales@christianbauer.com Telephone +49 (0) 71 82/ 12-0 · Telefax +49 (0) 71 82/ 12-315

tolerances DIN 2093 possible CB tolerances theoretical disc spring line possible CB tolerances tolerances DIN 2093

displacement

E-mail: sales@christianbauer.com

The art of flexibility

cb stands for decades of familiarity with the market and solid expertise. cb provides the narrowest of production tolerances and consistent solution orientation. Creative flexibility. That‘s our job. Learn more about cb at the Fastener Fair. Find out more about cb at the Fastener Fair. We look forward to meeting you, and to hearing all about your requirements!

Visit us at Fastener Fair: Booth D120, Hall 4

The cb-portfolio • Disc springs • Disc spring stacks 1 BAU077_AZ-GA58E-FASTENDER-A4-141208-NE.indd • Slotted disc springs • Special springs, wave springs

• Ball bearing disc springs, conical spring washers • Vanes, rotors and complete subassemblies for vane pumps

Christian Bauer GmbH + Co. KG Schorndorfer Straße 49 · 73642 Welzheim, Germany Telephone +49 (0) 71 82/ 12-0 · Telefax +49 (0) 71 82/ 12-315 E-mail: sales@christianbauer.com

09.12.14 08:53

FASTENER + FIXING TECHNOLOGY

Baker & Finnemore continues to invest Baker & Finnemore Ltd, based in Birmingham, UK, has had a busy 12 months that has involved the continuing investment in its machinery and infrastructure, as well as the appointment of three new directors.

I

n November the company announced that it had appointed Paul Watkins-Burke as operations director, David Wilkinson as works director and Ian Styles as sales director. Joan Matthews the management accountant was also appointed as the company secretary.

Baker & Finnemore traces its roots back to the 1850s, when Mr Baker, Mr Finnemore and Mr Wagner (from Frankfurt, Germany) came together to produce pen nibs. History seemed to be repeating itself in 2012 when Gebr Titgemeyer of Osnabruck, Germany, bought the company as part of its continuing investment in UK manufacturing. In the 30 months of ownership over GB£700,000 has been invested in both the new plant and training.

One of the first departments to receive the investment was in the cleaning, scouring and finishing department, which was completely transformed and is now unrecognisable from how

New wire eroder

it looked before. That is thanks to new state of the art Vibro scouring machine and Vibro dryers (pictured bottom left) which have all been fitted with automatic loaders and unloaders.

Baker & Finnemore has also seen its capacity dramatically increase and the quality of finished parts further improved.

The tool room has also benefited from a new CNC lathe – increasing small hole drilling and long bed grinding capacity.

Most recently, over GB£100,000 of new state of the art wire eroding was installed, with Baker & Finnemore saying that the level of investment will continue for 2015.

Around the factory, Baker & Finnemore has also improved the working environment with better work handling, new lighting and the disposal of obsolete plant and tooling (over 40 tonnes). To support its ISO 14001 qualification the company has also improved sound proofing, changed many lights to LED, is working on plans for a heat exchange system from the compressors and furnaces, as well as looking to reduce water consumption, and examining the viability of solar panels. The company also now generates all of its own endothermic gas and has put in over GB£30,000 of monitors on its furnaces. In addition, truly modern optical measuring equipment has been purchased for the quality department.

“At Baker & Finnemore we are looking forward to 2015 with enthusiasm,” states Paul Watkins-Burke, operations director. “We export over 60% of what we make across the globe and meet ISO 9001:2008 Management, ISO 14001:2004 Environmental and ISO 18001 Health & Safety standards. We are also TS 16089, TS 16949:2009 and VDA approved suppliers to the automotive industry.” www.bakfin.com

“ At Baker & Finnemore we are looking forward to 2015 with enthusiasm… We export over 60% of what we make across the globe…”

20 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

F+F Tech(NEW)_Jan2015(1).qxd

15/1/15

Solid, Semi and Fully Tubular Rivets Specialised Cold Forgings Customer Special Fasteners Self Piercing Rivets Products made to order Kan Ban, Consignment and Discrete Orders 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

2:40 pm

Page 1

F+F Tech(NEW)_Jan2015(2).qxd

15/1/15

2:41 pm

Page 1

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

Products are stored in a totally scalable, third party logistics facility to supply OEMS and Distributors in the UK and Worldwide.

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

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

FASTENER + FIXING TECHNOLOGY

Lesjöfors invests in laser technology Lesjöfors AB has recently made a large machine investment at its factory in Värnamo, Sweden, on an advanced fibre laser that it says meets many customers’ requirements for increased technical flexibility in production.

L

esjöfors explains that its customers’ needs and requests are dynamic and constantly evolving and its stated strategy is to be at the absolute forefront in terms of technical know-how and machinery. This enables flexible and optimised solutions based on each individual need.

“We have a massive inflow of new business and in many cases it is the opportunities with creative product optimisation – linked to modern production techniques – that make the deal possible,” says Jakob Lindquist, managing director of Lesjöfors Banddetaljer in Värnamo.

In line with the strategy, the new fibre laser from LMI is initially intended for laser welding, but has a number of other uses, such as cutting, marking, polishing, soldering and local heat treatment.

“We have noticed an increasing demand in the market for products based on advanced technical solutions. Our job is often about finding technically rational production solutions including welding and bonding, but also product concepts in which materials saving is in focus. We are very pleased that we can offer a higher flexibility with the new fibre laser,” says Jakob Lindquist.

The investment in the fibre laser is only one in a number of technology investments Lesjöfors is implementing to further advance its market position and to meet customers’ needs.

Lesjöfors enters US market following acquisition Lesjöfors AB recently purchased the spring operations of Sandvik Materials Technology – a leading manufacturer in the US market. The company focuses on power springs and has a revenue of approximately MSEK 100 (10.6 million euros).

The acquisition opens up a new market for Lesjöfors and provides the opportunity for support to existing customers.

Sandvik Materials Technology, which operates plants in both the US and Mexico, is a leader in the specialty area of power springs, with a significant market share. The company’s principal market is the NAFTA zone – the free trade area encompassing the US, Canada and Mexico – which accounts for slightly more than 90% of its sales.

“This acquisition opens up a new market area for Lesjöfors, a market we have studied for a long time. It also gives opportunity to support our existing customers with operations in the NAFTA area,” says Kjell-Arne Lindbäck, president and CEO of the Lesjöfors group. “It has strengthened our presence in the US spring market and will provide us with the scope for further expansion in North and South America. It has also strengthened our offering in the area of flat coil springs, which will benefit our companies with operations in Europe and Asia. The acquisition will also open the door to attractive sales opportunities for Lesjöfors’ other spring products in the US market.” www.lesjoforsab.com

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

screw bolt rivet nut

www.fastenerandfixingsearch.com

FASTENER TECHNOLOGY INNOVATOR

Fastener Technology Innovator 2015 Competition One of the many attractions of Fastener Fair Stuttgart, from 10th – 12th March 2015, is the first-hand opportunity to assess new products and services that exhibitors have brought to the market since the last show.

F

astener + Fixing Magazines are once again pleased to sponsor the Fastener Technology Innovator Competition.

The editorial team will review the products and services you can find on the following pages, looking for a worthy recipient of the title of Fastener Technology Innovator 2015.

To find out more read on – we have a record number of entrants this year. Remember to take a note of the stand numbers or look out for the distinctive Fastener Technology Innovator 2015 logo on participants’ stands.

There will be a special presentation to the winners on the organisers’ stand during the show.

616 WS – 6-die progressive header

4.A10

Carlo Salvi SpA has recently launched onto the market the header model 616 WS – a 6-die progressive header capable of handling wire with diameter from 10mm to 17.5mm.

J

ust by touching an icon on the control panel the operator can recall, in a few seconds, jobs that have been previously produced. In fact it is possible to set up electronically the position of the K.O pins inside the dies and the wire feed without using wrenches.

Wire is fed by grippers, which ensure very high precision (+/-0.05mm) thus avoiding damage to wire and offering the maximum clamping over a greater wire surface area. One set of grippers covers the whole standard wire diameter range for which the machine is rated and avoids the use of wire stops, reducing drastically set up times and operating costs.

24 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

The cutter holder is fully guided in order to avoid even minor flexing, while transfer fingers consist of independent finger units. The part to be transferred is pneumatically serrated by fingers so that the correct air pressure can be applied to each set of fingers as needed.

The oscillating transfer provides for greater flexibility and degrees of operation available for the opening and closing of the fingers; a special device allows retention of the part during ejection from dies and is ideal for the production of short, special and very complex shape parts.

K.O on the punch side is innovative and independent from ram movement; trimming is made with an advanced cam system that is permanently assembled on the header; and the independent hydraulic lock of the dies are further devices that make the 616 a complete machine.

The header model 616 WS can be equipped with a pre-heating system. The pre-heating system with induction, if housed in a strategic position, allows the operator to heat the material from 600°C up to 950°C and then it can be transferred in to the tooling area. Prior to the pre-cutting area there is an optical pyrometer that constantly monitors the correct wire temperature. This is linked to the transfer finger, in order to ensure only material with the correct temperature reaches the working area.

A special refrigeration system positioned in the die holder ensures circulation of the cooling fluid, while the fire-proof sound enclosure and automatic firefighting equipment assures maximum safety when working in extreme situations.

High strength and security with FH FiberLock

C2.2/450

Flaig + Hommel GmbH, in collaboration with the Fraunhofer Institut and the Bundesministerium für Wirtschaft und Technologie, has developed the FH FiberLock, especially for use in lightweight applications.

B

ased in Aldingen, Germany, the company says the FH FiberLock is a modern, resuable, state of the art connection for fibre plates. For installation, the FH FiberLock consists of a bolt and an expansion sleeve to be inserted into a borehole. When tightening the hex nut, the profiled sleeve becomes locked into the borehole and forms a reliable and stable attachment – resulting in simple and fast assembly/disassembly.

The borehole has to be drilled into the plate with a commonly used drill – no special tools are needed to install the FH FiberLock. To avoid a twisting between the expansion sleeve and the borehole during the mounting, the bolt is designed with an inside hex to keep the bolt in position. This allows the user to obtain the highest strength and the highest security for this type of connection. The FH FiberLock can also be used in a large-scale production, as well as in a single application, and can be custom designed according to customers’ specifications.

New Microvert PRO from Imanpack Imanpack, with 40 years of experience and more than 45 agencies worldwide, offers complete lines of automatic packaging equipment to meet the needs of any industry such as hardware, food, non-food, plastic, medical and technical products.

N

ew to its product range is the Microvert PRO – a vertical packaging machine equipped with motorised film unwinding, pneumatic reel-holder and encoder controlled pouch-length. This renewed version of the Microvert integrates all the features of the previous models including small dimensions, quick and easy bag length adjustment, pneumatic cross seal jaws and user-friendly PLC controls.

The Microvert PRO is designed to package small hardware and can be integrated in automatic production lines and synchronised with automatic feeding, counters and scales – with a maximum bag width of up to 270mm.

C2.2/430

The machine can be additionally equipped with print-on-film systems, bag support for heavy products, and a chain package option. Other features of the Microvert PRO include: • Painted steelwork or stainless steel frame.

• Film pulling unit by pneumatic adjustable toothed belt.

• Double film unwinding system for long bags.

• Available in a PE or heat sealable material version.

• Available in an incline version of 45°.

“We give our customers the most suitable and profitable packaging solution, from the smallest economic wrapper to complete and customised packaging lines.”

Driving for number five Tite-Fix Ltd, previously a recipient of a Fastener Technology Innovator Award in 2005, 2007, 2009 and 2011, has once again entered the competition for 2015 with the Tite®-Recess and drive bit.

8.S02

T

ite-Fix states that the drive outperforms, yet accepts, a standard cross recess – eliminating both the infuriating search for a driver bit or having to constantly change bits.

The Tite ® -Recess and drive bit is ideal for awkward applications and where driving efficiency is crucial thanks to its stick-fit. There is minimum cam out due to the bit’s resistance to unseating, leading to a straight and accurate drive because the bit sits perpendicular in the recess.

Accurate driving means that there is less bit wear, meaning a longer life for the bit. It also means there is minimum damage to the timber, as the bit is less likely to slip out of the recess.

“At Tite-Fix we are proud of our ability to produce innovative products that really make a difference in the market. The Tite-Recess and drive bit is the most efficient cross recess drive available, thanks to its ability to accept standard cross recess bits perfectly – whilst maintaining drive efficiency. We invite all visitors to Fastener Fair Stuttgart to come to our stand to find out more.”

www.fastfixtechnology.com

25

FASTENER TECHNOLOGY INNOVATOR

RIV939 – for rivet nuts up to M12

4.E03

Rivit Srl, a specialist in the production and distribution of fasteners and installation tools for sheet metal working, will be launching RIV939 at Fastener Fair Stuttgart.

R

IV939 was designed to place rivet nuts up to M12 and is the upgraded version of the RIV938 that, for the time being, is on the market for rivet nuts up to M10.

The new RIV939 model is designed to place Rivsert female rivet nuts from M3 to M12 and Rivbolt male rivet nuts from M4 to M10. It installs the rivet nuts using the adjustment of the oil pressure (force). Rivit points out that the hydro-pneumatic system and the mechanical parts of the internal structure of the tool, when compared to other models of riveters, ensure excellent reliability.

RIV939 features a substantial reduction of the problems due to wear of components, with consequent increase in duration and functionality. Further advantages include: • Kit assembling with ring nut gear (the key is not necessary).

• Tie rods are now commercial screws.

• One phase trigger mechanism.

• Lightweight.

• Easy handling.

• Easy stroke adjustment.

• Adjustment ring stops against the counter ring.

One system – precise screwing

6.L130

With the new collation system from adunox GmbH many screw types can be used in a collated system instead of using them screw by screw – offering a much higher efficiency in the working process.

I

n the adunox-ONE collation system the screws are collated in an oblique position, with the magazine strip automatically returned. On one side the strip is used for the transport in the magazine. On the other side, the screw is held. This separation means that all head shapes and thread forms can be used. Even screws of different lengths can be collated. adunox-ONE also features a screw tip that is visible when installing, leading to a more precise installation being guaranteed. The system can be used in a variety of applications including slate fixing, timber connectors, decking, cladding, and perforated plates. adunox-ONE is also suitable for the furniture and automotive industry.

26 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

Environmental responsibility 4.C04 without performance loss

fischer launched its greenline range in April 2014, initially with six plugs and one two-component injection resin for heavy loads, reflecting the company’s longstanding concern for sustainability and environmental protection but also ensuring performance was in no way compromised.

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ischer is formally committed to active environmental management and owner and CEO, Professor Klaus Fischer, is emphatic this is more than paying lip service. The first evidence of that commitment was the launch of UX GREEN 2012, the world’s first synthetic plug made from renewable materials. For the greenline programme, fischer added five more tried and tested plug types in green alternatives, as well as FIS GREEN 300 T – the first chemical injection resin made from renewable primaries.

Fixings must always be safe and fischer was adamant its biobased fixing systems must comply with technical requirements. The green plastic plugs, therefore, have the same performance features and load bearing capacities as the grey originals – and are naturally just as long-lasting.

Chemical injection resins are complex products and there are currently few biobased equivalents for their base substances, precluding the simple substitution of an identical biobased substance. In developing FIS GREEN 300 T fischer, therefore, had to totally reformulate, adopting organic components that fulfilled varied functions.

FIS GREEN 300 T resin is suitable for fixing high loads in concrete, perforated and solid bricks for inside and outside use. It carries the Environmental Product Declaration (EPD) of the Institute Bauen und Umwelt e.V and therefore has a database for ecological building assessment. The resin is extremely low in emissions, placing it in the French emission category A+ “very low in emissions” for volatile substances. It carries no hazardous substance markings whatsoever.

Experience & professionalism since 1966

Global Inch - Fasteners

for more than 40 Years

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

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

Bonfatti Filettature s.r.l.

Via De Nicola, 42 - 41100 Modena, Italy Tel: +39 059 251604 Fax: +39 059 254226 email: info@bonfattifilettature.it w w w.bonfa ttifilettatu re.it

Tel.: +49 (0) 71 32/99 60-0 • Fax.: +49 (0) 71 32/99 60-60

www.schroederschrauben.de

New Series 20 Catalogue Over 200 pages of Stock springs, including • New High Pressure Compression Springs • Lite Pressure™ Series additions • Metric Bantam™ Mini Compression Springs • Expanded Heavy Duty Die Spring line • Belleville Washers Parts added Call or email us today for your FREE copy.

From 10 to 10 million.

Stock Springs or Custom Design Springs.

See Lee Spring on Stand V51, Hall 8 at the Fastener Fair, Suttgart, 10-12 March 2015.

Visit: www.leespring.com | Fon: + 49 2353 669933-0 | Email: sales@leespring.co.uk / verkauf@leespring.com Lee Spring_FastnerFair-Studdgart_130x186mm_Dec14.indd 1

23/12/2014 09:37

FASTENER TECHNOLOGY INNOVATOR

Two part wood filler now in foil bag cartridge

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UK based Chemfix Products Ltd has launched the Pre-Mix wood filler – the first ever two part styrene free wood filler in a foil bag cartridge that is ready for extrusion.

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re-Mix wood filler is ready for extrusion, without cutting the bag, thanks to the patented ChubSeal system. The result is a mix of resin and hardener in the perfect ratio during extrusion. Designed for fixings and repairs in wood, the resin is extruded using a simple DIY silicone tool giving a simple and clean mixing and filling process.

Pre-Mix wood filler can be used to fix screws, hooks or threaded rods into wood for a durable high strength bond. It can also be used to repair wooden applications, with the optional mixing nozzle simply pointed directly into long strips and gaps. The cured resin is then sanded down with ease, and over painted or stained.

The Pre-Mix wood filler is also suitable for bonding various wood materials to a range of substrates. The bond is cured within just a few minutes of application.

“By combining our wealth of specialist knowledge in cartridge technology, along with the prestigious and strong history of the Metolux brand, we have been able to produce the first ever two part wood filler in a cartridge.”

Revolution in cylindrical thread rolling technology At Fastener Fair Stuttgart Regg Rolling, a division of Regg Inspection Srl, will introduce its R40 HD ‘High-Speed’ two-dies cylindrical thread rolling machine.

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40 HD ‘High-Speed’ has a production rate of up to 60 parts/min and can roll threads with diameters ranging from ½ inch to 3 inches. The machine ranges from 40kN up to 1,000kN force for the widest range of applications – from a small high precision, high-tensile aerospace fastener to large threaded bars for the oil and power transmission industries. A new PLC control also helps to reduce set up and cycle times.

All machines at Regg Rolling are designed with the most updated technologies to grant maximum rigidity and to constantly maintain a high degree of accuracy and uniformity of parts.

“At a production rate of up to 60 parts/min, the new R40 HD ‘High-Speed’ is four times faster than any other machine. It is a real revolution in cylindrical thread rolling technology.”

Introducing the Intervis® for UHPFRC With 85 years of innovation in assembly, fastener and fixing systems, Gardette Groupe has departed from its usual markets to offer what it sees as a true innovation to the construction sector – a special insert for highly technical cement called Ultra High Performance Fiber Reinforced Concrete (UHPFRC), allowing unseen architectural applications.

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rchitects and concrete manufacturers were looking for an innovative solution to easily fix the new UHPC (Ultra High Performance Concrete). The defined specifications were to have a particular length depending on concrete thickness, high wrenching resistance for optimal security, and a moulded item to avoid drilling and thus weakening of the panels. Last but not least was the necessity of a mass-produced item responding to all requirements of this highly performing concrete.

LGC, a subsidiary of Gardette Groupe, developed a special insert within its Intervis ® range especially for this Ultra High Performance Concrete. It responds to all criteria demanded by end users. The insert is directly cast in when the concrete plate is poured. The size remains compact but still ensures an exceptional resistance to wrenching, offering high security, even on the thinnest thickness. Because of the direct casting, Intervis for UHPFRC allows perfect anchorage in the concrete

28 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

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plate, without any slack with the receptive piece. A specific design development has permitted avoidance of insert rotation in the concrete during tightening. With Intervis UHPFRC plates can be fixed with maximum security, minimum operations and sustain the unique design offered by this high-end concrete.

The high performance of this concrete means its main applications are building façades, urban furniture, interior architecture and modern art pieces. Intervis for UHPFRC was recently used for fixing the façade of the Louis Vuitton foundation, which opened in Paris in October 2014.

THREAD ARMOR

™

ADVANCED ANTI-GALLING AND LUBRICATING THREAD COATING

• Under intense torque and high friction loads, Thread Armor can increase the life of the threads by 10-15 times over an uncoated part.

• Reduces friction to insure consistent clamp load.

• Prevents galling in long thread run-down applications.

• Reduces heat build-up during high-speed installations.

• Protects the coated area of the thread from corrosive environments.

• Insulates dissimilar male and female thread materials for protection from galvanic corrosion.

APPLICATIONS • • • • •

Compressors Clamping applications Mining equipment Tool holders on lathes and screw machines Any parts subject to repeated installations and removals for service or adjustment • Stainless steel bolts in aluminum mating threads

SPECIFICATIONS • • • •

Dry to the touch 5 year shelf life High temperature resistance Water resistant

Non-Hazardous • RoHS and REACH compliant

www.ndindustries.com • products@ndindustries.com U.S.A. Processing Locations: New Jersey • North Carolina Michigan • Ohio • Illinois • Texas • California International Processing Locations: China • Taiwan • Turkey

CERTIFICATIONS & ACCREDITATIONS AS9100:2009, Rev. C • QPL-18240F • QSLM ITAR • ISO-9001:2008 • ISO/IEC 17025:2005 CE Directive 2006/42/EC • ISO-14121 ISO-12110-1/12110-2 • IEC-EN 60204-1

FASTENER TECHNOLOGY INNOVATOR

New External MORTORQ® Super bolt design Phillips Screw Company has introduced the newest addition to the MORTORQ® family of high performance fastener designs – the External MORTORQ® Super bolt design.

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hillips Screw states that this new wrenching system is quickly gaining acceptance as a high performance light weight replacement for hex head, bi-hex, and six lobed bolt head designs in both aerospace and automotive applications. First introduced as a weight saving option for high performance special alloy aerospace bolts, the new design reduces head height by 20% compared to the 12-point bolt it replaced. In addition, the new design provides 1.4 times the drive surface contact area and 2.5 times the removal surface contact for improved torque transmission and assured serviceability and maintenance. Weight savings were 30 pounds (13.6kg) per 1,000 pieces compared to the original ¾ inch (19mm) diameter bi-hex head multiphase alloy bolt.

The new design is also easier to forge with fewer secondary operations required to achieve the final product. The innovative design creates the lightening hole during the initial forging operation – eliminating an entire secondary operation while filling the head form completely. When used to replace a standard hex flange bolt the new design has a 30% lower head height

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and provides 2.1 times the contact surface area on the removal faces of the drive – due to the unique spiral engagement of the socket and bolt head. The new design is available in a size range from #10 (M5) up to 2 inch (M50) from a global network of licensed manufacturers. All manufacturers are subject to initial qualification and regular quality monitoring to assure the global compatibility and performance of bolts and sockets in all applications.

Available in materials ranging from Grade 5.8 to ultra-high strength multiphase aerospace alloys such as MP159, these bolts are the latest addition to the MORTORQ® family of fasteners that have proven themselves in applications from the front seat bolts of cars to the window bolts of the space shuttle.

New Keramo extreme Austrian based ALPEN-MAYKESTAG GmbH says that its new Keramo extreme drill bit is the perfect problem solver for the toughest tiles.

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eramo extreme’s patented tungsten carbide tip with centre cutting geometry allows precise placement and accurate holes without chipping. ALPEN-MAYKESTAG says that it can be used on the hardest porcelain/gres tiles up to Mohs/Ritz hardness grade 9, as well as glass and porcelain. No cooling is required making the drill bit easier to handle and it can be used in all standard drills.

The Keramo extreme offers high stability due to a reinforced shank diameter and also includes a special ground tip that enables low-wear drilling and very long service life of the bit. Keramo extreme also includes a white ring mark, which signifies to the operator the ideal drilling depth.

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Unique timber lifting tool Pitzl Metallbau GmbH & Co KG, a supplier of innovative connection systems for timber construction, says its aim is to introduce systems of increasing efficiency and competitiveness for its customers.

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itzl’s latest innovation is the Pitzl Power Clamp, which will be presented officially at Fastener Fair Stuttgart. Power Clamp is an innovative system that allows a gentle and smooth lifting of solid wood panels and boards such as glued laminated and cross-laminated timber.

Power Clamp is easy to fix in a (40mm) pre-drilled hole by just ‘clicking’ it into place and ensures load capacities up to 1,000kg per clamp. In addition, an innovative closure technique allows for a quick release, when the element is seated in the right position.

“The Power Clamp enables users to save an enormous amount of time in comparison to existing methods. There is no need for further butts or hooks and no damage to solid timber elements. The Power Clamp can be used multiple times – up to 20,000 lifts.”

30 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

Jubilee’s new Quick Release Straps In 2013, Jubilee Clips acquired Elms Lightning Fasteners in Birmingham, UK, which enabled it to increase its involvement in the heating, ventilation, air conditioning and sign fixing markets.

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hen talking to both Elms’ existing and new potential customers for the Multiband banding system – the core of Elms Lightning’s production – there was a demand from some customers for a convenient pre-assembled clip, specifically designed for use where slipping the clip over the end of a fitting is not possible, i.e. where a closed installation requires the clamp to be opened fully for positioning of the clamp.

The result of these discussions is the new range of Quick Release Straps manufactured at the Birmingham plant. They are available in zinc protected mild steel 11mm band width, and in 304 stainless steel, available in both 7mm and 11mm band width. All 11mm band straps now have newly designed 7mm Hex-Head captive screws for ease of assembly with either a Jubilee Clipdriver or socketdriver or a screwdriver. Jubilee explains that this housing/screw combination is unique to its company, as it allows the user to tighten the straps using a high torque, without the need to lock the housing into place.

Having only been introduced towards the end of 2013, Jubilee Clips has already seen significant sales of the Quick Release Straps to the telecommunications and rail sectors, which shows the diverse potential markets for these products beyond HVAC, cable retention, fence repairs and sign fixing.

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

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Hall 4

Call +1-612-7299365

FAX +1-612-7298910

sales@bokers.com

www.bulte.com ®

BOKERS.COM/FFT

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

FASTENER TECHNOLOGY INNOVATOR

Hot forging for long and large bolts Videx Machine Engineering Ltd has added hot forging lines that it says are the first fully automatic lines in the world for long and large bolts.

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avid Wiesenfeld, who is the founder and owner of Videx Machine Engineering Ltd, started in the fastener industry 50 years ago as a plant engineer in an Israeli fastener plant. David gained his experience in hot forging at that time and has always dreamt of returning to this business.

Now with the addition of the hot forging lines to the Videx portfolio he has been able to do so. The forging machines are available in 300, 400 and 500 metric tonnes, covering the thread range of ¾ inch to 2 inch (M48) in the smallest machine and up to 3 inch in the largest machine. The length range is 8 inches – 32 inches (200mm – 800mm) under the head.

The line comprises the following machines: • Impact cutter – cutting long bars to length.

• Chamfer machine – accepting cut-to-length bars from the impact cutter or from a one-row magazine.

• Extrusion machine – extruding the chamfered side.

• Induction heating machine – (not made by Videx).

• Forging machine – with solid die, double blow, with 300/400/500 metric tonnes capacity.

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Then the dial indexes the parts to the first forging station, which upsets the parts and breaks the scale. In the next station the hex is formed in a slide closed die. After heading the parts are indexed to the ejection position, where they are ejected to a conveyor that takes them out of the machine area. The production rate is 4 – 6 parts per minute.

The hot forging machines can be supplied with a spray system for cooling and lubricating the die and punch and also as self-standing independent machines and not connected as a line.

The forging machine has five stations – one feed station, two forging stations and two ejecting stations. The chamfered and extruded bars are fed into the die by a pneumatic piston.

Reinhardt: New and better solutions for coating

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Located in the south of Germany are the production floors and construction facilities of Ernst Reinhardt GmbH. Once more, one of the biggest innovations in the coating sector comes from this area.

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he tasks set for the construction and the R&D departments were clearly defined – develop a coating unit that can easily, efficiently, and at low cost, coat small batches. Of course it must feature well established Reinhardt quality, have a starting price less than 100,000 euros, and a delivery time of less than 12 weeks.

The unit has to come in basket or barrel variation and comply with all the large material producers. To guarantee the required high grade of flexibility the unit also must be expandable as a construction kit system.

This was the kick off for project ‘Coatingflex’. For the first time it was possible to economically cover small batch sizes with a large coating unit (with a performance of 6 tonnes per hour). With an average capacity of 1,200kg per hour (700 litres per hour) and a set up area of just 3x3 metres as the basic configuration, Reinhardt hit the bulls’ eye – the only way small batch sizes can be processed profitably.

Maximum flexibility equals maximum efficiency. For starters, the coating medium can be changed without great hassle.

32 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

Secondly the conception of the unit is for modular growth.

Key is the capability to easily and quickly change batches – multiple changeover processes in a day are no problem.

The coating unit alone can be run with an existing batch furnace. At a later stage a flow furnace with cooling zone can be installed as well. The unit adapts to a company’s development.

“25 years experience has delivered a well engineered list of options, covering each and every scenario. Automatic part feeding, batch documentation, separate up and unloading stations, part-handling (half and fully automatic), cooling zones, and different drying processes (batch, belt or pallet oven), are not expensive special requests but standards that can be included into the base unit.”

Reinhardt also never forgets the environment and the people working with its units, so they are set up for maximum results with the least possible material use – “the unique and well engineered centrifugal method means an immense reduction in the use of material.”

GESIPA® AccuBird® Pro – as fast as air More than twenty years ago, GESIPA® invented Accu-riveting technology.

Now, at the beginning of 2015, the new AccuBird® Pro by GESIPA will be ready to replace the proven AccuBird®, which has been used for thousands of jobs by craftsmen on construction sites and in industry for two decades.

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ESIPA® says that its construction and development team has not only succeeded in providing a modern, attractive and extremely functional design but also in revolutionising the proven and robust technology in such a way, as to enable the AccuBird ® Pro to set rivets easily at a frequency that is up to four times higher than any other Accu-riveting tool on the market.

This enormous speed is possible due to an almost wear-free brushless motor with a setting force of 10kN, as well as the auto-stop/auto-reverse function. In other tools, the pulling mechanism has to finish the pulling process completely and then return to its forward end position again. However, the integrated intelligent control function on the AccuBird Pro detects the exact point where the mandrel breaks off and then immediately stops the pulling process. The pulling mechanism directly returns to its operating position and is ready for the next setting process.

“As the first of its kind in the world, this innovative technology allows the AccuBird Pro to work at the same setting speed as pneumatic-hydraulic setting tools, for example the TAURUS ® 3 produced by GESIPA.” In addition, the AccuBird Pro comes with a jaw system proven in thousands of applications, as well as with the ergonomic design of the TAURUS setting tool series. The quick charging function and the precise charge level indicator will provide real added value for the user, with the low weight of the tool being an additional advantage. To add to this LEDs, precisely focused on the workpiece, will illuminate the darkness in poor lighting conditions.

FASTENER TECHNOLOGY INNOVATOR

Portable inspection with INSPECTpro SCHATZ AG has introduced the new INSPECTpro – a portable system for torque, angle and clamping force – that uses changeable batteries and can be operated by bolt manufacturers, coaters and users of fasteners to determine friction coefficient on-site.

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NSPECTpro is an innovative portable measuring system that offers quick and effective determination of friction coefficients of fasteners combined with reliable analysis and complete evaluations.

Friction is always present, and due to friction it is not possible to determine the clamping force of a bolted joint directly from the torque alone. This is only possible if the friction coefficient of the fastener concerned is known. Factors that can cause changes in friction characteristics are roughness, hardness, surface treatment, lubrication, temperature and others.

It means that simply handling a bolt or nut can lead to failure of a bolted joint. A drop of oil on the operator‘s hand or a drop of oil falling from the tool can dramatically change the friction properties of the bolt.

Since friction has such a large impact on assembly results, it is important to be able to check the relationship between torque and clamping force in production.

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Accordingly, bolted joint analyses for determining the relationship between assembly torque and clamping force are usually performed in labs or research departments. Although lab tests are in any case indispensable, SCHATZ points out that most production departments need to be able to carry out quick tests on the assembly line with portable devices that are easy to use and therefore take less time than lab tests.

A suitable device for such tests is the portable INSPECTpro instrument, which allows a clamping force sensor and a manual torque/angle sensor to be connected simultaneously. Using the touchscreen of the INSPECTpro, the operator can quickly select the type of analysis to be performed. After the measurement data is acquired the friction characteristics of the fastener are shown in numerical or graphic form, as well as whether or not the lubrication complies with the specification. The display is swivelling and can be set in 10° steps from 0° to 100°.

Fixing for seismic load Bossong says that its EPOXY 21 is the first pure epoxy resin on the market to have received the seismic qualification C2 with standard threaded rods. Since 2011 the product has also received two ETAs and has been CE marked for approval for threaded rod (Option 1 and Option 7) and post-installed rebar connections.

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he new seismic assessment according to ETAG 001 Annex E (design method TR045) with standard threaded rod for category C2 applications was released in 2013.

The assessment, which is optional, determines that the product is suitable for structural and non-structural applications and for every level of seismicity.

Two test protocols are identified in Annex E: • C1: Limited – only for low seismicity level areas.

• C2: Universal – for all levels of seismicity, both for structural and non-structural uses.

The C1 protocol requires fewer, less severe tests compared to protocol C2 – which is very different and substantially more stringent. The C2 protocol requires a minimum of 30 tests per diameter. Anchors must also be qualified in cracks up to 0.8mm in width by simulating the inversion of the moment through the

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active compression of the concrete around the anchor.

EPOXY 21 is certified for fixing with variable anchorage depths. This means that the project engineer has considerable flexibility in the design phase. The ETA for post installed rebar connections is in accordance with Eurocode 2 and TR023 with maximum allowed depth of 250cm, including certified installation with both drill and core-drill (dry/wet cutting system), which makes it most suitable for professional rebar applications.

In addition, the Option 7 for uncracked concrete and Option 1 for installation in cracked concrete with rods guarantee to the user an extreme broad spectrum of applications. EPOXY 21 is available in many different sizes: 900ml, 470ml, 400ml and 265ml.

“Thanks to these qualifications, BCR EPOXY 21 is confirmed as one of the most advanced pure epoxy resins in the market – offering the highest performance.”

ADVERTISERS INDEX Albert Pasvahl........................................................................ 18 Baker & Finnemore Limited.................................................... 21 BOKER’S Inc........................................................................... 31 Bonfatti Filettature Srl............................................................. 27 BÜLTE GmbH.......................................................................... 31 Christian Bauer...................................................................... 19 Clevedon Fasteners............................................................... 21 Clevtec................................................................................. 21 DEPRAG SCHULZ GmbH Co.................................................... 11 Enthone GmbH...................................................................... 17 Fastener + Fixing Search....................................................... 23

34 Fastener + Fixing Te chnology • Issue 16 Jan – Mar 2015

Fastener + Fixing Technology..................................................2 Lee Spring............................................................................. 27 Lesjöfors.................................................................................22 ND Industries..........................................................................29 NOF Metal Coatings..............................................................36 NORMA Group.........................................................................1 Precision Technology Supplies...............................................35 RIVELIT......................................................................................7 Schröder Schrauben.............................................................. 27 TOBSTEEL GmbH..................................................................... 13 Top Screw Metal Corp............................................................33