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4 Handy Tips from an Engineer for Using Washers

Washer Selection

When designing joints with washers, it is important to understand and use the correct washer for the job. Below are a few tips for making a good selection:

1. When using flat washers, match washer hardness with bolt and/or nut hardness to avoid joint settling.

  • 140 HV ≤ 8
  • 200 HV ≤ 8
  • 300 HV ≤ 9

2. Split lock washers are not intended for use with hardened bolts/nuts, only with property class ≤ 8.

Washer 1

3. Toothed lock washers are designed to permit electric current flow between components, and do not provide much of a locking feature. They are also only used for low property class ≤ 8.

Washer 2

4. Specialty washers exist for high strength joints, for example:

  • Rip-Lok – designed for property class 8.8
  • Conical spring washer with serrations on top

Washer 3

  • Schnorr washer – designed for property class 10.9
  • Small OD conical spring washer with serrations on both sides

Washer 4

For more details on selecting the correct washers for your application, checkout www.bossard.com or send us an email at ProvenProductivity@bossard.com.

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Doug Jones
Applications Engineer
djones@bossard.com

September 28, 2018
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4 Recommendations for Installing Self-Drilling Screws

Self Drilling Screws

Self-drilling screws are unique, multi-functional screws. They are designed to drill its own hole into metal and then form threads into the hole. Often used for attachment of steel siding or roofing, they can also be used in other applications where a premade hole is not possible or convenient. While these screws can be a great solution for your application, here are 4 things to keep in mind:

1. Length of Drill Flute

The length of the drill flute must be longer than the thickness of the material being drilled. If the material is too thick, the chips cannot escape, which will cause excessive heat and damage to the screw or mating material. The point length must be long enough to complete the drilling operation before threading starts, otherwise damage may occur.

2. Thread Pitch

For thinner sheet metal applications, a coarse thread (wider thread spacing) is recommended. For thicker metal, (3/8 to 1/2″ thick) a fine thread will work better, creating less drive torque.

3. Thread Length

The thread length of the screw should be sufficient to fully engage into the base metal, keeping in mind that the first few threads are not fully formed. Two to three threads should show on the back side of the base material.

4. Installation Tools

Specialty-corded and cordless tools are available specifically for drill screws which run up to 2500 RPMs for fast setting of screws. Standard drills or drivers may be used as well, but impact drivers are not recommended for hard joint applications that are considered structural. Depth gages are often incorporated into the nose of the tool to disengage the head after it has been properly set. Some tools may also have an adjustable clutch that will allow for proper setting torque.

Do you have an aluminum or stainless-steel application which requires corrosion resistant self-drilling screws? Checkout our ecosyn®-MRX screw!

Looking for a self drilling screw supplier, or have additional questions? Contact us at ProvenProductivity@bossard.com!

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Doug Jones
Applications Engineer
djones@bossard.com

September 21, 2018
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Quick Guide: Installing Rivet Nuts

Rivet Nuts

How do I know if I have the right installation force? Did I set it right? Do I have the right tool? These are some of the most valid questions when installing and using rivet nuts. Knowing the mating material, grip range, hole size, and clamp force will aid in getting the right fit for the joint in your application. Securing a proper clamp load will prevent from loosening and/or rotational loss. Understanding the creep and material relaxation is also important when using this joint design.

Finding the Correct Fit

 

 

Examples of Rivet Nut Applications

There is a lot to consider when choosing the right rivet nut. There are many choices for body styles, material, and coating finishes. Let the experts at Bossard help you narrow down your search and get you on the right path to a secure joint. Let us help you save money and avoid costly warranties or claims. Contact us at ProvenProductivity@bossard.com to learn more.

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John Syharath
Technical Sales
jsyharath@bossard.com

September 14, 2018
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How Pre-Applied Thread Lock Patches Can Save You Time and Money

Preapplied Thread Patches

If assembly requires applying liquid thread locker to any threads, pre-applied thread locking patches should be investigated.  Pre-applied thread locking patches could potentially be an untapped area for both time savings and cost savings.

Thread Locking Materials

Pre-applied thread locking materials work in a couple different ways. A nylon thread locker pushes work by forcing metal to metal contact between the threads on the opposite side of the applied area. Because of the way this type of thread locker works, coating all 360° of the threads is not advised.  This type of patch can be reused if care is taken. A thread locking patch works like a two-part epoxy. When installation occurs, the two parts mix together and after the two parts set, the area between the threads are filled. This type of thread locker can only be used once and if the joint needs to be serviced, a bolt with a new patch must be used.

Filling the thread tolerance area between the threads will help resolve some vibrational loosening that might be occurring.

There are many features of pre-applied thread locking patches including the amount of locking material applied to the threads is more consistent, parts can be processed in large lot quantities, and the pre-applied thread locking patch usually has a long shelf life.

Please feel free to contact Bossard to help answer any questions that may arise.

For more information on thread locking patches, check out www.bossard.com or contact us directly at ProvenProductivity@bossard.com.

Brandon Bouska
Application Engineer
bbouska@bossard.com

September 07, 2018
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Benefits of Low Force Seals

SFC Koenig Banner

Now more than ever consumers are demanding vehicles that are ecologically friendly, as well as fuel efficient, so they can save more at the pump. To meet this demand, automotive engineers are faced with the task of designing capable engines to fit these new requirements. Often, that means making the engines on all vehicles, from small compact cars to large trucks, smaller and lighter.

To reduce engine weight and size, the components must be tightly condensed together, giving the engine parts little wiggle room. The necessary ports and passages used to deliver oil and all the other mandatory engine operations must be carefully integrated into the remaining available space, resulting in thin port walls.

The Challenge of Thin Port Walls

Engine Block BossThin port walls are quickly becoming more common, but they aren’t built to withstand the usual methods of older style plugs, such as cup plugs or threaded screws. These older plug styles can vary greatly in their results, causing a larger fluctuation in process performance—and with thin port walls and tightly packed engine components, even a small discrepancy during the installation process can cause a disaster.

The process must be precise and accurate every time to prevent damage or leakage, as many times ports are in a dangerous proximity to bearings or moving parts. Engineers have consequently been relying on low stress expander seals to attain reliable, precision sealing.

Benefits of Low Force Seals

Low Force SealsLow force seals, such as SFC KOENIG EXPANDER® plugs, cause less damage to the port wall and components, having minimal effect on even the most complex engine geometries. All the advantages of low force seals are listed here below:

  • Less negative effects on engine components
  • Prevent cracking of base
  • Avoid expansion of port into nearby components
  • Reduce the risk of leaks and wear
  • Less effect on overall system performance
  • Comes with its own installation equipment to ensure needed precision; gives the installer more control

Unlike cup plugs, threaded plugs and the like, low force seals provide leak-proof security and work well when dealing with extremely sensitive applications. Their reliability is even more critical when dealing with ports located deep within the maze of a tightly packed engine. Due to the little to no margin-for-error in engines with thin port walls, the strict tolerances and reliable installation methods of low force seals are essential to the successful performance of these modern machines.

For more information about SFC KOENIG EXPANDER® plugs and their other products, contact us at ProvenProductivity@bossard.com.

August 31, 2018
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A Complete Guide to Fastener Strategy – Part 4

Fastener Strategy Part 4

Another consideration when building a fastener strategy is drive styles, especially in smaller screws with internal recess drives. If no fastener strategy is enforced, many customers may have several different styles in their bill of materials, creating a proliferation of similar parts. Some of the more common drive styles are shown below:

Fasteners

Slotted

  • A slotted head style is not recommended for use in high volume or automated assembly. Sometimes this drive is still the best option for access panels that need to be serviced in the field using simple, readily available tools.

Phillips

  • This is a common drive for most head styles and okay for higher volume assembly. One disadvantage is that the tapered side walls of the drive require significant down force during tightening or removal to prevent the tool from slipping and damaging the drive. Once the drive is damaged, it can be hard to remove.

Pozidriv

  • Similar to Phillips, a Pozidriv head style has vertical side walls in the drive which have less tendency to “cam-out” when installing or removing. This drive typically extends tool life in high volume assembly but does require a Pozidriv driver bit which can be confused for a Phillips drive bit. Pozidriv heads can be identified by the four tick marks around the cross (see above). Driver bits are marked with a “pz” while Phillips are marked with a “ph”. 

Torx, Torx Plus or Hexalobular

  • These drives have been around for several years and are more readily available in metric than inch hardware. Torx and hexalobular are very similar and use the same driver, while Torx Plus has slightly different geometry and offers longer tooling life in high volume assembly. Torx driver bits are marked with “T” while Torx plus are marked with “IP”.

Socket

  • This is an internal hex drive which uses a hex key, sometimes also referred to as an Allen key. It is often used in larger diameter bolts which have limited space for a standard socket as a driver. In smaller screws, the internal hex may become damaged as tooling wears, which can make them difficult to remove.

For more information on the availability of these drive styles, and which one best fits your needs, check out www.bossard.com or contact us directly at ProvenProductivity@bossard.com.

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Doug Jones
Applications Engineer
djones@bossard.com

August 24, 2018
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A Complete Guide to Fastener Strategy – Part 3

Fastener Strategy Part 3

Another key component to a fastening strategy is managing or eliminating high risk fasteners. What are high risk fasteners? High risk fasteners are those which are subject to delayed failure, also known as hydrogen embrittlement (HE).

High-Risk Parts

For a part to be considered high risk, it must have three overlapping elements:

  1. A hardness (core or case) in excess of Rockwell C 38
  2. Subjected to processing, which induces hydrogen gas, such as electroplating or acid cleaning
  3. Assembled in a manner which sustains high tensile or bending stress

Common high-risk fasteners are listed below:

  • Electroplated
    • Property class 12.9 screws
    • Alloy steel grade socket head cap screws
    • Case hardened thread rolling screws
    • Retaining rings
    • Spring pins & clips
    • Conical washers – by themselves or assembled to screws of any grade/class (SEMs screws)

Any of the above listed fasteners can be managed by selecting a finish other than electroplating which does not induce hydrogen along with using mechanical cleaning methods.

For more information on high risk fasteners, check out www.bossard.com or contact us directly at ProvenProductivity@bossard.com.

For general hardware shop here.

Doug Jones
Applications Engineer
djones@bossard.com

August 17, 2018
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A Complete Guide to Fastener Strategy – Part 2

Fastener Strategy Part 2

As mentioned in part one of this series, many manufacturers treat fasteners as an afterthought, but having a clearly defined fastener strategy can offer many benefits in the long term.

Another key point to consider when building a fastener strategy is joint criticality.

Joint Criticality

Looking at each joint and asking yourself, “What happens if this joint comes loose or fails completely?” is a good way to help guide your strategy. Your levels of response may look something like this:

  • Level 1 – Product may cease to function, but can be easily repaired by consumer – generally not a warranty claim
  • Level 2 – Product may fail but warranty claim is unlikely
  • Level 3 – Product may fail and warranty claim is likely
  • Level 4 – Product may fail and injure consumer

Levels 3 and 4 should help guide your strategy in friction control, locking features, and method of assembly. These joints should use controlled tightening methods and tools along with finishes having specific friction ranges engineered into them. If you are unable to incorporate the five times the diameter clamping range into the joint, locking features may also need to be incorporated to help keep things from loosening.

Warranty issues may be worth investigating when building a fastener strategy as well. If loosening or corrosion problems are prevalent, changes to the strategy may help address these claims in the future.

For help with critical joints, or warranty claims, check us out at www.bossard.com or contact us directly at ProvenProductivity@bossard.com.

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Doug Jones
Applications Engineer
djones@bossard.com

August 10, 2018
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A Complete Guide to Fastener Strategy – Part 1

Fastener Strategy Part 1

For many manufacturers, fasteners are somewhat of an afterthought, but having a clearly defined fastener strategy can offer many long-term benefits.

A few key points to consider when building a fastener strategy are as follows:

Metric or Inch System

Many manufacturers in the United States still primarily use inch fasteners for obvious reasons, but if there are any plans to expand into foreign markets, metric fasteners will be a preferred choice. It may seem like a scary proposition to switch, but the right fastener supplier can help!

Finish Requirements

Understanding the life cycle of your product, the environment it will be operating in, and which fastener finishes will satisfy your needs is important. Selecting specific finishes and building them into your strategy can also help prevent part proliferation. It’s also important to understand regulations that may be associated with certain finishes, such as RoHS and REACH. Even if your industry is not bound by these regulations, they may still affect the product you are getting whether you know it or not. If you have been using what you think is the same zinc electroplating for ten years, it’s almost certain that you are getting a different finish now than was being applied originally. You should be aware of things such as reduced corrosion protection resulting from material handling, and different coefficients of friction which could require different assembly torques.

Property Class or Grade

If your bill of materials contains multiple fasteners of the same size and configuration, but with a different grade/property class, you may want to consider consolidating to one part that will work for all strength requirements.

Keep a lookout for future blogs on this topic, and as always, check us out at www.bossard.com or contact us directly at ProvenProductivity@bossard.com to see how we can help you build your fastener strategy.

For more shopping options click here.

Doug Jones
Applications Engineer
djones@bossard.com

August 03, 2018
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6 Ways to Save on Your C-Parts Management Costs

6 Ways to save on C-parts management costs

When prioritizing the necessary components of your end product, C-parts such as screws, washers and nuts often take the backseat. While it’s true these small pieces may not be the most noteworthy aspect of your product, there’s no question they are a vital part of the machine you are selling.

However, acquiring C-parts—even small consumer articles—is often a very costly business. This leads to high process costs in relation to the purchase costs. So how do you save money on secondary parts while maintaining excellent end product quality?

That’s where our free e-book comes in.

How Our E-Book Can Help

In this e-book, you will find 6 proven ways to help you reach up to 70% cost savings on your C-parts management. With the book as your guide, you will learn the importance of several factors that affect C-parts cost and useful tips on how to recognize these issues so you can find a better long-term solution.

This book will help you identify potential problems early on, allowing you to pinpoint a management area that needs work and fix it accordingly, saving you money in the long run. You’ll learn the benefits of outsourcing C-parts management and avoiding over-production, which can cost you time as well as money. Our e-book helps you understand the value of minimizing your movements for better efficiency, as well as how to focus on time management and process analysis to make sure you are on the right track.

Experience in the industry has shown that cost savings of up to 70% can be achieved in the areas of logistics of C-parts management. This has a lasting effect on the total cost of the end product. Success stories from Bossard’s customers are the true proof of saving immense costs on your C-parts management.

For more information, check out www.bossard.com or contact us at ProvenProductivity@bossard.com.

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July 27, 2018
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