0271/03.

02

Precision processing competence from

AMTEC

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A joint project between
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Overview of installation methods for AMTEC threaded inserts

HES

HES

EWS

EWS

USS

RSS

Cold fitting

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EWS (electromagnetic resistance welding) is a method developed by KVT Bielefeld for interconnecting metal and thermoplastic parts. The threaded insert is heated without contact through an electromagnetic field, thus plasticizing the contact area of the plastic part. The molten material is displaced into any size are heated within a very short space of time (approx. 2 6 seconds). Since the melt cools rapidly as soon as the energy is switched off, parts USS (ultrasonic welding) was originally developed for joining thermoplastic mouldings. The plastic material is plasticized very rapidly through friction between the mating surface and vibration absorption of the parts to be combined. This is then followed by the actual joining process. The required energy is produced by the ultrasonic generator in the form of an AC voltage which is converted into mechanical vibration (20 40 kHz) and then applied to the RRS (rotational friction welding) is used to connect thermoplastic parts with rotosymmetrical joining zone. The joint effect of the bonding force and rotation produces friction heat at the mating surfaces, thus causing both parts to plasticize and enter into a positive connection. Suitable Bllhoff threaded inserts: plastic in plastic Type 163. Process for connecting thermoplastic and thermoset materials without producing fusion heat. The range of Bllhoff products for this application extends from self-tapping screw-in parts through thread-cutting parts to expansion anchoring systems. Suitable Bllhoff threaded inserts: HITSERT 3; QUICKSERT; EXPANSIONSERT 1 and 2; SPREDSERT.

HES (heated tool welding) is a tried-and-tested method for installing metal threaded inserts in thermoplastic mouldings. This is a one-phase process in which contact heat is transmitted via the metal insert to the joining zone of the plastic moulding. the two parts are joined as the plastic material melts around the contact area. The plasticized material is displaced into defined recesses and undercuts to produce a positive connection.

Suitable Bllhoff threaded inserts: HITSERT 2 and 3, SONICSERT.

can be fitted with an accuracy of up to 0.05 mm. Suitable Bllhoff threaded inserts: HITSERT 2 and 3; SONICSERT.

parts by a vibrator (sonotrode). The molten material is displaced into recesses and undercuts as the threaded inserts (metal parts size M 2 M 6) are installed in the thermoplastic. Suitable Bllhoff threaded inserts: HITSERT 2 and 3; SONICSERT.

KVT Bielefeld

Selection of suitable fitting methods

AMTEC threaded insert M2

< 50.000

< 0,05
kk

0,1

0,2

HES EWS USS

= Ideal

AMTEC threaded insert M2 M8

< 50.000

< 0,05
kk

0,1

0,2

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HES EWS USS

= Ideal

AMTEC threaded insert > M 10

< 50.000
k

< 0,05
kk

0,1
k

0,2
k

HES EWS USS

= Ideal

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>> 11 million Mio.

fitting accuracy < 0,05 0,1 0,2

Quantity 500.000

< 0,05

0,1

0,2

kk

kk

= Good

= OK

= Not so good

k = Not recommended

e. g. for telecommunications

Quantity 500.000

>> 11 million Mio.

fitting accuracy < 0,05 0,1 0,2

< 0,05

0,1

0,2

kk

kk

= Good

= OK

= Not so good

k = Not recommended

e. g. for furniture

k
Quantity 500.000
k
fitting accuracy < 0,05 0,1 0,2
kk k k

1 million
k

< 0,05
kk

0,1
k

0,2
k

= Good

= OK

= Not so good

k = Not recommended

e. g. for automotive applications

KVT Bielefeld

Thermal installation of metal threaded inserts (HES)

Equipment types
Thermofitting gun Lever-type hand-operated thermofitting tool Pneumatic thermofitting machine Thermofitting unit with automatic fitting head Type AEK I Automatic thermofitting head Type AEK I Thermofitting components

Range of sizes
M2 - M6 M 1.4 - M 8 M 1.4 - M 8 M2 - M8 M2 - M8 M2 - M8

Economic batch size

up to 5.000 up to 20.000 over 50.000 over 50.000

Toggle-operated thermofitting tool

Thermofitting unit with automatic fitting head Type AEK I

3-axis thermofitting machine

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HES

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HES
Dimensions: Insertion time: Special features: Possible: Recommended: M 1.4 - M 8 M2 - M6 M 4 approx. 3 - 4 seconds Materials: Low tension Multiple insertion possible Highly suitable for threaded bolts Tolerance +/- 0.1 mm Can easily be converted to other insert sizes Thermoplastics Thermoplastic elastomers

Thermofitting gun

Lever-type hand-operated thermofitting tool

Thermofitting machine for multiple insertion

KVT Bielefeld

Thermal installation of metal threaded inserts through electromagnetic resistance welding (EWS)
Equipment types
Hand-operated EWS gun Lever-type hand-operated EWS thermofitting tool Pneumatic EWS thermofitting machine EWS thermofitting unit with automatic fitting head Type AEK II EWS thermofitting components Automatic thermofitting head Type AEK II

Range of sizes
M 1.4 - M 8 M 1.4 - M 12 M 1.4 - M 40 M3 - M8 M2 - M8 M2 - M8

Economic batch size

up to 5.000 up to 20.000 over 50.000 300.000 100.000

EWS thermofitting machine for multiple insertion

Automatic thermofitting head Type AEK II

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EWS thermofitting components

EWS

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EWS
Dimensions: Insertion time: Special features: Materials: M1.4 - M40 M5 approx. 3 seconds - Low tension - Multiple insertion possible - Specially for inserts < M2 and for inserts with sealing ring - Tolerance up to 0.05 mm - Choice between one and two-phase process - Thermoplastics - Thermoplastic elastomers

Pneumatic EWS thermofitting machine

Hand-operated EWS gun

EWS thermofitting unit with automatic fitting head Type AEK II Lever-type hand-operated EWS thermofitting tool

KVT Bielefeld

Ultrasonic installation of metal or plastic in plastic threaded inserts (USS)

Equipment types
Hand-operated ultrasonic welding gun Semi-automatic ultrasonic welding machine Ultrasonic welding components

Range of sizes
M2 - M6 M2 - M8 M2 - M8

Economic batch size

<= 5.000 <= 50.000 > 10.000

Semi-automatic ultrasonic welding machine

Ultrasonic generator

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USS

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Dimensions: Insertion time: Special features: Materials: Possible: M 2 - M 6 for metal inserts Recommended: M 2 - M 12 specially plastic in plastic-inserts Approx. 2 seconds - High noise levels when fitting metal inserts - Considerable abrasion when fitting metal inserts - Unsuitable for threaded bolts - Can easily be converted to other insert sizes - Thermoplastics

Hand-operated ultrasonic welding gun

Ultrasonic transducer

KVT Bielefeld

Friction installation of threaded plastic in plastic inserts and screw-welded connections (RRS)
Equipment types
Rotational welding components Semi-automatic rotational friction welding machine

Range of sizes
M2 - M8 M2 - M8

Economic batch size

< 5.000 > 5.000

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Rotational friction welding machine

RRS

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Rotational welding components Dimensions: Insertion time: Special features: Materials: M 3 - M 8 plastic in plastic inserts Approx. 2 seconds - Screw connections can also be welded - Can easily be converted to other insert sizes - Thermoplastics

KVT Bielefeld

Thermal installation of metal threaded inserts (HES)

Thermal installation of metal threaded inserts through electromagnetic resistance welding (EWS)

Ultrasonic installation of metal or plastic in plastic threaded inserts (USS)

Friction installation of plastic threaded inserts and screw-welded connections (RRS)

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KVT Bielefeld

Overview of AMTEC threaded inserts

Thermal installation

HITSERT 2 Tapered metal threaded insert for all thermoplastics. Particularly suitable for installation by transfer of heat and induction heating.

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Thermal installation, screwing-in and cold insertion Ultrasonic installation
KVT Bielefeld

HITSERT 3 all-purpose Tapered metal threaded insert for thermoplastic materials. Particularly suitable for thermal installation using the HES and EWS processes, for screwing-in and for cold insertion.

Plastic in plastic Type 163 Tapered plastic threaded insert for thermoplastic materials. The plastic part and the plastic in plastic insert can be jointly recycled.

SONICSERT Metal threaded insert for all thermoplastics. Particularly suitable for fitting by means of ultrasonic processes, as well as by the HES and EWS processes. This insert which can be used from both ends is particularly suitable for automatic insertion. Available on request with defined screws....

Overview of AMTEC threaded inserts

Expansion anchoring

EXPANSIONSERT 1 Metal threaded insert for all plastics and their composites.

EXPANSIONSERT 2 Metal threaded insert for casting resins, polyurethane, structural foam, elastomers and wood composites.

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Self-tapping
KVT Bielefeld

QUICKSERT Type 1230 Metal threaded insert for chipless insertion in smooth locating bores. Creates a loadable screw connection in light metals, thermoplastics and thermoset materials . SPREDSERT 1 Metal threaded insert for all thermoplastics and their composites. Also vibration-proof screw connection. SPREDSERT 2 Metal threaded insert for all thermoset materials, also vibration-proof screw connection. SPREDSERT with locking collar Metal threaded insert for through-holes in all plastics with high pull-out values.

QUICKSERT Self-tapping threaded bush for brittle and ductile plastics, e. g. unsaturated polyester resins (SMC, ZMC), polyethane and glass fibre reinforced thermoplastics. High load capacity, can be used for all purposes, optimum fitting properties.

Plastic in plastic Type 173 Plastic threaded bush for components made from rigid foam, PE and PP thermoplastics, as well as wood materials. The plastic part and the plastic in plastic insert can be recycled together if paired accordingly. The innovative solution for metal-free components (e. g. for use in radiography).

Overview of tools for fitting AMTEC threaded inserts by expansion anchoring and self-tapping insertion
EXPANSIONSERT 1, EXPANSIONSERT 2, SPREDSERT 1 and 2 Fitting mandrels for manual insertion of EXPANSIONSERT 1, EXPANSIONSERT 2 threaded inserts QUICKSERT expansion insert Type 1230

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Medium to large volume production QUICKSERT expansion anchoring Setting tool P 2001 is used for rapid and reliable insertion. For large volume production For large volume production (dimensions on request)

EXPANSIONSERT 1, EXPANSIONSERT 2 The tool can be integrated into lever-type hand-operated units or other presses. QUICKSERT self-tapping insertion, plastic in plastic Type 173, HITSERT 3 Can be mounted in adapters on pillar drilling machines and battery-operated power screwdrivers.

EXPANSIONSERT 1, EXPANSIONSERT 2, SPREDSERT 1 and 2 - Automatic fitting machine, including helical conveyor, separation and automatic infeed For large volume production

QUICKSERT self-tapping insertion, plastic in plastic Type 173, HITSERT 3 pneumatic screwdriver High performance through automatic reversal upon reaching the set torque Stationary operation when mounted by adaptation to parallel guide

QUICKSERT self-tapping insertion, with collar plastic in plastic Type 173 Universal quick-action screw system BM 2100 UNIQUICK system with hand-held telescoping screwdriver, special version with automatic infeed of threaded inserts.

KVT Bielefeld

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KVT

Brief description A powerful representative of the compact toggle units with temperature controller and various thermal tips for heating several metal threaded bushes (inserts) of the same size. The inserts are heated and simultaneously fitted in the plastic part. Suitable for multiple insertion of standard inserts in sizes from M 3 to M 6 or for individual insertion of standard inserts in sizes from M 8 to M 10.

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Technical data Method: Heating time: Insertion force: Fitting tolerance: Temperature: Technical data Method: Heating time: Cycle time: Insertion force: Fitting tolerance: Power output:

Technical data

Method: Heating time: Insertion force: Fitting tolerance: Temperature:

Thermal, one-phase 3 - 7 seconds (multiple insertion) Max. 10.000 N 0.15 mm Up to 400 C, variable

Brief description A compact hand-operated unit with temperature controller and various thermal tips for heating metal threaded bushes (inserts). The thermal tips can rapidly be changed, thus making this unit ideal for fitting different insert sizes in small batches. The inserts are heated and simultaneously fitted in the plastic part. Suitable for insertion of standard inserts in sizes from M 3 to M 5. Thermal, one-phase 3 - 5 seconds Max. 200 N 0.20 mm Up to 400 C, variable

Brief description The photograph shows the patented electromagnetic thermofitting head for contactless heating of metal threaded bushes (inserts). The inserts are fed to the thermofitting head by a vibratory conveyor and electromagnetically heated to exactly the melting temperature of the plastic part. They are then introduced into the locating bore in the plastic part via the guide tube and accurately pressed into place by the subsequent insertion mandrel. Suitable for thermofitting standard inserts without collar in sizes from M 5 to M 8. Electromagnetic, two-phase 2 - 3 seconds 4 - 5 seconds Max. 1700 N 0.05 mm 650 - 1500 W

KVT Bielefeld

KVT

Brief description Rotational friction welding machine for installing plastic in plastic inserts or for welding rotosymmetrical thermoplastic parts. Spin welding components are also available for integration in customized machines. Technical data Method: Welding time: Insertion force: Drive type: Rotational Approx. 0.4 seconds Max. 6.5 kN Pneumatic, motor-driven or motordriven with precise angular positioning, as preferred, depending on the application in question.

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Technical data Method: Heating time: Insertion force: Fitting tolerance: Power output: Technical data Method: Heating time: Cycle time: Insertion force: Fitting tolerance: Temperature:

Brief description The photograph shows the single patented thermofitting head for electromagnetically heating metal threaded bushes (inserts). The fitting heads are used for plastic parts (such as suction tubes) into which a large number of inserts must be fitted simultaneously and in large batches. The number of inserts present and the depth reached are scanned, thus ensuring optimum production reliability when thermofitting the inserts. Suitable for thermofitting standard inserts in sizes from M 5 to M 10. Electromagnetic, two-phase 3 - 5 seconds Max. 1700 N 0.05 mm Up to 1000 W

Brief description The photograph shows the automatic fitting head for heating metal threaded bushes (inserts). The inserts are delivered to the thermofitting head by a vibratory conveyor and heated to exactly the melting temperature of the plastic. They are then introduced into the locating bore in the plastic part via the guide tube and accurately pressed into place by the subsequent insertion mandrel. Suitable for thermofitting standard inserts without collar in sizes from M 4 to M 6. Thermal, two-phase 3 - 5 seconds Depends on the number of inserts Max. 1700 N 0.10 mm Up to 400 C, variable

KVT Bielefeld

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KVT

Brief description The photograph shows an automatic fitting head for multiple insertion of metal threaded inserts in an all-automatic thermofitting machine operating in 3-axis mode. Two NC axes position the plastic part so that the locating bores for the inserts are located under the fitting head. The fitting head is lowered onto the plastic part by the third axis. Heating and insertion by the fitting head are then performed automatically. Suitable for thermofitting standard inserts without collar in sizes from M 4 to M 6.

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Technical data Method: Heating time: Cycle time: Insertion force: Fitting tolerance: Temperature: Technical data Method: Heating time: Cycle time: Insertion force: Fitting tolerance: Power output: Technical data Method: Heating time: Insertion force: Fitting tolerance: Temperature:

Thermal, two-phase 3 - 5 seconds Up to 20 inserts per minute Max. 1700 N 0.10 mm Up to 400 C, variable

Brief description The photograph shows an electromagnetic thermofitting machine for contactless heating of special inserts (e. g. vent valve with sealing ring). It is a special feature of this machine that the vent valve is pneumatically picked up by the upper tool and then fitted in the fuel distributor after being heated. This eliminates the need for time-consuming preassembly of the insert in the plastic part. Thermal damage to the sealing ring is prevented by controlled heating of the valve. Suitable for thermofitting special and standard inserts in sizes from M 6 to M 12. Electromagnetic, two-phase 4 - 5 seconds 8 - 10 seconds Max. 1800 N 0.05 mm Up to 1500 W

Brief description The photograph shows a fitting machine for thermal installation of metal threaded inserts in the front panelling of motocycles with the aid of individual thermofitting heads. Independent operation of the fitting heads permits controlled insertion of every single insert by adjusting the depth stop. The thermofitting process is not complete until the monitor for each fitting head signals OK. Suitable for thermofitting standard inserts in sizes from M 3 to M 6. Thermal, one-phase 4 - 5 seconds Max. 500 N 0.10 mm Up to 400 C, variable

KVT Bielefeld

KVT

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Technical data Method: Heating time: Cycle time: Fitting tolerance: Power output: Technical data Method: Welding time: Insertion force: Working frequency: Power output either: Working frequency: Power output either: Technical data Method: Welding time: Insertion force: Working frequency: Power output either:

Brief description The photograph shows a set-head machine for thermofitting metal threaded inserts with four electromagnetic single-setting heads. Heating and insertion are started simultaneously by the machine when the number of prefitted inserts in the plastic part has been established. The process is not complete until all inserts have been inserted to precisely the set depth. This is realized by means of an OK signal from an electropneumatic monitor. Suitable for thermofitting standard inserts in sizes from M 5 to M 8. Electromagnetic, one-phase 4 - 5 seconds 7 - 8 seconds 0.05 mm Up to 1500 W

Brief description Ultrasonic welding machine for installing plastic in plastic inserts or for welding thermoplastic parts. In addition to complete ultrasonic welding machines, we also supply components for integration in customized machines. UItrasonic Approx. 0.4 seconds Max. 6.5 KN 35 kHz 300 W, 400 W, 800 W, 1000 W 20 kHz 1000 W, 1500 W, 2000 W, 3000 W, 4000 W

Brief description Compact hand-operated ultrasonic welding unit for installing plastic in plastic inserts or for welding thermoplastic parts. Complete with ultrasonic generator, ultrasonic welding unit and sonotrode. Rapid replacement of the sonotrode makes this unit ideal for welding different plastic inserts in small batches. Of limited suitability for installing metal inserts. Ultrasonic Approx. 0.4 seconds Max. 200 N 35 kHz 300 W, 400 W, 800 W, 1000 W

KVT Bielefeld

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Business Unit Fastening and Assembly Technology P.O. Box 14 02 29 33622 Bielefeld Archimedesstrae 14 33649 Bielefeld Germany Telephone (+49) 5 21 / 44 82 - 03 (2 32) Telefax (+49) 5 21 / 44 82 - 3 71 Internet: www.bollhoff.com E-Mail: ihoernlein@boellhoff.de

KVT Bielefeld GmbH

Plastics and connection systems Werkering 6 33609 Bielefeld Germany Telephone (+49) 5 21 / 9 32 07 - 0 Telefax (+49) 5 21 / 9 32 07 -11 Internet: www.kvt-bielefeld.de E-Mail: kvt-bielefeld@t-online.de

KVT Bielefeld

Subject to change without notice Printed in Germany No part of this brochure may be reprinted without our explicit consent.

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