EuroFasteners January 2020

Contents

Diary of Events

2020

January 2020

30 March - 3 April: wire 2020 – trade exhibition – Düsseldorf, Germany Organisers : Messe Düsseldorf GmbH Fax : +49 211 4560 668 Email : wire@messe-duesseldorf.de Website : www.wire.de

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20-24 April: MACH – trade exhibition – Birmingham, UK Organisers : MTA (Manufacturing

Technologies Association) Email : mach@mta.org.uk Website : www.machexhibition.com

2–4 June: Wire Expo – trade exhibition and conference – Uncasville, Connecticut, USA Organisers : Wire Association International Fax : +1 203 453 8384 Email : sales@wirenet.org Website : www.wirenet.org trade exhibition – Seoul, South Korea Organisers : KT Fairs Fax : +82 02 784 6810 Email : master1@ktfairs.com Website : www.korea-metal.com 23–26 September: wire China – trade exhibition – Shanghai, China Organisers : SECRI and Messe Düsseldorf (Shanghai) Co Ltd Fax : +86 216 169 8301 Email : shanghai@mdc.com.cn Website : www.wirechina.net 11–14 October: IWCS – technical symposium – Providence, Rhode Island, USA Organisers : IWCS Tel : +1 717 993 9500 Website : www.iwcs.org 17–20 June: Korea Metal Week –

bigstockphoto.com/Scanrail

New year, new industry WITH a new year comes a new sector of the industry for EuroWire to focus on – fasteners. EuroFasteners is a new part of EuroWire magazine as we aim to increase our comprehensive coverage of the wire and cable industry. With its own glossy covers to separate it from the rest of the magazine, EuroFasteners will provide detailed coverage of industry news, products and manufacturing technology, as we highlight everything from machinery manufacture to the end products. Thiswill alsobe expandedon at the forthcomingwire 2020 exhibition in Düsseldorf, Germany, where exhibitors will be appealing to distributors, wholesalers and buyers from a broad range of sectors in the fasteners industry. Sister publication Wire &Cable ASIA will also be launching Fasteners ASIA in its January issue.

Visit us online at: www.read-eurofasteners.com

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Corporate News

▲ “Frazer-Nash is able to produce components cost-e ectively in small batch sizes”

Faster and cheaper with additive manufacturing

results in improvements in speed and a reduction in manufacturing costs, particularly for such a di cult-to- machine part.” “The Kwikbolt project is a true AM success story,” said Paul Mortlock, managing director at Frazer-Nash. “Using AM means we can easily produce a bespoke component based on each aerospace customer’s requirements. Renishaw’s AM systems have been awless since we started working together. Frazer-Nash now produces 25,000 AM parts a year and has expanded its range of com- ponents. Over the last ve years, we have developed a close partnership with Renishaw, added Mr Mortlock. “We originally chose to partner with Renishaw due to its support services and we have found these to be invaluable.” Frazer-Nash Manufacturing https://frazernash.com

the world to produce a speci c temporary fastening device used to align aircraft panels and fuselage during assembly. The component simpli es the manu- facturing process and ensures that aerospace companies no longer require a bespoke tool for every panel, helping to reduce costs, improve precision and speed up assembly. To simplify the manufacturing process, Frazer-Nash now additively manu- factures the fasteners on Renishaw’s AM 400. By using AM instead of subtractive machining, the fasteners can be produced with custom geometries at comparatively lower cost. “By using AM, Frazer-Nash is able to produce components cost-e ectively in small batch sizes,” explained Stuart O er, AM sales manager at Renishaw. “In contrast to machining, no custom tooling is required, which

Since investing in a Renishaw AM 400 additive manufacturing (AM) system, Frazer-Nash has produced a unique fastener for a customer, Kwikbolt, for use during aircraft assembly. The new component can be made quicker, and at a lower cost, when compared to traditional subtractive machining methods. In 2014 Frazer-Nash decided to bring AM capabilities in-house with Renishaw’s AM 250 system. The company has since purchased the AM 400, which is currently used to produce metal parts for customers. One of Frazer-Nash’s most successful projects is for its customer Kwikbolt, which is working to revolutionise the assembly of aircraft.

Kwikbolt is one of only a few businesses in

Graphics bigstockphoto.com/Artist tereh

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January 2020

Corporate News

Joint venture company for cold heading and forging in USA

Nippon Steel & Sumitomo Metal Corporation (NSSMC) established Nippon Steel & Sumikin Cold Heading Wire Indiana Inc (NSCI), a US company manufacturing and selling steel wires for cold heading and forging, in February 2016. NSCI started its commercial production and held an opening ceremony, inviting the governor of Indiana and other related Indiana and Shelbyville o cials, the Consulate-General of Japan in Chicago, customers, shareholders, and employees’ families. The steel wire manufacturing plant is NSSMC’s third overseas plant, in addition to those established in Thailand and China. The new plant at NSCI has an annual production capacity of 36,000 tons and is capable of manufacturing steel wires with a maximum diameter of 40mm. By making use of the plant’s proximity to customers, NSSMC will meet demand from the major production plants of Japanese automobile and parts manufacturers and display strong delivery capability. Steel wires for cold heading and forging, which are produced by adding secondary processes (such as pickling, coating, wire drawing and heat treatment) to hot rolled wire rods, are mainly used for important safety-related parts such as automobile bolts. These steel wires require a very high standard in terms of internal quality and surface defects. In order to satisfy these requirements, NSSMC and NSCI are cooperating in performing strict and uni ed quality management for wire rods and steel wires.

The team celebrates the rst shipment

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Under the banner of SteeLinc, the brand name of NSSMC’s bar and wire rod unit, NSCI will contribute to enhance the value of customers’ products through proposals that optimise the combination of steel materials and secondary processes (steel materials x processing methods). The steel product portfolio includes steel for high-strength bolts (MB series and ADS series) and steel that omits processes, such as new soft wire rods and untempered steel for cold forging (NHF ® and SUC80D). Nippon Steel & Sumikin Cold HeadingWire Indiana Inc www.nsciinc.com

Industrial Fasteners market forecast

lack of product di erentiation. This has resulted in price wars among manufacturers, leading to pro t crunching. A focus on product enhancement is the key strategy for manufacturers. The report includes six parts, dealing with: 1) Basic information 2) Asian industrial fasteners market 3) North American industrial fasteners market 4) European industrial fasteners market 5) Market entry and investment feasibility 6) Report conclusion A report sample is available at: https:// www.credenceresearch.com/sample- request/58059 Credence Research www.credenceresearch.com

It then analyses the world’s main region market conditions, including the product price, pro t, capacity, production, supply, demand, and market growth rate and forecast etc. Finally, the report introduces new project SWOT analysis, investment feasibility analysis and investment return analysis. The global industrial fasteners market is fragmented by sti competition, with several small and large players competing to maintain their market share. In developed economies, market consolidation is a major trend as small companies are merging operations with established players to leverage their resources. market for industrial fasteners is highly matured and has been marred by a Furthermore, the global

The global industrial fasteners market is expected to expand at a compound annual growth rate of 5.3 per cent during the forecast period 2016 to 2023. A new report from Credence Research expects the market to be worth $107 billion by 2023. “Industrial Fasteners – global market size, analysis, share, trends, growth and forecast to 2026” is an in-depth research report on the world’s major regional market conditions, focusing on the main regions (North America, Europe and Asia-Paci c) and the main countries (United States, Germany, United Kingdom, Japan, South Korea and China). The report rstly introduces indus- trial fasteners: de nitions, classi - cations, applications and market overview; product speci cations; manufacturing processes; and cost structures etc.

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Corporate News

Formation of Aluform USA Duncan MacLean, president and CEO of MacLean-Fogg, has announced the joint venture formation of Aluform USA between Richard Bergner Verbindungstechnik GmbH & Co KG (RIBE) of Schwabach, Germany, and MacLean-Fogg Component Solutions (MFCS) of Mundelein, Illinois, USA. The RIBE-Aluform ® product is claimed to be a market leader in the automotive industry for high strength aluminium bolt, screw and stud fasteners for lightweight, corrosion-sensitive automotive applications. Aluform USA combines the strengths of RIBE ® and MFCS to bring the Aluform product line to the North American marketplace. Mr MacLean said, “RIBE is a terri c, innovative fastener company. The RIBE-Aluform product line sets the global standard for high strength automotive aluminium fasteners, and vehicle lightweighting will continue to be a major industry trend as OEMs work to improve fuel economy and battery range. We’re excited to further help our North American customers in their lightweight e orts by including Aluform high strength aluminium bolts in our range of fastener solutions.” Frank Bergner, managing partner of RIBE, said: “MacLean-Fogg has been well-known for 94 years as a leader in innovative fasteners and high quality manufacturing. MacLean-Fogg’s excellent manufacturing capabilities, application engineering and high customer service makes them an ideal partner to support and grow Aluform in North America.” Aluform USA LLC will be headquartered within the existing MacLean Maynard division of MFCS in Chester eld, Michigan, USA. RIBE ® Verbindungstechnik o ers lightweight construction, new materials and material combination solutions with secure, comprehensive systems integrated into the fastening element itself or as an automated fastening system. RIBE ® interlinks product development and engineering to ensure rational, sustainable production for the entire product portfolio. RIBE’s range includes high-strength aluminium screws, RIBE–Aluform, RIFIXX ® functional modules, maximum strength steel screws, complete sheet metal joining systems including RIFAST ® , and an extensive selection of special cold-formed parts. Aluform USA www.macleanfoggcs.com

Bufab completes HT Bendix acquisition Last year, Bufab con rmed the group’s acquisition of all outstanding shares in HT Bendix A/S. The plan was originally announced in June 2019. Bendix has annual sales of approximately SEK 500 million (DKK 345 million) and an operating margin of approximately ten per cent.

HT Bendix A/S was founded in 1975 and is a leading C parts supply chain partner in the Nordics with a strong expertise in the furniture and ttings industries. Bendix’s head o ce and main operations are in Herning, in Jutland, Denmark, but the company generates sales throughout Scandinavia, the Baltics, Germany, the UK, France and Poland. “I am honoured and very happy to announce this acquisition, which is a signi cant and attractive add-on to our existing businesses in the Nordics, and which presents attractive growth synergies for both companies,” said Jörgen Rosengren, Bufab’s president and CEO. Johan Lindqvist, who manages Bufab’s Segment Sweden added: “HT Bendix A/S is well known in the industry for its high product and service quality, solution-oriented approach, and skilled sta . We wish the HT Bendix A/S team a very warm welcome into the Bufab Group,” “In the past years, Bufab has become known as a leader in the C parts industry globally. We have looked for a global player with the strength to help us bring HT Bendix A/S to a new level. And we have searched for a company with a mindset and culture that t HT Bendix A/S. We are convinced that Bufab is the ideal partner to continuous successful growth,” commented Kaj Østergaard, MD and spokesman for the owners of HT Bendix A/S. Bufab Group www.bufab.com HT Bendix is well known in the industry for its product and service quality

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▼ High strength aluminium bolt, screw and stud fasteners from Aluform

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Corporate News

India-based manufacturer of precision fasteners Paragon Fasteners has acquired Kuduma Fasteners Pvt Ltd, a manufacturer of high tensile fasteners and cold-headed components for automobile and industrial applications. Kuduma Fasteners is a tier 1 vendor to many southern India-based automotive producers, and has operated in the fastener industry for over 30 years. The company has an in-house continuous furnace and a wire processing facility with a total installed capacity of 300 tonnes per month. Almost all of Kuduma’s machinery is Taiwanese: multi-station bolt formers ranging from M4 to M16, up to 250mm long (up to M8), it makes for an ideal facility for fastener production. Established in 1996 with a small capacity for making precision fasteners, Paragon Fasteners today boasts a large capacity and range to produce precision fasteners in both ferrous and non-ferrous metals, catering to major OEMs of automobiles, machine manufacturers, electronics, electrical, and furniture manufacturers. The company has acquired some big names in the industry, including Kadimi’s fasteners unit, Electronic Fasteners, and EkaEngg Technics. Described by Dilip Sheth, CEO of Paragon Fasteners, as the realisation of a “long standing dream”, the acquisition of Kuduma is also Paragon’s biggest. With this acquisition, Paragon believes it will have the largest range of standard Paragon acquires Kuduma Fasteners

A focus on precision for Paragon Fasteners

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and custom-made import substitute cold forged fasteners, supported by in-house heat treatment and wire drawing units. Paragon Fasteners www.paragonfastener.com

Cooper & Turner acquires Beck Industries

the Watermill Group, we see tremendous opportunity to accelerate innovation and growth within the global energy and infrastructure markets.” Steven E Karol, managing partner and founder of private investment rm Watermill, commented: “This is an ideal time for these companies to come together. Both are thriving and well positioned in their respective markets. We are looking forward to supporting the combined management team in capitalising on the inherent opportunities.” Founded in the 1800s by Joseph and James Turner as a gun barrel manufacturer, Cooper & Turner is a UK-based manufacturer and distributor of high strength, large diameter industrial fastener systems. The company is headquartered in She eld, UK, with operations in the UK, China and North America. Beck Industries International is a manufacturer and distributor of fully certi ed, high-security bolting com- ponents for re neries, power gener- ation, subsea oil and gas and the nuclear power end markets. Cooper & Turner Ltd www.cooperandturner.co.uk

Andaray (Holdings) Ltd and its subsidiary Cooper & Turner have acquired Beck Industries, a manufacturer and distributor of high security bolting components. The combined company aims to be the rst truly global manufacturer of safety-critical fastening applications, supporting a range of industries that includes renewable energy, power generation, nuclear, construction and heavy equipment. Established in France more than 100 years ago, Beck is now a global organisation with capabilities that complement and expand those of Cooper & Turner. As one entity, the company’s services span all key production processes, including hot and cold forming, heat treatment, CNC machining, thread rolling, robotics and automation. “We are excited to join the Cooper & Turner family,” said Hugues Charbonnier, former Beck president. Mr Charbonnier and his wife, Karine, will both remain on the management team as executive vice presidents of Cooper & Turner. “Our complementary technologies, facilities, services and product portfolios will form an unequalled platform to serve local and international clients.”

▲ A “one-stop shop for the highest quality, mission-critical industrial fasteners” our position as a seamless, one-stop shop for the highest quality, mission-critical industrial fasteners,” said Tony Brown, group CEO and president, Cooper & Turner. “Supported by our partners at “The acquisition strengthens

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Products

▲ Rapierstar, a supplier of window and door fasteners

West Port’s fastener focus helps deliver assured re door performance

as its weakest components, and all too often that turns out to be the fasteners as a result of choosing the wrong type of screws for the application or sourcing poor quality screws. With re doors, it goes without saying that weak points simply must not exist, given that their role is to protect lives and assets. That’s why it’s vitally important that fastener choice is given the same attention and scrutiny as the glass type, the insulating qualities of the door slab and the intumescent seals. “A re-rated door-set is tested as a complete system, so there is absolutely no scope to substitute the components at a later stage, no matter how small. We can help eliminate the risk of fasteners being substituted through a process of regular reviews and monitoring to provide assurance to end-customers.” Rapierstar www.rapierstar.com

re doors actually achieving 42 minutes in testing. Our 60-minute re door is another really important development which, like our FD30 option, is built using only technically superior components.” Rapierstar, whose collective technical expertise in fastener design, manufacture and application totals more than 100 years, has provided West Port with detailed guidance on which fasteners to use throughout the door-sets’ construction in order to achieve the 30 and 60 minute re ratings. In addition to input at the design stage, this includes training to ensure fabricators use fasteners correctly, and regular auditing of the factory to maintain consistency in the quality and promised protection level in nished door-sets. Paul Balfe, technical consultant at Rapierstar, said: “Any door is only as good

Rapierstar’s specialist technical support has played a key role in helping West Port to achieve high-performing re-rated door-sets, by eliminating the risk of failure during testing as a result of the incorrect choice and application of fasteners. Rapierstar, which is a UK supplier of window and door fasteners, is recommending that re door manu- facturers follow West Port’s lead and not overlook the major role that these smallest of components play in a door-set’s structural integrity, durability and long-term quality. West Port door-sets o er performance in either 30-minute or 60-minute options, providing installers with a trusted re protection solution. Andy Tyas, operations director at West Port, said: “From the outset we wanted to create re doors that o er performance that far exceeds the ratings they are awarded, demonstrated by our 30-minute

Graphics bigstockphoto.com/Artistnd 3000

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Products

Rawlplug products in space

Rawlplug DIN 7984 screws were used to build the NASA Mars Curiosity rover which, as part of the Mars Science Laboratory programme, performs research on the former and current environment on the Red planet. Curiosity is the largest and most technologically advanced vehicle so far sent to Mars by NASA. Due to the extreme conditions to be faced by the Curiosity vehicle, only elements capable of meeting the highest demands in terms of resistance to external factors were selected during the design process. the development of the project was weight reduction which, given that the surface of Mars ranges in temperature between -127º and +40º Celsius, was a di cult task. The vehicle demanded solid construction and strength. Curiosity’s mission in the Mars crater was originally planned to last 687 days but, given the robust elements and construction of the vehicle, the period has been extended. Rawlplug www.rawlplug.co.uk Among the priorities for

▲ Rawlplug DIN 7984 screws are in use on NASA’s Mars Curiosity

Jubilee Clips – British made, world class

The worm drive hose clip was invented almost 100 years ago by Commander Lumley Robinson. The company he founded, Jubilee ® Clips, still produces hose clamps in its factory in Gillingham, Kent, UK. Jubilee Clips o ers a full range of hose clips, including the Original Range worm drive hose clips for a wide range of applications. High Torque clips and Superclamps o er a choice of di erent types of clamp for high pressure and heavy duty applications, while the all-new Flexiband band and buckle clamping system can be used in tamper-proof applications such as sign xing. Multiband cut-to-length banding and Quick-release straps are a solution for ventilation and ducting applications, and the company also produces Light Range and Wingspade worm drive clips, P-clips, O-clips and nut-and-bolt fuel line clips.

Downtime resulting from failure of a hose clip can be extremely costly. This is why some of the world’s leading manufacturers specify Jubilee Clips for use on their assembly lines. Jubilee Clips’ Original Range and High Torque worm drive hose clips in stainless steel are approved by Lloyd’s Register for use in marine, o shore and industrial applications. The British Standard BS5315:1991 is one of the most stringent standards for hose clips in the

A range of hose clamps from Jubilee Clips

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Jubilee Clips are claimed to have excep- tional sealing properties, able to withstand very high tightening torques and o er a high level of corrosion resistance. Jubilee Clips www.jubileeclips.co.uk

world. By adhering to this standard and being awarded the Kitemark by the British Standards Institute for its Original Range of worm drive hose clips, Jubilee Clips demonstrates dedication to producing hose clamps of the highest quality.

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Products

Plastic spring technology from Lee Spring

Engineers are increasingly seeing the bene ts of plastic spring technology, as exempli ed by Lee Spring in its LeeP range. By o ering non-magnetic, non-corrosive and chemically inert properties in a lightweight package, LeeP springs are described as often a complete solution for applications in areas of medical device manufacturing, pharmaceutical equip- ment, aerospace and lightweight/ portable instrumentation. The LeeP range combines the strength of metal springs with the attributes of high-performing engineered thermo- plastics – in this case, Ultem PEI (polyetherimide) resin, which has excellent thermal stability and electrical insulation properties, while being non-contaminating. They have low ammability and are recyclable in compliance with global regulations, including RoHS and REACH. LeeP plastic composite springs are stocked in a variety of standard sizes, each available in a range of strengths formulated from di erent Ultem resins. The ve increasing strengths are easily

identi able by distinct colours: red, orange, yellow, green and violet. These plastic compression springs o er high strength- to-weight ratios that opti- mise performance, while reducing mass; they are said to have excellent stability of physical and mechanical properties at elevated temperatures up to 170°C; high corrosion resistance; and are gener- ally compatible with many chemicals, including strong acids, weak bases, aromatics and ketones.

Plastic spring technology from Lee Spring

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Their does not interfere with imaging and other ferro-sensitive technologies and, being of a dielectric insulating material, they are suitable for non-conductive applications. Being inert and non-contaminating, the plastic composite protects the purity of products they come in contact with. Other applications include medical products and processing equip- ment, pharmaceutical delivery devices, non-magnetic material

Index makes anchor improvements Index Fixing Systems has improved and extended its range of structural MTH anchors, with the introduction of a new MTH-A2 anchor. Improvements in the design mean that load performance is increased by 40 per cent in all three versions (zinc, A2 stainless steel and A4 stainless steel). interiors, pollution control systems, semi-conductors, instrumentation, com- munication devices, and cosmetics packaging equipment. Lee Spring www.leespring.com imaging and X-ray equipment, food processing and packaging equipment, aerospace products, marine products, electronics and electrical equip- ment, water puri cation systems, chemical environments, automotive

Light-weighting solution for attaching carbon bre and composite panels

EFC BCT rivet nut is a best practice light-weighting solution for attaching carbon bre and composite panels in automotive applications. The rivet nuts are manu- factured by BBA with BCT ® (bulge control technology). BCT rivet nuts are ultra-high strength and engineered to prevent cracking or de-lamination of carbon bre panels. The patented design enables an International’s

EFC International’s BCT rivet nuts

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engineered yield point on the body of the rivet nut, ensuring the bulge formation always begins beyond the panel and is drawn back on the panel. BCT rivet nuts can be placed near the edge of the panel without risk of inducing a crack in the panel. The installation process of BCT rivet nuts can be fully process-monitored and controlled, and they can be installed into areas with limited rear side clearance. For example, an M6 rivet nut needs only 8mm of rear side clearance prior to installation and only 5mm after installation. This is suitable for use in thinner versions of sandwich (composite) materials, avoiding the need for a through hole. The bulge of the BCT product is strong enough to form by pushing away any material in the sandwich material. In addition, by producing BCT rivet nuts from aluminium for use in aluminium and magnesium, weight is said to be “dramatically reduced”. EFC International www.efc-intl.com

Anchor improvements from Index

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The MTH range is designed for use in concrete, reinforced concrete and stone. Installation distances to the edge of the material, and between anchors, can be calculated using INDEXcal software. Index Fixing Systems www.index x.com

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January 2020

Products

Cable hangers’ evolution

hanger, and a convex hanger; the latter is designed speci cally for use in tunnels, where the mounting surface is often curved. Bene ts of the new Mk2 cable hangers include: • Rounded corners that reduce snagg- ing points • Spin galvanised (55µm or 150µm thickness) to protect against erosion • Only 6mm thick, leading to reduced product and shipping costs • Wide range of sizes available • Suitable for cables up to 100mm diameter • Custom designs available • Rolled designs for tunnels available Meanwhile, the convex cable hanger has all the bene ts of Mk2 plus the removal of all sharp edges, while o ering the same strength as the Mk2, but being only 5mm thick. “To take a product that to all intents and purposes was a commodity product, and redesign it in a manner that makes it not only better, but also cheaper and stronger than anything else on the market, goes to show the commitment we have at Ellis to not just sell cable cleats and cable hangers, but to sell the very best,” added Mr Walton.

Cable cleat manufacturer Ellis has shown that innovation does not have to be restricted to new product development, having enhanced a product that has been amongst its best-sellers for over 20 years. Ellis’s technical team has taken the company’s cable hangers, which are used primarily in the rail industry, and made them stronger and cheaper. technical director, said: “We’ve been successfully manufacturing and selling our cable hangers for two decades, and it’s fair to say that the design is tried, tested and completely trusted by all those who use it. But with the market for cable hangers growing, and the number of extremely similar products also expanding, it was felt we needed to improve on the design in order to capitalise on new opportunities, while at the same time protecting our current customer base.” Ellis achieved this by looking at every aspect of the product and exploring ways to improve on it. rst key development is that there are two versions of the new Ellis cable hanger – a standard Mk2 cable Stephen Walton, Ellis’s The

▲ New cable hangers, stronger and cheaper from Ellis

Ellis www.ellispatents.co.uk

Quarter-turn catches in stainless steel

The EMKA range of stainless steel quarter-turn catches now includes the new Program 1000 System incorporating a sealed cover. This is thought to be especially valuable for railway appli- cations, and for other situations where a oor-mounted latch is required. The sealed cover prevents the in ltration of dirt and moisture into the latch mechanism. The threaded cover may be used with a number of Program 1000 latches, which o er square, slotted, triangular, hexagon and proprietary railway key inserts.

▲ The new Program 1000 System is a new addition to EMKA’s range

The is installed onto the oor-mounted cover plate or access panel. The O-ring sealed cover ts over it for protection and for a neat ush appearance, and provides a safe footing for pedestrians. EMKA www.emka.com quarter-turn catch

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Products

EFC’s utility pole fastening solution

EFC of engineered fasteners, has announced the approval of Sherex Fastening Solutions’ Large Size rivet nuts for use in steel utility poles by a leading energy company. The approval is in accordance with the speci cation Tubular Steel Pole Transmission Line Structures SES-PD- 027. The speci cation covers the minimum requirements for the design, drawings, material, fabrication, welding, coating, inspection and delivery of tubular steel pole structures. Sherex Large Size rivet nuts eliminate the welding process and reduce the number of components for installation. They also allow for a safer, one-handed installation of the step bolts in the eld. Paul Musgrove, industrial and distri- bution sales manager, said: “This is a International, a supplier

▲ Large Size rivet nuts for use in steel utility poles from EFC

out resistance for pole structures. It is thought the rivet nut will serve other industries including automotive, truck, agriculture, heavy equipment, rail and HVAC.

signi cant cost savings for pole and tower manufacturers and we are excited to bring this product to the market.” The new rivet nuts exceed application performance and safety requirements, including maximum retention in breglass material and increased spin

EFC International www.efc-intl.com

German discount supermarket chain Lidl has built its new headquarters on a 4.6ha area with a gross oor area of 130,000m 2 in Heilbronn, Germany. The project involved the construction of an o ce building, meeting rooms, a reception facility, cafeteria, underground parking facilities, tness centre, logistics facilities and outdoor parking facilities. Lidl headquarters – a Lindapter case study

A hot dip galvanised (HDG) nish was also speci ed for the girder clamps to provide a high level of corrosion protection. The decision to use Lindapter type A girder clamps was in uenced by independent technical accreditations, which include the CE mark (ETA-13/0300), TÜV and Lloyd’s Register approvals. Secondary steel sections were xed onto the existing concrete façade in preparation for the T-shaped brackets to be installed. The brackets were connected to the steel sections using Lindapter type A girder clamps through the end plates in a four-bolt con guration. Installation was quick and easy as each bolt is simply inserted into the pre-drilled holes with the type A on one end and the nut on the other. The recessed top of the clamp holds the bolt captive while the nut is tightened with a torque wrench to the recommended tightening torque. This arrangement provided the necessary stando distance from the original structure and allowed the large cladding panels to be attached to the other end of the T-shaped brackets to complete the installation. Lindapter type A girder clamps provided a drilling- and weld- free connection on-site that was quick and easy to install. The clamps are fully adjustable, which gave the contractor the ability during installation to manoeuvre the brackets into their nal positions before fully tightening them. Bene ts of the type A: • Recessed top holds the bolt captive while the nut is tightened • Fully adjustable on-site to provide an easy installation • Supports up to 78.8kN tensile in four-bolt con guration • HDG nish o ers a low-maintenance solution • CE mark (ETA-13/0300), TÜV and Lloyd’s Register approvals

Part of the development included a requirement for a façade sun protection cladding system for the multi-storey sta car park. Main contractor Leonhard Weiss sub-contracted this building element to Colt International, a specialist cladding designer and installer. The challenge was to nd a suitable method of connecting the cladding system to the steel structure on the car park, and one that was easy to install. The engineers at Colt International designed a T-shaped steel bracket with an end plate incorporating four pre-drilled holes. Lindapter type A girder clamps with M12 bolts were speci ed for the end plate connection to achieve the required tensile resistance and safe working load. ▲ Cladding panels tted by Colt International on the new Lidl headquarters in Germany

Colt International www.coltinfo.co.uk

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Manufacturing Technology

▲ On the right successful track at KTMwith the 450 SX-F engine

Fastener management system proves a winner Manufacturing high-quality products

and more reliable than before. Empty bins are often replaced within one day. According to Mr Reiter, the ECOSIT system also reduces the need for excessive inventory, and improves inventory security and tidiness. Bettina Schober, purchasing manager at KTM, says that, despite reducing inventory values, the RFID-based system enables the company to always stay on top of demand uctuations in material supply. The system’s bene ts convinced KTM to implement the ECOSIT system at the warehouse of its engine assembly plant in Munder ng, Austria. This warehouse features high shelves loaded with boxes and pallets of all the parts for engine assembly: spark plugs, pistons, transmission components, cylinder studs, clutch springs and electric starters. An SX-F engine, for example, consists of 389 parts and 78 screws. Nearly 200 people work at Munder ng, producing 13 di erent types of engine. Daily production volume is 300 to 400 units, including two-stroke, four-stroke, single- and twin-cylinder models. KTM Group www.ktmgroup.com

resulted in empty parts bins and production delays during the busy season. To help workers respond better to seasonal uctuations, KTM recently switched to the ECOSIT bin system made by the Bollho Group. This system consists of an RFID antenna, RFID tags on bin labels and enterprise resource planning (ERP) software. KTM kept its bin shelves, and with Bollho ’s help, installed and commissioned the system in only one day. During production, workers take parts from each bin as needed. Once a bin is empty, it is placed in a collection box next to the shelf, and data is automatically transmitted from the bin’s RFID tag to the ERP software. This process takes only a few seconds and immediately noti es stock workers, via computer, to promptly re ll the speci c bin. Mr Reiter and others at KTM are very impressed with the system, citing many important bene ts. First, the risk of C-parts being unavailable has essentially been eliminated, thereby cushioning seasonal demand uctuations in production. In addition, delivery of replenishment parts requires no manual ordering and is considerably faster, easier

is always serious business – even when the products are used for fun. KTM AG, for example, builds each of its o -road motorcycles with top-notch and thoroughly tested parts so that each model is “ready to race”. Riders of the motorcycles appreciate this level of commitment, and have driven KTM bikes to win more than 200 world championship titles over the past 27 years. KTM is the largest motorcycle manu- facturer in Europe, with annual sales of more than 200,000 o -road motorcycles worldwide. The company also makes a wide variety of street bikes and two-seater sports cars. KTM’s growth has brought with it some production challenges at its non-engine plant in Mattighofen, Austria. A major one, according to Christian Reiter, materials group manager at KTM, is the need for workers to better manage their use of fasteners and connecting components (ie, C-parts) during the busy spring season. Monitoring and re-ordering of C-parts was done manually for many years. Unfortunately, this approach often

Graphics bigstockphoto.com ArtistYoura_P

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Manufacturing Technology

Wa os has a new process for hairpin production

Wa os has developed what is described as “the most exible machine currently available on the market”, speci cally for the production of bent wire hairpins. This exible new process means that the majority of hairpin geometries for a stator, including the connection assemblies required, can be manufactured in any sequence without the need to change tools. A patent application has been led for the new process that enables bending work to be accurate, and free of physical damage. The measurement and feedback control algorithms employed ensure that the machine is able to monitor and control itself during production operations. Geometric programming dispenses with the need for the user to program individual CNC axes, and speeds the de nition of hairpin geometry. Flexibility depends on the geometric programming of bending parts and/or hairpins. The Wa os controller WPS 3.2 EasyWay also allows users to import 3D geometries automatically with STEP/IGES les. After the coordinates have been imported, the requisite bending program can be produced automatically. There is also the option of integrating and using the simulation tool to run through the complete production sequence of the bending component. The entire process is simulated using a digital twin, including machines, tools and workpieces to create a dependable collision check in advance.

A new process for hairpin production fromWa os

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The entire production planning process, including the programming of parts, simulation, de nition of cycle time and the collision check, can be performed in a parallel manner at an external programming station. In addition, simulation is used to establish the optimum tool arrangement for the speci c bending part. Wa os www.wa os.com

Second Aichelin furnace for fasteners

tective-gas-tight tempering furnace with oil or emulsion hardening baths. Measuring and switching systems are included, along with the process control system FOCOS 4.0 for the new plant (as well as an update of the data acquisition of the existing plant) and a protective gas generator. As with the previous order, the customer provides the loading and unloading device and the component washing machines under their own direction. Aichelin GesmbH, with head-quarters in Mödling near Vienna, is a leading European company for high-quality industrial plants and systems for thermal and thermo-chemical heat treatment of metallic components. Bulten AB www.bulten.com Aichelin Group www.aichelin.com

At 80m length, the furnace plant has a performance of two tons per hour. It is the second industrial furnace plant for the Swedish Hallstahammar site. This is the second 2,000kg/h cast link belt furnace plant supplied by Aichelin to Bulten. Thanks to the positive

Swedish fastener manufacturer Bulten commissioned the Austrian heat treatment specialist Aichelin with the production of a cast link belt furnace for the re nement of high-strength steel screws and nuts.

The new furnace at Bulten

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references at Bulten, the current project was nalised within a few months between the rst request and the nal negotiation. The plant line measures 80m x 10m and weighs around 180 tons; counting liquids and components, it can weigh up to 230 tons. Aichelin is delivering the electrically heated high- temperature hardening furnace and the pro-

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January 2020

Manufacturing Technology

Spring calculator for professionals

WTI invests in dyeing technology WTI prides itself on adapting to new trends and developments within the fastenings market, and has invested in a new machine to keep up with the increasing demand for dyed inserts. The Rotamat R60 is an innovative coating system that allows the company to colour its inserts with optimum control and e ciency, with the fully automatic spraying system and rotating drum ensuring a uniform dye coating. to colour small components, the easily exchangeable drum sizes enable WTI to colour a variety of insert sizes in a range of quantities, meaning it can quickly adapt to customer needs. The process is further streamlined due to the Rotamat’s sensitive IR sensors, which carefully monitor and adjust the temperature of heated inserts to allow them to dry during the colouring process. This removes the need for further treatment, so WTI can despatch dyed inserts faster than before. With repeatable, visually homo- geneous results, the new machine enables WTI to provide dyed inserts to high quality standards in low lead times, allowing WTI to meet the increasing industrial demand for coloured inserts as a means of identi cation. Though specially designed

▲ Spring Calculator Professional software from the Institute of Spring Technology

Integral to the Institute of Spring Technology (IST) is the design, production, consultation and accreditation process within the spring industry. To assist this, IST has developed software, Spring Calculator Professional (or SCP for short), that facilitates and simpli es the creation of even the most challenging spring designs. SCP has continued to evolve since its creation in 1988, and is widely recognised by industry professionals. The software allows designers to create designs and validation work throughout the whole of the project, for a range of spring types. Spring Calculator Professional is user-friendly software that allows spring characteristics to be evaluated. The user can make changes to materials, design standards and spring parameters, which are quickly and automatically assessed. The designer gets a clear overview of a spring that is t for purpose with the assurance of correct design. Using the software aids the entire design process, saves time and reduces human errors. The life of the designed spring at various operating positions can be predicted using fatigue and relaxation data based on the Institute of Spring Technology’s own research, drawn from many years of experience and testing. Other key features included in the SCP software are that it provides Goodman diagrams, load/length, and other graphical tools to help evaluate the design. In addition, there are options to allow a design to be optimised to fit in with “real-world constraints” such as limited space for the spring when it is integrated into equipment. Graphical and test-based data are available, including engineering drawings. Spring design drawing documentation can be customised with a company name and logo, which adds to the professionalism of design projects. Choosing to use SCP design software can ensure that the spring is designed with the exact and correct tolerances, therefore preventing unnecessary failures. The Institute of Spring Technology has complete con dence in its Spring Calculator Professional software – made by the professionals for professionals. Institute of Spring Technology www.ist.org.uk

WTIhasanewmachine fordyed inserts

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Red dyed inserts are currently the most popularly requested colouring option, particularly for screw locking inserts, though the company also o ers blue dyed inserts and green dyed inserts upon request. WTI www.wti-fasteners.co.uk

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January 2020

Manufacturing Technology

William Hughes – endurance testing for springs

▲ Two new compression spring fatigue testing machines fromMicro Studio are in use by William Hughes

production speci cation that a certain component must be able to achieve a given number of operations,” explained Ms Burgon. “If a main assembly has to meet, say, 20,000 cycles, then all of the components within that assembly must be able to meet that cycle requirement, under stress conditions, even if they’re not involved in all actions. Knowing that a particular spring will not fail during those 20,000 operations gives the customer con dence, and means he can in turn guarantee the safety of the whole assembly.” With two machines, William Hughes can test up to 24 springs simultaneously, with the machines ensuring accurate strain tests of compression springs, even at the highest speeds. The equipment gives William Hughes the capability to test springs up to a load of 30kN as standard, and the machines can be equipped to test springs up to a load of 40kN. The company can fatigue springs to speci ed numbers of cycles without breaking, or until the spring breaks. When a spring does nally break, the machines record the number of cycles achieved at that point. “It’s not unusual for us to be asked to produce springs that will o er spring lifecycles of tens of thousands or even tens of millions of operations without breaking,” said Ms Burgon. Ms Burgon added “With these new machines, we can back up spring theory with real-world testing, and o er the guarantees that give our customers the highest levels of con dence.” William Hughes www.wmhughes.co.uk

William Hughes has increased its component endurance testing capabilities with the acquisition of two new compression spring fatigue testing machines from Italian test equipment specialist Micro Studio. With the investment in these new machines William Hughes can test fatigue on compression, tension and some torsion springs. There are also facilities for endurance testing of torsion bars and seat mats. This enables the company to guarantee its springs will meet customer requirements for a minimum number of cycles without breaking. Springs in di erent applications are subject to di erent levels of usage – from modest usage in an automotive seat mechanism to much more demanding duties in typical aeronautical applications – and it can be important to have data for spring fatigue in these real-world tasks. “Fatigue is not just a body function for athletes,” says William Hughes technical director Emma Burgon. “Any component working in a dynamic application is prone to fatigue. We can – and do – model theoretical lifespan, and that’s useful information, but practice can di er from theory so the only way to guarantee lifespan is to test in real life.” The new machines enable William Hughes to test large numbers of cycles on compression springs very quickly, establishing the minimum number of operations a component or assembly can achieve.

“More and more customers are demanding within their

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January 2020

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