FastenersAsia January 2020

January 2020

Diary of Events 2020

FA 2/52 Industry News FA 7/57 Products FA 13/63 Manufacturing Technology

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 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 17–20 June – Korea Metal Week – trade exhibition – Seoul, South Korea Organisers : KT Fairs Fax : +82 02 784 6810 Email : master1@ktfairs.com Website : www.korea-metal.com 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 23–26 September: wire China – 

bigstockphoto.com/fortton

New year, new industry WITH a new year comes a new sector of the industry for Wire & Cable ASIA to focus on – fasteners. Fasteners ASIA is a new part of Wire & Cable ASIA 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, Fasteners ASIA will provide detailed coverage of industry news, products and manufacturing technology, as we highlight everything from machinery manufacture to the end products. This will also be expanded on at the forthcoming wire 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 EuroWire will also be launching EuroFasteners in its January issue.

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

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Fasteners ASIA – January/February 2020

Faster and cheaper with additive manufacturing ❍ “Frazer-Nash is able to produce components cost-effectively in small batch sizes”

reduction in manufacturing costs, particularly for such a difficult-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 flawless 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 five 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

used to align aircraft panels and fuselage during assembly. The component simplifies 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-effectively in small batch sizes,” explained Stuart Offer, AM sales manager at Renishaw. “In contrast to machining, no custom tooling is required, which results in improvements in speed and a

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 the world to produce a specific temporary fastening device

Graphics bigstockphoto.com/Artist Kumruen Pakom

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Industry 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 officials, 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 unified quality management for wire rods and steel wires.

❍ The team celebrates the first shipment

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 Heading Wire Indiana Inc www.nsciinc.com

Industrial Fasteners market forecast

This has resulted in price wars among manufacturers, leading to profit 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

structures etc. It then analyses the world’s main region market conditions, including the product price, profit, 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 stiff 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. Furthermore, the global market for industrial fasteners is highly matured and has been marred by a lack of product differentiation.

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-Pacific) and the main countries (United States, Germany, United Kingdom, Japan, South Korea and China). The report firstly introduces indus- trial fasteners: definitions, classifi- cations, applications and market overview; product specifications; manufacturing processes; and cost

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Industry 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 terrific, 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 efforts 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 Chesterfield, Michigan, USA. RIBE ® Verbindungstechnik offers 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 ❍ High strength aluminium bolt, screw and stud fasteners from Aluform Image: Aluform

Bufab completes HT Bendix acquisition Last year, Bufab confirmed the group’s acquisition of all out- standing 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 fittings industries. Bendix’s head office and main operations are in Herning, in Jutland, Denmark, but the company generates sales throughout Scandi- navia, the Baltics, Germany, the UK, France and Poland. “I am honoured and very happy to announce this acquisition, which is a significant 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 staff. 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 fit 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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Industry 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, elec- tronics, electrical, and furniture manufacturers. The company has acquired some big names in the industry, including Kadimi’s fasteners unit, Electronic Fasteners, and EkaEngg Technics. Paragon acquires Kuduma Fasteners

❍ A focus on precision for Paragon Fasteners

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 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

innovation and growth within the global energy and infrastructure markets.” Steven E Karol, managing partner and founder of private investment firm 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 distri- butor of high strength, large diameter industrial fastener systems. The company is headquartered in Sheffield, UK, with operations in the UK, China and North America. Beck Industries International is a manufacturer and distributor of fully certified, high-security bolting com- ponents for refineries, 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 first 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

❍ A “one-stop shop for the highest quality, mission-critical industrial fasteners” product portfolios will form an unequalled platform to serve local and international clients.” “The acquisition strengthens 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 Watermill Group, we see tremendous opportunity to accelerate

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West Port’s fastener focus helps deliver assured fire door performance ❍ Rapierstar, a supplier of window and door fasteners

good 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 fire 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 fire-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

doors actually achieving 42 minutes in testing. Our 60-minute fire 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 fire 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 finished door-sets. Paul Balfe, technical consultant at Rapierstar, said: “Any door is only as

Rapierstar’s technical support has played a key role in helping West Port to achieve high- performing fire-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 fire door manufacturers 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 offer performance in either 30-minute or 60-minute options, providing installers with a trusted fire protection solution. Andy Tyas, operations director at West Port, said: “From the outset we wanted to create fire doors that offer performance that far exceeds the ratings they are awarded, demonstrated by our 30-minute fire specialist

Graphics bigstockphoto.com/Artist Wladimir

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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. Among the priorities for 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 difficult 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

❍ 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 offers 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 offer a choice of different 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 fixing. 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, offshore and industrial applications. The British Standard BS5315:1991 is one of the most stringent standards for

❍ A range of hose clamps from Jubilee Clips

hose clips in the 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.

Jubilee Clips are claimed to have exceptional sealing properties. They are able to withstand very high tightening torques and offer a high level of corrosion resistance. Jubilee Clips www.jubileeclips.co.uk

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Products

Plastic spring technology from Lee Spring

Their non-magnetic material 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, imaging and X-ray equipment, food processing and packaging equipment, aerospace products, marine pro- ducts, electronics and electrical equip- ment, water purification systems, chemical environments, automotive interiors, pollution control systems, semi-conductors, instrumentation, com- munication devices, and cosmetics packaging equipment. Lee Spring www.leespring.com 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).

Engineers are increasingly seeing the benefits of plastic spring technology, as exemplified by Lee Spring in its LeeP range. By offering 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 equipment, aerospace and lightweight/portable instrumentation. The LeeP range combines the strength of metal springs with the attributes of high-performing engineered thermoplastics – in this case, Ultem PEI (polyetherimide) resin, which has excellent thermal stability and electrical insulation properties, while being non-contaminating. They have low flammability 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 different Ultem resins. The five increasing strengths are easily identifiable by distinct colours: red, orange, yellow, green and violet. These plastic compression springs offer high strength-to-weight ratios that optimise 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 generally compatible with many chemicals, including strong acids, weak bases, aromatics and ketones. ❍ Plastic spring technology from Lee Spring

Light-weighting solution for attaching carbon fibre and composite panels

EFC International’s BCT rivet nut is a best practice light-weighting solution for attaching carbon fibre 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 fibre panels.

❍ EFC International’s BCT rivet nuts

The patented design enables an 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

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.indexfix.com ❍ Anchor improvements from Index

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Products

Cable hangers’ evolution

– a standard Mk2 cable hanger, and a convex hanger; the latter is designed specifically for use in tunnels, where the mounting surface is often curved. Benefits of the new Mk2 cable hangers include: • Rounded corners that reduce snagging 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 benefits of Mk2 plus the removal of all sharp edges, while offering 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

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. Stephen Walton, Ellis’s technical director, said: “We’ve been success- fully 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. The first key development is that there are two versions of the new Ellis cable hanger

sell cable cleats and cable hangers, but to sell the very best,” added Mr Walton. Ellis www.ellispatents.co.uk ❍ New cable hangers, stronger and cheaper from Ellis

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 situa- tions where a floor-mounted latch is required. The sealed cover prevents the infiltration of dirt and moisture into the latch mechanism.

The threaded cover may be used with a number of Program 1000 latches, which offer square, slotted, triangular, hexagon and proprietary railway key inserts. The quarter-turn catch is installed onto the floor-mounted cover plate or access panel. The O-ring sealed cover fits over it for protection and for a neat flush appearance, and provides a safe footing for pedestrians. EMKA www.emka.com ❍ The new Program 1000 System is a new addition to EMKA’s range

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Products

EFC’s utility pole fastening solution

EFC International, a supplier 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 specification Tubular Steel Pole Transmission Line Structures SES-PD-027. The specification 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 field. Paul Musgrove, industrial and distri- bution sales manager, said: “This is a significant cost savings for pole

❍ 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.

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 fibreglass 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 floor area of 130,000m 2 in Heilbronn, Germany. The project involved the construction of an office building, meeting rooms, a reception facility, cafeteria, underground parking facilities, fitness centre, logistics facilities and outdoor parking facilities. Lidl headquarters – a Lindapter case study

Register approvals. Secondary steel sections were fixed 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 configuration. 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 standoff 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 final positions before fully tightening them. Benefits 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 configuration • HDG finish offers a low-maintenance solution • CE mark (ETA-13/0300), TÜV and Lloyd’s Register approvals Colt International www.coltinfo.co.uk

Part of the development included a requirement for a façade sun protection cladding system for the multi-storey staff car park. Main contractor Leonhard Weiss sub-contracted this building element to Colt International, a specialist cladding designer and installer. The challenge was to find a suitable

❍ Cladding panels fitted by Colt International on the new Lidl headquarters in Germany

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 specified for the end plate connection to achieve the required tensile resistance and safe working load. A hot dip galvanised (HDG) finish was also specified for the girder clamps to provide a high level of corrosion protection. The decision to use Lindapter type A girder clamps was influenced by independent technical accreditations, which include the CE mark (ETA-13/0300), TÜV and Lloyd’s

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Manufacturing Technology

Fastener management system proves a winner ❍ On the right successful track at KTM with the 450 SX-F engine

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 fluctuations in material supply. The system’s benefits convinced KTM to implement the ECOSIT system at the warehouse of its engine assembly plant in Munderfing, Austria. This warehouse features high shelves loaded with boxes and pallets of all the parts for engine assembly: spark plugs, pistons, transmission com- ponents, 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 Munderfing, producing 13 different 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 fluctuations, KTM recently switched to the ECOSIT bin system made by the Bollhoff 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 Bollhoff’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 notifies stock workers, via computer, to promptly refill the specific bin. Mr Reiter and others at KTM are very impressed with the system, citing many important benefits. First, the risk of C-parts being unavailable has essentially been eliminated, thereby cushioning seasonal demand fluctu- ations in production. In addition, delivery of replenishment parts requires no manual ordering and is considerably faster, easier and more

Manufacturing high-quality products is always serious business – even when the products are used for fun. KTM AG, for example, builds each of its off-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 manufacturer in Europe, with annual sales of more than 200,000 off-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 Artist Koloj

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Fasteners ASIA – January/February 2020

Manufacturing Technology

Wafios has a new process for hairpin production

Wafios has developed what is described as “the most flexible machine currently available on the market”, specifically for the production of bent wire hairpins. This flexible 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 filed 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 definition of hairpin geometry. Flexibility depends on the geometric programming of bending parts and/or hairpins. The Wafios controller WPS 3.2 EasyWay also allows users to import 3D geometries automatically with STEP/IGES files. 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.

The entire production planning process, including the programming of parts, simulation, definition 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 specific bending part. Wafios www.wafios.com ❍ A new process for hairpin production from Wafios

Second Aichelin furnace for fasteners

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.

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

This is the second 2,000kg/h cast link belt furnace plant supplied by Aichelin to Bulten. Thanks to the positive references at Bulten, the current project was finalised within a few months between the first request and the final negotiation. The plant line measures 80m x 10m and weighs around 180 tons; counting liquids and com- ponents, it can weigh up to 230 tons. Aichelin is delivering the electrically heated high- temperature hardening fur- nace and the protective-gas-

❍ The new furnace at Bulten

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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 efficiency, with the fully automatic spraying system and rotating drum ensuring a uniform dye coating. Though specially designed 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 identification.

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 simplifies 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 fit 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 confidence in its Spring Calculator Professional software – made by the professionals for professionals. Institute of Spring Technology www.ist.org.uk ❍ Spring Calculator Professional software from the Institute of Spring Technology

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

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Fasteners ASIA – January/February 2020

Manufacturing Technology

William Hughes – endurance testing for springs

❍ Two new compression spring fatigue testing machines from Micro Studio are in use by William Hughes 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.

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 confidence, 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 specified numbers of cycles without breaking, or until the spring breaks. When a spring does finally 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 offer spring lifecycles of tens of thousands or even tens of millions of operations without breaking,” said Ms Burgon. “With these new machines, we can back up spring theory with real-world testing, and offer the guarantees that give our customers the highest levels of confidence.” William Hughes www.wmhughes.co.uk

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 different applications are subject to different 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 differ 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 production specification that a certain component must be able to

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