Technical Tutorial

Low cost automation

Screws
[1] Various screw application issues in automation design
Screws (fasteners) are the most universal machine components absolutely needed for construction of any machinery. They are, therefore, classified into JIS, ISO, and other industrial standards according to shape, size, and strength (strength classifications). In actual automation design and build practices, however, shortcuts such as selecting fasteners by experience based intuition, as well as careless use of then-in-stock variety of fasteners are often seen. In this article, well discuss the key points of screws, bolts, and nuts as well as the basic theory that makes up the foundations of fasteners.

A screw (Stainless-steel Socket Head Cap Screw)

(1) Application issues related to screws during the design stage

In automation design and construction, most of automated machinery and production jigs are fastened together by screws, nuts and bolts. The fastener design, therefore, will have the following influences. Items affected by fastener design
Affected items Part machining cost Part assembly cost Machine appearance Operational reliability Functionality assurance Maintainability Examples of design methods Standardization, Easy to machine layout design Easy to assemble design, Standardization Sophisticated design that shows no wastefulness Strength, rigidity, fastening reliability, reliability over time Assuring and maintaining the machine precision Ease in disassembly and repair (layout / direction)

(2) Screw issues during and after automation assembly

The screw issues during and after automation assembly can be categorized into the following two cases.

(a) Problems that occur when assembling / tightening --- Mistakes during design phase. EXAMPLES 1. Lack of proper bolts in stock for given counterbore dimensions and threaded hole depths. 2. Threaded holes and bolts are not aligned. 3. Thread damage during tightening. 4. Distortion of parts due to tightening force. (b) Problems occurring over time (post production) --- Part strength design mistakes during design. EXAMPLES 1. Screws becoming loose and the parts are no longer properly aligned Equipment damage. 2. Destruction of bolts. Both a) and b) above are typically caused by LCA designers engineering mistakes.

The fastener design must not be overlooked for streamlined automation designs that are functional and cost effective.

[2] Dangers in irrational use of double nuts

Double nut method is a reliable way to prevent screws from selfloosening. There are, however, some important application key points that need to be well understood. Fig. 1 and Fig. 2 show the representative methods and rules of double nut applications. If these rules are ignored, proper double nut effect will not be obtained, though the arrangement may seem to be reliable. [Fig. 1] Tightening procedure of a double nut arrangement
Contact force is on top facing thread faces of the nut Contact force is on top facing thread faces of the nut High tightening force is on top facing thread faces of the nut

Basics of double nut methods for prevention of screw loosening

1. Effective when the screws become loose due to vibration induced screw rotation. 2. Not effective for loosening due to elongation of bolts body caused by the material the bolts. Non-rotation type of loosening.
Step 1

Zero tightening force on the lower nut

Low tightening force on down-facing thread faces of the bottom nut. Step 3

Step 2

Tighten the lower nut

Tighten the top nut

Hold the top nut still Reverse rotate and tighten the lower nut

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3. Exact procedures must be followed when tightening double nut arrangements. (See Fig. 1) 4. The top nut determines the strength of a double nut arrangement (in principle), so the thickness of two nuts matters greatly. (See Fig. 2)

[Fig. 2] Nut thickness rules in double nut arrangement

The top nut determines the strength against bolts tortional force A double nut arrangement will give in to tortional force if the top nut is too thin

Make both nuts equal in thickness, or the top nut thicker than the bottom nut Important to properly manage the top nut tightening torque

[3] Drawing basics for multiple screw holes and threaded holes
Many tapped holes are made on parts such as machine bases and cover frames. If careful design considerations are not given to the tapped hole placements, the results may lead to problems such as positioning/alignment errors and excessive machining time. Therefore, the bolt placement layout is not to be taken lightly, as a designers technical ability can be measured by how the design was developed.

Case 1: Through hole and tapped hole design in round objects

If reading error of the drawing is not anticipated, the hole placement layout can be represented with the first hole and the last hole (one pitch pair) in actual hole drawings, and the rest may be drawn as radial hole pitch lines and pitch circle diameter line [Fig. 1]. The hole property and the number of places to be machined are shown with a leader line extending from the hole location, written as: number of holes followed by a dash (hyphen) and the hole dimensions and/or screw size [Fig1]. Design basics for screw holes in round objects * Equally divided pitch placement * Placed on a common pitch circle diameter

Case 2: Screw hole design for rectangular covers

When drawing multiple holes on a common center line, intersecting pitch lines on the center line can be omitted if all the cross points are clearly understandable by the first dimensioning entry. In such cases, the quantity of repeated holes must be clearly indicated within the dimension text, or as a notation entry [Fig. 2]. a) of Fig. 2, the end hole location is at a intersecting point of center lines of two sides of the rectangle. This makes the hole positioning a single easy task, contributing to an economical design. b) of Fig. 2, the end hole location is on the covers corner radius. This design will drive the machining cost higher since a separate positioning procedure is required just for this single hole. Design basics for rectangular objects * Place all holes on a common straight line * Place all the holes at a equal pitch distance [Fig. 2] Screw hole designs and an example of dimensioning text entry
# of places 10 12-M8 8 x 10 (=80) 10 Place on a common center line and at an equal pitch distance Difficult to locate this hole Pitch distance 12 x 10 (=120)

[Fig. 1] Dimensioning examples of through holes and tapped holes on round objects
# of places 8 - 12 holes Hole properties

Placed on a concentric pitch circle diameter, on equally divided circular arc angles.

a) Dimensioning example of through holes

b) Dimensioning example of tapped holes a) Example of a standard screw hole placement design and dimensioning text entry b) Example of a screw hole that is more difficult to machine

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Technical Tutorial

Low cost automation

Screws
[4] Preplanning to prevent thread damages
The following are the common cases of screw thread damages.

(1) Common cases of thread damages

Threaded hole side In case where assembly and disassembly are frequently repeated, the entry portion of the thread may be damaged and the screws may become difficult to start. When this occurs, use a tap to clean the damaged portion of the thread so the new thread will be smoothly connected to the existing portion of the thread. If a bolt is forced into the damaged thread, the deeper portion of the thread is further damaged and the entire tapped hole may become stripped. Bolt side When a bolt is tightened with a nut, inadvertent object strike on the exposed thread portion of the bolt may crush and damage the thread. This would make the machine impossible to be disassembled.

[Fig. 1] Countermeasure against thread damages

Threads get smashed

Chamfer the entry portion Functions as a straight entry guide

Initial thread condition

(2) Small trick in avoiding thread damages

Threaded holes (see Fig. 1) Chamfer the entry hole opening so the bolt will enter perpendicularly to the hole. This can be done with sufficient results by touching-off the entry hole with a drill slightly larger than the female thread size. Take extra care in specifying the drawing notations if the material to be machined is soft (aluminum and non-hardened steel). Bolt side (see Fig. 2) Grind and smooth away the threads exposed beyond the nut. Machine the bolt prior to use so the unneeded thread portion is removed. Do not use unnecessarily long bolts.
Initial thread condition

Countermeasure against thread damage

[Fig. 2] Countermeasure against thread damages on bolts

Thread damage due to object collision The cannot be removed

Countermeasure against thread damages on bolts

Grind and remove the excess threads

[5] Strength classifications of steel bolts and nuts

ISO standards provide a set of classifications regarding strength as a part of mechanical properties. This section explains the strength classifications of steel bolts and nuts. FA catalog 08, page 1111 shows the strength classification of socket head cap screws CB as 12.9 (M3~M20) and 10.9 (M24). [Table. 1] Mechanical properties of steel bolts
Mechanical properties Min. tensile strength R m,min N/mm2 Hardness HV min max min min min min 6.8 600 190 250 480 Strength Grade 8.8* 10.9 800 250 320 640 1040 320 380 940 12.9 1200 385 435 1100 A ISO6892 (tensile test) Applied only when 6d Test methods and conditions A ISO6892 (tensile test) B Bolt pulling test AB/B ISO6507-1 Min. hardness is substituted Rm

(1) Mechanical properties of steel bolts

1. Mechanical properties of steel bolts In ISO and JIS, the mechanical properties of bolts are categorized by strength classification numbers. The [Table. 1] is a part of ISO 898-1:1998 standards.

Lower yield point Rcl. N/mm2 0.2% stress immunity Rp0.2 N/mm2 Elongation after breaking A% Shrinkage Z% Wedge tensile strength Torque to destruction MBN m Proof load stress Sp N/mm2 Impact resistance KU J

12 9 8 52 48 44 Larger than min. tensile strength Rm,min 440 580 30 As per ISO898-7 830 20 970 15

min

min

A ISO6892 (tensile test) B Wedge tensile test of bolts ISO898-7 (Tortional test) Substitution of Rm B Proof load stress test A ISO83 (Charpy impact test)

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2. How to read strength class in the table The first number denotes 1/100th of the bolts minimum tensile strength. The second number denotes a ratio between the tensile strength and the yield point. EXAMPLE: Strength Class 10.9
Minimum tensile strength Yield strength Elongation property Maximum load a bolt can withstand Applicable to bolts 3mm in diameter and length of 2.5d (2.5 times the diameter) Maximum load a bolt can withstand without any plastic deformation. The amount of bolt elongation before breakage.

(2) Mechanical properties of steel nuts

The strength classifications for nuts are represented in proof load stress value according to the screw diameter (see [Table. 1] ). Make nut selections to match the strength class of bolts to be used together. For instance, combining a nut of class 8 from the table 2 and a bolt of class 8.8 will result in a fastened strength where the bolt shank would break before the meshing threads would yield. Numbers on STYLE column in Table 2: Style 1: > Relatively high material strength with nut thickness of 0.8d ~ 0.9d Style 2: > Relatively low material strength with nut thickness of approx. 1d [Table. 2] Mechanical properties of steel nuts
Thread diameter d mm Strength Class 8 Style Proof load Vickers hardness Heat HV stress treatment SpN/mm2 min max Style Proof load Vickers hardness Heat HV stress treatment SpN/mm2 min max d<4 800 180 = 4<d<7 855 = 302 None 7 < d < 10 200 870 = < 16 10 < d = 880 16 < d < 39 920 233 353 Treated =

3. Items regarding mechanical properties Minimum tensile strength is the maximum load a bolt can withstand. Applicable to bolts 3mm in diameter and length of 2.5d (2.5 times the diameter). Yield strength is the maximum load a bolt can withstand without any plastic deformation. Elongation property is the amount of bolt elongation before breakage.

890

180

302

None

[6] Strength classifications of stainless-steel bolts and nuts

The strength classes of stainless steel bolts are categorized according to the stainless-steel material types used. MISUMI FA catalog 06, page 880 shows the strength classification of socket head cap screws SCB in SUS304 stainless steel as A2-70
2. How to read strength class in the table

The strength class number denotes 1/10th of the bolts minimum tensile strength. Example: Austenitic stainless steel bolts with A2-70 strength class means: guaranteed tensile strength of 500 (N/mm2), proof stress of 210 (N/mm2), and elongation of 0.6d to the point of brakage. Classified according to the material the bolts are made of (Austenitic SS, Martensitic SS, Ferrite SS). Additionally, the Martensitic SS is further categorized into different classifications according to heat treatments applied or not.

(1) Mechanical properties of stainless steel bolts

1. Mechanical properties of stainless steel bolts

Properties of stainless steel bolts are also categorized by strength classes, but with a different numbering system. [Table 1] shows a part of ISO 3506-1: 1997, the rules on mechanical properties of stainless steel bolts. [Table. 1] Mechanical properties of stainless steel bolts (from ISO 3506-1: 1997)
SS materials SS material class A1, A2, A3, A4, A5 C1,C4 C1 C3 Ferrite SS F1 Strength class 50 70 80 50 70 10 80 45 60 Tensile strength Rm,min N/mm2 500 700 800 500 700 1100 800 450 600 0.2% Stress Elongation at Rp0.2,min break N/mm2 A,min mm 210 0.6d 450 0.4d 600 0.3d 250 410 820 640 250 410 Hardness HV 155 - 220 220 - 330 350 - 440 240 - 340 135 - 220 180 - 285

(2) Mechanical properties of stainless steel nuts

The mechanical properties of stainless steel nuts are also categorized into strength classes like the standard steel nuts, where represented by proof load stress numbers used with matching bolts. The stainless steel bolts are classified according to the type of material, and since the SS nuts are designed to be used together with SS bolts, it can be assumed that the strength classifications of SS nuts are the same with SS bolts. For the reason above, there will be no thread damage at the engagement region of SS bolts and SS nuts, but special attention must given for thread damages when thin nuts with fewer number of thread engagement is used.

Austenitic SS

Martensitic SS

0.2d

Technical articles written by Akihiro Inada, Ph.D. with an English translation arranged by MISUMI Corporation
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