SFT 14298 Mechatronic-Mechanical

Fasteners and Torque Requirement

Training
PLEXUS CONFIDENTIAL

Revision Table
Revision Date Origin Reason for Change
4/13/2021 Choon-Thai Tan / Initial Development
Gary Gower
4/1/2022 Choon-Thai Added slide to direct instructor to cover GAP training updates
Tan/Susan to 6351 Rev T while slides are in the process of being updated
Lancaster to include changes.
4/13/2022 Choon-Thai Tan/ Align with DCS 6351 Rev T content.
Susan Lancaster

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Agenda
• Torque Consideration
• Determine Torque Requirement
• First Piece Verification on Non-Integrated Driver
• Torque Driver Overview
• Torque Driver Selection Guide Line
• Torque Driver Operation Requirement
• Rivet
• General Requirement
• Adjustment, Calibration & Verification
• Liquid thread lock application

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Training Objective
The trainee’s will be able to:

 Understand overall of Torque Requirement

associated with DCS 6351.

 Identify the uses and function of torque driver

tool.

 Select correct torque driver used in operation.

 Perform mechanical fastening process.

 Perform Liquid thread lock application

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Torque Consideration

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Torque Consideration

DYNAMIC TORQUE RESIDUAL TORQUE BREAKAWAY TORQUE PREVAILING TORQUE

• The applied torque while • Torque necessary to • Torque necessary to re- • Existence of torque
the fastener is in motion. restart an at-rest fastener start a fastener in the during the rundown stage
in the tightening direction loosening or tightening before parts are seated
direction or clamped together

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Effects of Under/Over-Torque

Negative impact on the quality of the mechanical

connection.

Under torque : loosening due to vibration

Over torque : product damage

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Clamp Load and Torque

Clamp load : Achieved through application of torque.

Application of torsional force to a threaded fastener

creates bolt tension and clamp force.

Control of friction is the key to this process.

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What is Torque? Fastening Theory [Part 1]

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Video Part 1
1. The state of a bolt’s tensile load (stress) and joint
1. What is PreLoad/Clamp Load?
compressive load

2. There have four phases of Tightening. What

2. 1st phase – Rundown.
is the 1st phases,2nd phase, 3rd phase and 4th
2nd phase- Drawdown/alignment.
phase.
3rd phase – Elastic

4th phase – Plastic/ Post Yield

3. What is Torque? What is the formula?

3. Torque = Force (F) * Moment Arm (r) * sinθ

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Friction Factors, Fastening Theory [Part 2]

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Video Part 2
1. 90%.
1. How many percent of applied torque is used
to overcome friction?
2. How many percent of applied torque 2. 10%
is used for clamping?

3. Please list the factors of friction? 3. a) Tolerance

b) Alignment (shadowing)

c) Surface Finishes
d) Material (steel, plastics)
e) Lubricants (type, amount used)
f) Fastener types (thread-forming, nylock patch, trilobulor)
g) Other materials within the bolted joint (gaskets, washers, etc)

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Prevailing Torque/ Rundown Torque

• Existence of torque before parts are

seated or clamped.

• Under 1st phase of tightening

process.

• Intentional

• Unintentional

• Effect of prevailing torque:-

• Reduce rundown RPM
• Increase reaction impulse
• Reduce durability

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Prevailing Torque/ Rundown Torque Measurement

Prevailing torque/ rundown torque can be measure by following method:

Manual/ Digital Torque Measurement Smart Driver Measurement

• Using a dial torque tool or digital torque tool • Using Prevailing Strategies

• Measure the peak amount of torque required to • Forward/ Backward prevailing program/function.
turn a fastener prior to the fastener seated
position • The prevailing torque value is auto calculated and
monitor by angle

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Torque Driver Considerations

Moving past the “click” on a Moving

manual torque driver can add Manual Can strain an operators
substantially more torque than
Pass the Wrenches wrist if there are many
desired. Click threads

Operator fatigue Adding an adapter to a

can increase hand
Operator
Speed
Adding wrench can change its output.
Fatigue Adapter
torque variance by
5%.

The speed at which the

operator uses the wrench can
affect the output,
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PLEXUS CONFIDENTIAL
Torque Auditing Methods
Breakaway loosening
torque
• The amount of torque
required to put the fastener
in motion in the loosening
direction.
• This value is typically less
than the final specified
torque.
Torque Auditing Method shall establish together with customer and it should align with pFMEA.
Breakaway tightening
torque
• The amount of torque
required to put the fastener
in motion in the tightening
direction.
• This value is typically greater
than the final specified
torque
Screw marking method
• mark the edge of the screw head,
and onto the surface next to the
head.
• Using the specified torque driver
for the operation, back the screw
off ¼ to ½ turn.
• Use the same torque driver to re-
torque the screw to specification.
• Check the screw position
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Determine Torque Requirement

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Determine Torque Requirement

Torque Settings and Values
1. Torque settings and values shall be obtained based on the following order of precedence:

Provided by • Highly
Customer recommended

Provided by • Equipment/Tool
supplier
Supplier

Utilize
• Characteristic specified
Characteristic
Data Table

Using Common • Common thread size vs

Table material

• Thread Forming
Experiment • Fastening with excessive
level

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Determine Torque Requirement

2. Determined from IPC-A-610, J-STD-001, and other Industry Standards, Torque – Longevity and Mistake-Proofing.
The following methods can be used, when specified within the ABI:

Loctite Red Paint

• Application of Loctite
• Approved Red Paint
• Apply on Fastener head
or Nut
• Indicate possible
tempering

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Determine Torque Requirement

3. Critical fastener determination

ASSEMBLY DRAWING ASSEMBLY DRAWING CUSTOMER INPUT INTERNAL

NOTE CLASSIFICATION

• Torque value applied in the
product is specified in the
assembly drawing as special
characteristics/critical
characteristics
• Torque value applied in • Information comes from
the product is spelled/ the customer in any form
marked as critical (PPQP,CP, Customer
characteristics in Quality Plan, and etc.) for
assembly drawing NOTES critical fastener
requirements
• Safety critical-failure of
the bolt or screw will
result in danger to life
• Function critical - failure
of the bolt or screw will
lead to a major
malfunction

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1st Piece Verification on Non-
Integrated Driver

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PLEXUS CONFIDENTIAL
1st Piece Verification on Non-Integrated Driver
Identified critical
fastener
• Site shall identify and
establish the first piece
verification/audit for
critical fastener on the non-
integrated driver
Non-Integrated Driver Setup CDC
• Non-integrated driver is the • Site shall setup/configure
driver that does not have a CDC with WO level.
feedback loop to a controlling
system to verify the torquing • It’s required to fill the CDC
operation is correct. at least 1 unit of each WO.
• Example:
1. Smart driver not integrated
with ATDS or Cell Fussion,
2. Manual torque driver
3. Electric torque driver
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1st Piece Verification of Critical Fastener on Non Integrated Driver

Overall Process Flow

Assigned person to *Pass
Set up CDC for 1st piece Record the result in
Identified Critical perform
Start verification/audit of new CDC and start End
Torque requirement verification/audit
work order Production

**Fail

Pass
Perform Torque
verification on
impacted tool

Fail

Impacted tool send for

calibration/ repair

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1st Piece Verification of Critical Fastener on Non Integrated Driver

Verification /Audit step:

Obtain the 1st Using a color Stop tigtening

unit of new marking pen, Using the when tool Is the color marking
work order mark the edge verification Yes
showing the on screw head and
Start which of the screw driver/tool to
surface align and
* Pass
head, and onto torque value
completed tightening show straight line
the surface next screw slowly. same as
fastener
process to the head requirement.

No

** Fail
`

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1st Piece Verification of Critical Fastener on Non Integrated Driver

Accept and Reject Criteria

Bolt and Nut

Reject criteria
Accept criteria

Above illustration is the standard guideline for the Acceptance Criteria. However, the responsible Quality Engineer or
Product Engineer also can define the Acceptance Criteria based on the nature and variables in the assembly
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PLEXUS CONFIDENTIAL

1st Piece Verification of Critical Fastener on Non Integrated Driver

Accept and Reject Criteria

Screw / Fastener
Accept criteria Reject criteria

Above illustration is the standard guideline for the Acceptance Criteria. However, the responsible Quality Engineer or
Product Engineer also can define the Acceptance Criteria based on the nature and variables in the assembly
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1st Piece Verification on Non-Integrated Driver

Note:
1. Please ensure the color-marking pen used on this audit activity is approved or allowable from the
customer.

2. Please use a removable color pen and clean it after the audit for those customers not allowing color
marker on the screw head. The cleaning material used shall be approved or allowable from the
customer.

3. General guideline for marking pen width is 3-4 mm, however, it is recommended the marking width
shall not exceed 1/10 from the bolt/screw head perimeter.

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Torque Driver Overview

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Preset Torque Driver

Simplest type of driver.

While the torque reach the preset torque value, the

toggle will slip and prevent further torque being apply.

Available Torque range : 5 -500 cN.m

Achievable Accuracy: +/- 5%

Torque range and Accuracy may vary from manufacturer;

please checking with Manufacturer/supplier for the detail
specification.
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Electric Smart Torque Driver

There are three major element of the electric smart torque

driver:-
• Smart Torque Tool
• Controller
• Software (controlling and monitoring)

Target torque can be set in the controller.

Integrated spring system and smart speed configuration to

avoid overshoot and floating screw issue.

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Electric Smart Torque Driver

Some of the electric smart torque driver are built-in

transducer, its most intelligent tool in the market.

There is a feedback loop between the built-in transducer &

the controller.

Achievable Accuracy: +/- 5%

Torque range and Accuracy may vary from manufacturer;

please checking with Manufacturer/supplier for the detail
specification.

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Torque Driver Selection Guideline

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1. Type of Torque Driver Selection

Start

Is the application require

power/electrcic to assits
on the s ecuring process NO
Preset torque tool C
ba s ed on Customer
reuqi rment?

YES

Is the securing process i n NO Is the securing process NO

verti ca l oerientation? requi re confined a rea Pistol Grip
or l ow profile?

YES YES
B

Inline Angle Head

B B

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2. Wired, Wireless, Smart and Torque Driver Selection

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3. Targeted Torque vs Torque Driver Selection

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3. Targeted Torque vs Torque Driver Selection (continue)

Example: Targeted torque : 0.1 N.m and Tolerance requirement : 6%

Step 1:
Select the Smart torque driver at the Model Group. Key in 0.1 in the Torque Target
and 6% at the Application Tolerance.
Preferred
Smart Drivers

Microsoft Excel
Macro-Enabled Worksheet

Step 2:
Look at the Result: If Pass, select the torque driver. If Fail, go to next step.

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3. Targeted Torque vs Torque Driver Selection ( continue)

Example: Targeted torque : 0.1 N.m and Tolerance requirement : 6%

Step 3:
Select the application type and presentation. Key in the targeted torque (0.1) and
application tolerance (6%).
Look at the Result: Atlas Copco model ETD MT4150 is recommend for this application.

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Torque Driver Operation
Requirement

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Verify Setting Of Torque Tool Matches Abi Torque Specification

Verify Torque
Tool Label vs ABI
spec

Return to Torque Tool

identified Label Nominal =
location ABI Nominal

Tolerance of
Verification is
Selected Tool at
required if new
nominal ≤ ABI
setting needed
Spec

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Manual Torque Driver Operation

Hand- Kept Clean

tighten

Consistent Adjustment
motion Screw

Even Alignment
Pressure

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Power Torque Driver Operation

Kept Parallel
Clean

Even
Pressure FOD

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Rivet

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Rivet

DYNAMIC TORQUE BREAKAWAY TORQUE PREVAILING TORQUE

• The applied torque while • Torque necessary to • Torque necessary to re- • Existence of torque
the fastener is in motion. restart an at-rest fastener start a fastener in the during the rundown stage
in the tightening direction loosening or tightening before parts are seated
direction or clamped together

Whether the riveting process is manual or automatic, the gun should always be straight / perpendicular
to the work surface, with the rivet held flush to the mating materials before activating the pressure.

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Rivet

DYNAMIC TORQUE BREAKAWAY TORQUE PREVAILING TORQUE

• The applied torque while • Torque necessary to • Torque necessary to re- • Existence of torque
the fastener is in motion. restart an at-rest fastener start a fastener in the during the rundown stage
in the tightening direction loosening or tightening before parts are seated
direction or clamped together

Care must be taken when inserting the rivet to avoid excessive scratching to the workpiece. After
completion, work must be inspected to confirm head of rivet is flush to the surface and that no FOD
has been created.

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Rivet Removal

DYNAMIC TORQUE BREAKAWAY TORQUE PREVAILING TORQUE

• If torque
• The applied for somewhilereason a rivet must
• Torque be removed,
necessary to It must be removed
• Torque carefully,
necessary to re- so that the
• rivet
Existence of torque
restart an at-rest fastener
the fastener is inwill
hole motion.
retain its original size and shape, the process start a fastener in the
to be during the rundown stage
followed is similar, regardless
in the tightening direction loosening or tightening before parts are seated
of type of rivet. direction or clamped together
• Combination of power and hand tools is required.
• Use a small center drill to provide a guide for a larger drill on top of the rivet stem and
drill thru the rivet head to destroy the lock.
• Drive out the rivet stem using a tapered steel pin.

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General Requirement

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General (Tools)

DYNAMIC TORQUE BREAKAWAY TORQUE PREVAILING TORQUE

• The applied torque while • Torque necessary to • Torque necessary to re- • Existence of torque
the fastener is in motion. restart an at-rest fastener start a fastener in the during the rundown stage
in the tightening direction loosening or tightening before parts are seated
direction or clamped together

• Each Work Station will be equipped with the correct tools to perform the operation.
• Do not mix tools /improvise.
• Phillips type driver bit is different from Pozi type bits.(even though they look same)
• Metric tools and Imperial (Inches) are not interchangeable (even though they look same)

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General (Sequence)

DYNAMIC TORQUE BREAKAWAY TORQUE PREVAILING TORQUE

• The applied torque while • Torque necessary to • Torque necessary to re- • Existence of torque
the fastener is in motion. restart an at-rest fastener start a fastener in the during the rundown stage
in the tightening direction loosening or tightening before parts are seated
• Where a work piece has multiple screws to be inserted the ABI should
direction specify the order/sequence
or clamped together
of inserting the screws to ease assembly process and produce acceptable results.

• In general the sequence will follow similar pattern to above ( Diagonally opposite first)

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General (Sequence)

DYNAMIC TORQUE BREAKAWAY TORQUE PREVAILING TORQUE

• The applied torque while • Torque necessary to • Torque necessary to re- • Existence of torque
the fastener is in motion. restart an at-rest fastener start a fastener in the during the rundown stage
in the tightening direction loosening or tightening before parts are seated
direction or clamped together

• Some product specific ABIs, may require screws inserted in a specified manner to enable the
assembly to meet all criteria ( Alignment / Flatness / Rigidity)

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Adjustment, Calibration and
Verification

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General Guideline for Calibration

cv cv
• All Manual & Power torque driver
Calibration Control System • Under Site Calibration system
• SOP 56

cv cv • Calibrate according to Tool

Manufacturer Specification.
Calibration • TSR calculation is 4 sigma level or
meet Cpk 1.33

cv
cv • Using appropriate and Calibrated Torque
Transducer/Analyzer.
Torque Transducer • Target verification/calibration torque
plus tolerance must be between the
transducer’s range of 10% to 90%

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General Guideline for Calibration

cv cv
• The need to calibrate angled tools
Angled Tool with the adaptor installed if used on
an application.

cv cv
• The requested calibration tolerance has to be within
the tool tolerance.
Calibrated Tolerance
• Eg: Tool is 5 Nm +/- 11%, when we send it for
calibration we CAN NOT ask for the tool to be calibrate
to 5 Nm +/- 8%.
cv
cv

Torque Verification • Bi-weekly (every 2 weeks/14 days)

Frequency • Customer specified

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Calibration Guidelines for Smart Torque Tools

• Plexus Standard Operating Procedure control for Calibration (SOP 56)

should be followed for each torque tool accordingly

• Psets should be created for calibration based on 0%, 25%, 50%, 75%,
and 100% of the tool with 5 rundowns completed for each torque
range unless otherwise required.

• By comparing the value recorded from the torque analyzer to the

actual torque from the controller, the tool calibration value should
centered with its tolerance equal at the 0% and 100% range
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Calibration Guidelines for Preset Torque Tools

• Preset torque tools are considered all torque tools labeled and tested
to standard calibration procedures per SOP 56.

• All the preset torque tools are required calibrated to the targeted
torque setting with the manufacturing specification tolerance.

• The tool calibration TSR should be calculate at 4 sigma level or meet

Cpk 1.33 at targeted torque.

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Adjustment Guidelines for Operator Adjustable Torque Tools

(changing the torque setting of a torque tool)
• If the torque tool is changed (adjusted) to a new value it must be
verified before it is used.

• Each tool checked for verification must pass a test of 5

consecutive rundowns and be recorded in form #6540 or
equivalent.

• The driver must be labeled with the new torque nominal setting
and the range that it was verified to be within (specified in the
ABI)

• Use electrical tape or heat shrink tubing to secure the adjustable

torque setting and place the label over the tape or tubing to
avoid tampering during production
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Tool Verification
• Place the corresponding size fastener onto the Phillips bit.

• Place the threaded end of the fastener onto a flat work

surface with the Phillips bit still engaged into the head of
the fastener. See figure 1.
Figure 1

• Apply downward pressure to bit, let go of the fastener,

and slowly tip the bit to approximately a 45 degree angle
to the work surface.

• Continue to put downward pressure on the bit. See figure 2.

• If the bit does not stay in the screw for a minimum of 5 Figure 2
seconds within the first 3 attempts, it is recommended that
the bit is replaced.

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Liquid Thread Lock Application

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PLEXUS CONFIDENTIAL

Liquid Thread lock Application

• Dip Method

• Through-hole Transfer Method (special application)

• Blind-hole Method (standard application)

• Needle Method

• Direct Application Method

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Dip Method

• Dip hardware into the thread-locker.

• make sure that the top 3 to 4 threads of

engagement contain Loctite.

• Ensure that the thread-locker wets 360° around

the threads.

• Remove the excess of Loctite of the hardware tip

prior to engagement.

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Through-hole Transfer Method

(special application)
• Remove male fastener (screw) from the board and
holding it in place.
• Dip applicator into thread-locker to get one drop
or less (drops should not be falling off of the
applicator when removed.)
• Touch the applicator to the threads of the
protruding screw that will be in direct contact
with the mating fastener once applied.
• The thread-locker should wet 360° around the
threads, covering three to four threads of the
mating surface. Install the mating fastener as
required. Remove any excess thread-locker if
present with a dry Q-tip or wipe.

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Blind-hole Method (standard

application)

• Remove the male fastener (screw) form the board

and hold it in place. Add thread-locker to male
fastener to three to four threads on the thread
end. Add thread-locker to blind hole.

• The thread-locker should wet 360° around the

threads. Install the male fastener into the board.
Remove any excess thread-locker, if any if present
with a dry Q-tip or wipe.

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Needle Method

• Install needle tip directly to the Loctite bottle,

Gently squeeze bottle to dispense thread locker
on 3 to 4 threads of engagement. Use a lint free
cloth to dab any excess Loctite from the fastener.

• Clean needle frequently to prevent buildup or

drips. Discard needle when finished

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Direct Application Method

• Gently squeeze bottle to dispense thread locker

directly from bottle applicator so there is 3 to 4
threads of engagement

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Thank You!

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