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Toll Free: 866-4-SHEREX

(866-474-3739)

SEALING PLUGS

SYSTEM FOR SEALING AUXILIARY

DRILLED HOLES

■ Largest selection of permanent

sealing plugs

■ For use in fluid power, automotive,

industrial, aerospace and

machine tools applications

■ Blowout pressure exceeds

40,000 PSI

■ QS 9000/ ISO 9001/ ISO 14001

■ Available in metric and inch sizes

■ No tapping or reaming of holes

required

■ Special sizes available upon

request


© 2001 by KVT

Sherex Industries Ltd.

www.sherex.com

Sherex Industries Ltd. has been the North American exclusive

representative for Koenig Verbindungstechnik AG and the Koenig

Expander Plugs since 1976. We are an award winning company

who specializes in the distribution of niche Fluid Power products

for both the Fluid Power and Automotive Markets. In this capacity,

Sherex prides itself in the ability to act as the manufacturer here in

North America. Sherex has degreed engineers on staff to assist

customers in properly applying the products we sell. Visit us on

the web at www.sherex.com for our other products and services.

Sherex's award winning service includes:

• Extensive In-House Stock ready for overnight delivery

• 100% Technical Backup

• JIT & Can-Ban Delivery Experience

• EDI Compatible

• Bar Coding

• Returnable Packaging System Experience

• QS 9000 & ISO 9000 Compliant

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739)

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


© 2001 by KVT

SHEREX INDUSTRIES PRESENTS:

KOENIG-Expander Sealing Plugs

Leakproof Sealing

of Auxiliary Drilled Holes

Overview

MB Series Plugs

SK Series Plugs

HK Series Plugs

LK Series Plugs

LP Series Plugs

Technical Information

i •

T

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

I


Tension-Pressure Test Equipment:

For verification of mechanical properties of

raw materials and component parts as well

as functional characteristics of Expanders.


Roughness Measuring:

For functional testing and tests

where accurate hole roughness

of base material is needed.

II


Production-Line

KOENIG-Expander:

The automated assembly

equipment and outside

diameter checking equipment

is in the background.

In the forefront is eddy

current testing equipment

for 100% comparison

measurement of important

characteristics of Expanders.


▲ Pressure Testing Facility:

Static burst pressure unit (left) heating/cooling

chamber (right) for extended life cycle testing.


KOENIG-Expander Sealing Plugs

System For Sealing Auxiliary Drilled Holes

Unique sealing and tightening system for holes

i

The KOENIG Expander is a system to seal holes with absolute integrity in various components in the Mobile and Industrial

Fluid Power Markets, as well as the Automotive Market. Compared to earlier methods, such as threaded

plugs with or without sealing software, press-in pins, welding, etc., the KOENIG Expander distinguishes itself by its

fast and reliable installation while incorporating reasonable installation tolerances. Thanks to the continuous

expansion of our product offering along with the capability to custom design sealing components to customer

specifications, Sherex offers a leak-tight sealing solution for every application.

As designed, the KOENING Expander plug pressure

ratings incorporate a minimum Factor of Safety to

accommodate for pressure spikes and cyclic

pressure loading. As a result of this reliable and leaktight

sealing system, the expanders have found

broad application on components such as: hydraulic

and pneumatic control valves and manifolds,

hydraulic pumps and motors, power transmission

components, brake components, engine components,

etc.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

III


Applications

KOENIG Expanders are used extensively in hydraulic and pneumatic components, for example:

• Control and regulator valves

• Pumps

• Connecting and distribution manifolds

• Power units

• Cylinders

• Hydraulic transmissions

• etc.

IV

i

The engineered process makes possible a quick and safe sealing of bores and channels. KOENIG EXPANDER has

established a name world-wide in a variety of industries.

Machine tools and other custom equipment

• Clamping devices

• Cooling and lubricating systems

• Molds for injection molding machines

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Applications

Mobile hydraulics/materials

handling equipment

• Control and drive units

• Lifts and platforms

• Elevators

• Construction equipment

• Fork lifts

Transportation

• ABS brake systems

• Power steering

• Vehicular dynamic control

systems

• Automatic door openers

• Railroad brake systems

Aircraft Industry

• Control gear

• Landing gear

• Flight simulators

Werksfoto Knorr-Bremse AG

i

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

V


System for Sealing Auxiliary Drilled Holes

VI

i

MB Series

Expansion and anchorage of sleeve in hole

wall is achieved by pressing the ball into the

sleeve. The MB Series plug is designed for

use in base materials from low to high

hardness.

SK Series

Pull/Expand principle. The installation tool

maintains sleeve position in the hole while

pulling the mandrel into and expanding the

sleeve until the mandrel breaks off at a

predetermined point. Anchorage is achieved

by the serrations on the outside of the sleeve

anchoring into the base material, especially in

soft material.

HK Series

This installation is also based on the

Pull/Expand principle. Thanks to the soft

sleeve material, anchorage is achieved by the

flow of sleeve material into the surface

roughness of the drilled hole. The HK Series

plug is especially suitable for use in hard

materials.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


System for Sealing Auxiliary Drilled Holes

LK Series

Available in both steel and stainless steel,this

plug has been designed for applications in the

low pressure range. It has an anchorage

principle similar to the SK Series plugs.

LP Series

This low pressure sealing plug is installed by

pressing the plug into a tapered hole. The

surface-hardened but flexible plug achieves

anchorage by gripping the hole wall.

i

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

VII


VIII

NOTES

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


MB Series

• Quantities in stock from 3 to 22 mm

diameter, also available in inch

versions

• Corrosion resistant construction

• Normal working tolerances

0/+ 0.1mm

• Simple, quick installation

• Complete mechanical sealing

through anchoring in base material

Contents Page

– MB 600 2

– MB 600, Inch-Version 3

– MB 700 4

– MB 800 5

– Installation instructions 6

– Setting Tools 8

– Automated Production Tools 9


MB 600 Series Sealing Plugs

Sleeve: Stainless Steel

DIN 1.4305, AISI 303

Sleeve and Ball clear passivated per MIL S 5002

Aerospace Quality

Dimensions in MM

2

d 1

l 1

l2 ~

d2 + 0.1

0

d 3

max.

l 3

min.

Ball: Stainless Steel

DIN 1.4301, AISI 304

x

± 0.2

3.0 3.6 4.6 3.0 2.2 3.4 0.4 MB 600-030 1000

4.0 4.0 5.2 4.0 3.3 3.8 0.2 MB 600-040 1000

5.0 5.5 7.0 5.0 4.3 5.3 0.4 MB 600-050 1000

6.0 6.5 8.6 6.0 5.3 6.3 0.4 MB 600-060 500

7.0 7.5 10.1 7.0 6.4 7.3 0.4 MB 600-070 250

8.0 8.5 11.7 8.0 7.4 8.3 0.3 MB 600-080 250

9.0 10.0 13.7 9.0 8.4 9.8 0.4 MB 600-090 250

10.0 11.0 15.2 10.0 9.4 10.8 0.4 MB 600-100 250

12.0 13.0 18.0 12.0 10.6 12.8 0.4 MB 600-120 100

14.0 15.0 20.8 14.0 12.7 14.5 0.4 MB 600-140 100

Type

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739)

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


MB 600 Series Inch-Version Sealing Plugs

Sleeve: Stainless Steel

DIN 1.4305, AISI 303

Sleeve and ball clear passivated to MIL S 5002

Aerospace Quality

Dimension in Inches

d 1

l 1

l2 ~

d 2

d 3

max.

Ball: Stainless Steel

DIN 1.4034, AISI 420 (.093" Dia.)

DIN 1.4301, AISI 304 (.125"-.281" Dia.)

.093 ( 3 / 32") .100 .120 .0937 .062 .095 MB 600-093 A 1000

.125 ( 1 / 8") .138 .170 .1250 .093 .125 MB 600-125 A 1000

.156 ( 5 / 32") .150 .195 .1562 .125 .130 MB 600-156 A 1000

.187 ( 3 / 16") .193 .260 .1875 .156 .152 MB 600-187 A 500

.218 ( 7 / 32") .225 .300 .2187 .187 .187 MB 600-218 A 500

.250 ( 1 / 4") .260 .350 .2500 .218 .212 MB 600-250 A 500

.281 ( 9 + .002

0

+ .004

0

+ .004

0

.0

+ .004

to max.

0

.012

+ .004

0

+ .004

0

/ + .004

32") .285 .380 .2812 .250 .250 MB 600-281 A 500

0

l 3

min.

x

Type

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739)

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

3


MB 700 Series Sealing Plugs

Sleeve: Stainless Steel

DIN 1.4305, AISI 303

Dimensions in MM

4

d 1

l 1

l2 ~

d2 + 0.1

0

d 3

max.

l 3

min.

Ball: Bearing Steel

Heat Treated

3.0 3.6 4.6 3.0 2.2 3.4 0.4 MB 700-030 1000

4.0 4.0 5.2 4.0 3.3 3.8 0.2 MB 700-040 1000 / 5000

5.0 5.5 7.0 5.0 4.3 5.3 0.4 MB 700-050 1000

6.0 6.5 8.6 6.0 5.3 6.3 0.4 MB 700-060 1000 / 2000

7.0 7.5 10.1 7.0 6.4 7.3 0.4 MB 700-070 1000

8.0 8.5 11.7 8.0 7.4 8.3 0.3 MB 700-080 500

9.0 10.0 13.7 9.0 8.4 9.8 0.4 MB 700-090 500

10.0 11.0 15.2 10.0 9.4 10.8 0.4 MB 700-100 500

12.0 13.0 18.0 12.0 10.6 12.8 0.4 MB 700-120 250

14.0 15.0 20.8 14.0 12.7 14.5 0.4 MB 700-140 250

16.0 17.0 23.7 16.0 14.7 16,5 0.6 MB 700-160 100

18.0 19.0 26.3 18.0 16.7 18.5 0.6 MB 700-180 100

20.0 22.0 30.5 20.0 18.7 21.5 0.8 MB 700-200 100

22.0 25.0 34.2 22.0 20.7 24.5 0.8 MB 700-220 50

x

± 0.2

Type

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739)

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


MB 800 Series Sealing Plugs

Sleeve: Case Hardening Steel

DIN 1.0403, AISI 10L15

Zinc plated chromate finish

Dimensions in MM

d 1

l 1

l2 ~

d2 + 0.1

0

d 3

max.

l 3

min.

Ball: Bearing Steel

Heat Treated

3.0 3.6 4.6 3.0 2.2 3.4 0.4 MB 800-030 1000

4.0 4.0 5.2 4.0 3.3 3.8 0.2 MB 800-040 1000 / 5000

5.0 5.5 7.1 5.0 4.3 5.3 0.4 MB 800-050 1000 / 2500

6.0 6.5 8.7 6.0 5.3 6.3 0.4 MB 800-060 500 / 2000

7.0 7.5 10.2 7.0 6.4 7.3 0.4 MB 800-070 1000

8.0 8,5 11.6 8.0 7.4 8.3 0.3 MB 800-080 500

9.0 10.0 13.6 9.0 8.4 9.8 0.4 MB 800-090 500

10.0 11.0 15.2 10.0 9.4 10.8 0.4 MB 800-100 500

12.0 13.0 17.9 12.0 10.6 12.8 0.4 MB 800-120 250

14.0 15.0 20.6 14.0 12.7 14.5 0.4 MB 800-140 250

16.0 17.0 23.4 16.0 14.7 16.5 0.6 MB 800-160 100

18.0 19.0 26.4 18.0 16.7 18.5 0.6 MB 800-180 100

20.0 22.0 30.1 20.0 18.7 21.5 0.8 MB 800-200 100

22.0 25.0 34.0 22.0 20.7 24.5 0.8 MB 800-220 50

x

± 0.2

Type

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739)

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

5


Installation Instruction for MB Series

Drilled Hole

• The drilled hole must be within the tolerances shown on the preceding dimensional sheets.

• The counterbored hole (d 2 ) must be properly sized for the through hole (d 3 ) according to the dimensional sheets.

• Holes must be round within 0.05 mm.

• With hard materials the bore roughness should be from R z = 10 - 30 µm for best results.

• Longitudinal rifles and spiral grooves should be avoided. These influence the sealing effectiveness.

• The bore must be free of oil, grease and chips.

Installation Chart

6

F

Fig. 1

Fig. 2

Fig. 3

d1 [in]

.093 .125 .156 .187 .218 .250 .281

S [in] Stroke .031 .047 .059 .079 .094 .109 .118

X [in]

MB 600 Series Inch-Version

Position of top of ball

relative to top of sleeve

Flush to .012 below

the sleeve

Setting Procedure

• With the ball facing out the KOENIG-Expander is

inserted in the counterbored hole. The top sleeve

should not be above the surface of the base material.

(Fig. 1)

• With only a slight or no counterbore, the base of the

sleeve must be adequately supported during

installation.

• The ball can now be pressed in until the top of the

ball is below the edge of the sleeve. (Fig. 2 and 3)

Corresponding approximate values for stroke S as

well as the dimensions X are from the Table below.

• Note: Use the proper size setting tool for the

KOENIG-Expander according to the Data Sheet.

Press

Small quantities or single parts can be installed with a

hammer and setting tool. Installation can also be done

with an arbor press. It is preferred to limit travel when

using a press because insertion force is difficult to control.

KOENIG-Expanders are also ideal for automated installation

because they are problem free.

d1 [mm]

3 4 5 6 7 8 9 10 12 14 16 18 20 22

S [mm] Stroke 1.2 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.5 6.35 7.0 8.0 9.0 10.0

X [mm]

±0.2

Position of top of ball

relative to top of sleeve

MB 600 / MB 700 / MB 800

0.4 0.2 0.4 0.4 0.4 0.3 0.4 0.4 0.4 0.4 0.6 0.6 0.8 0.8

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Installation Instructions MB Series

Setting Force

MB 600/700 MB 800 MB 600 Inch-Version

d 1 d 1 d 1

Note: 1 kN = 224.8 lbf

Measured in steel with a tensile strength of 1,000 N/mm 2 (145 ksi) . When installing in material with less strength

the values are less.

a) Force with minimum bore diameter tolerance.

b) Force with maximum bore diameter tolerance.

Plug Removal

With KOENIG-Expander MB Series removal of the plug is possible. The plug can be drilled out with a carbide tipped

drill or with a high speed steel drill.

MB 600-030 to 140, Ball HB ~200: High Speed Steel Drill

MB 600-093 A, Ball HRC ~ 55: Carbide Tipped Drill

MB 600-125 A to 281 A, Ball HB ~200: High Speed Steel Drill

MB 700-030 to 220, Ball HRC ~ 45: Carbide Tipped Drill

MB 800-030 to 220, Ball HRC ~ 45: Carbide Tipped Drill

Procedure

• To Expander Diameter 6 mm or .250 inch.

Drill out, in one process, to the next larger diameter according to the Data Sheet.

• Expander-Diameters over 6 mm or .250 inch:

Drill out in several steps with last step to the next larger diameter according to the Data Sheet.

• Clear chips, remnants of the sleeve, and oil and grease from the bore.

• Install a new KOENIG-Expander.

Note: After plug removal always use the next larger diameter Expander.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

7


Setting Tools –MB Series

Tools: Tool Steel

Heat Treated Hardness ~ HRC 50

8

TOOLS

d1 d3 - h9

d2 l2 x

Type

l 1

3.0 10 100 2.8 10 0.4 HT MB 030

4.0 10 100 3.8 10 0.2 HT MB 040

5.0 10 100 4.8 12 0.4 HT MB 050

6.0 10 100 5.8 15 0.4 HT MB 060

7.0 10 100 6.8 18 0.4 HT MB 070

8.0 10 100 7.8 20 0.3 HT MB 080

9.0 14 100 8.8 22 0.4 HT MB 090

10.0 14 100 9.8 25 0.4 HT MB 100

12.0 14 150 11.7 30 0.4 HT MB 120

14.0 20 150 13.7 35 0.4 HT MB 140

16.0 20 150 15.7 40 0.6 HT MB 160

18.0 20 150 17.7 45 0.6 HT MB 180

20.0 25 150 19.7 50 0.8 HT MB 200

22.0 25 150 21.7 55 0.8 HT MB 220

d 1

d 3

0

–.002

MB 600 / MB 700 / MB 800 (Dimensions in MM)

MB 600 Inch-Version (Dimensions in Inches)

.093 ( 3/32") .394 3.94 .082 .137 .012 HT MB 093 A

.125 ( 1/8") .394 3.94 .117 .137 .012 HT MB 125 A

.156 ( 5/32") .394 3.94 .148 .137 .012 HT MB 156 A

.187 ( 3/16") .394 3.94 .180 .137 .012 HT MB 187 A

.218 ( 7/32") .394 3.94 .211 .400 .012 HT MB 218 A

.250 ( 1/4") .394 3.94 .242 .400 .012 HT MB 250 A

.281 ( 9/32") .394 3.94 .273 .400 .012 HT MB 281 A

± 0.2

l 1 d 2 l 2 x

0

–.012

Type

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739)

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Assembly Press–MB Series–Pressure and Stroke Control

Type PH-450

Type PH-550

Technical Data PH-450

AUTOMATION

Hydropneumatic Table Press for the installation of MB

and LP Series Koenig Sealing Plugs. Stroke control of

press allows for consistent, repeatable installations to

meet quality system performance goals. On-board

monitoring of installation force with graph printing

capabilities as well as computer data output.

Further Equipment Styles: PH-400 / PH-500

Table Press with stroke control but without

installation force monitoring, graph printing capabilities,

and data output.

Dimensions Width 250 mm

Width (control unit) 470 mm

Height 1,190 mm

Depth 750 mm

Diameter Range 3 –7 mm (.093–.281 in.)

Air Pressure 6 bar

Air Consumption 5.3 L / Stroke

Pressing Force 28 kN

Power Stroke 3 mm

Cylinder Ram ~ 60 mm

Technical Data PH-550

Dimensions Width 250 mm

Width (control unit) 470 mm

Height 1,190 mm

Depth 750 mm

Diameter Range 3 – 14 mm

Air Pressure 6 bar

Air Consumption 16 L / Stroke

Pressing Force 40 kN

Power Stroke max. 16 mm

Cylinder Ram ~ 60 mm

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739)

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

9


10

NOTES

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739)

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Sidex-SK Series

• 4-10 mm diameter,

Extended mandrels for below

surface installation

•Working pressure to 500 Bar

(7,250 psi)

• Shorter Installed Length

• Larger working tolerances

0/+0.12 mm

• Installs directly into drilled holes

• Clean mechanical sealing through

positive anchoring

• Quick installation using handy rivet

type tools

Contents Page

– Sidex-SK Series 12

– Installation Instructions 13

– Spacers 14

– Setting Tools 15


Sidex-SK Series

Sleeve: Case Hardening Steel

DIN 1.0403 ~ AISI 10L15

Gun metal–finish

One Piece Construction ideal for automated

high production requirements.

12

d 1

l3

d1 l1 d2 l2 l3 max.

l1

d 2

l 2

l 4

max.

Mandrel: Heat Treatable Steel

~ DIN 1.0728

Special Oil Film Lubrication

Bore Diameter

4.0 4.5 2.50 39 9.0 6.5 4.0 SK 550-040 1000

5.0 5.5 3.00 41 10.0 7.5 5.0 SK 550-050 1000

6.0 6.5 3.40 43 12.0 8.0 6.0 SK 550-060 500

7.0

8.0

7.5

8.5

4.10

4.20

38

40

14.0

15.0

9.0

10.5

7.0

8.0

+0.12

0

SK 550-070

SK 550-080

500

500

9.0 9.5 4.50 43 17.0 11.0 9.0 SK 550-090 250

10.0 10.5 4.75 45 19.0 12.5 10.0 SK 550-100 250

Extended Mandrel Version - allows insertion of up to 30 mm deep

d1 l1 d2 l2 l3 max.

l 4

max.

Bore Diameter

4.0 4.5 2.50 69 9.0 6.5 4.0 SK 552-040 1000

5.0 5.5 3.00 71 10.0 7.5 5.0 SK 552-050 500

6.0 6.5 3.40 73 12.0 8.0 6.0 SK 552-060 500

7.0

8.0

7.5

8.5

4.10

4.20

68

70

14.0

15.0

9.0

10.5

7.0

8.0

+0.12

0

SK 552-070

SK 552-080

250

250

9.0 9.5 4.50 73 17.0 11.0 9.0 SK 552-090 100

10.0 10.5 4.75 75 19.0 12.5 10.0 SK 552-100 100

l4

Type

Type

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739)

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Installation Instructions Sidex-SK

Drilled Hole

• The drilled hole must be within the tolerances shown on the preceding data sheets.

• Holes must be round within 0.05 mm.

• With hard materials the bore roughness should be from R z = 10 - 30 µm for best results.

• Longitudinal rifles and spiral grooves should be avoided. These influence the sealing effectiveness.

• The bore must be free of oil, grease and chips.

Setting Procedure

Fig. 1

Fig. 2

Fig. 3

1. Insert the plug in the tool, making sure that the

sleeve is against the nosepiece. (Fig. 1)

2. After inserting the plug into the hole (making sure

the tool is flush to the work surface) activate the tool

to expand the plug. The mandrel will break apart

when the proper tension has been reached.

(Fig. 2 & 3)

Note

• The assembly of KOENIG-Expanders should only be

done in a clean working area.

• The sleeve and mandrel of the plug should not be

cleaned or lubricated.

Tools

For trouble free installation of KOENIG-Expanders use the tools and appropriate components according to the data

sheet.

Plug Removal

With KOENIG-Expander Sidex-SK Series plug removal is possible.

Procedure:

1. Drive the mandrel from the sleeve with a punch.

2. Drill out the sleeve and remove the mandrel.

3. Bore the hole to the next larger Expander diameter per the data sheet.

4. Clear chips, remnants of the sleeve, and oil and grease from the bore.

5. Install a new KOENIG-Expander.

Note: After plug removal always install the next larger size plug.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

13


Spacers, Sidex Series

Case Hardening Steel

DIN 1.0403, ~AISI 10L15

Case Hardened

For setting KOENIG-Expander Sidex SK

plugs with 30 mm longer mandrels

14

Dimensions in MM

d1 d2 Type

Sidex SK Series

4.0 2.7 4X30-SK SK 552-040

5.0 3.2 5X30-SK SK 552-050

6.0 3.7 6X30-SK SK 552-060

7.0 4.6 7X30-SK SK 552-070

8.0 4.8 8X30-SK SK 552-080

9.0 5.2 9X30-SK SK 552-090

10.0 5.6 10X30-SK SK 552-100

TOOLS

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SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Setting Tools–SK Series

TOOLS

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SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

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15


Setting Tools–Sidex-SK Series

Type KW-010 (shown)

Hydraulic/Pneumatic Tool

Type KW-010 MCS available.

Features a vacuum mandrel collection system.

Air Pressure max. 6.5 bar (95 psi)

Air Consumption per Expander 1 dm 3 (61 in3 )

Weight 2.1 kg (4.6 lb.)

16

4 SKW-104

Type KW-020

Hydraulic/Pneumatic Tool

Air pressure max. 6.5 bar (95 psi)

Weight 2.2 kg (4.9 lb.)

d1 Nosepiece Jaw Case Jaws Jaw Pusher

Tool

TOOLS

Type Type Type Type Type Type

5 SKW-105 PRG740-11AE PRG540-46E

6 SKW-106 PRG740-7A

7 SKW--107

8 SKW-108

HKW-010308 HKW-014208 HKW-010508

9 SKW-109 –

10* SKW-110

* For installation of d 1 =10 mm diameter plugs, the mandrel

collection system must be turned off.

PRG-14

KW-010 KW-020

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HK Series

• Extensive available stock from

3-12 mm diameter, special

oversize version and extended

mandrels for below surface

installation

• Normal working tolerances 0/+0.1

mm or 0/+0.05 mm

• Direct installation in Hydraulic

Component through holes

• Clean, mechanical sealing

• Quick installation using hand rivet

type tools

Contents Page

– HK 55 Series 18

– Installation Instructions 20

– Spacers 21

– Setting Tools 22


HK 55 Series

Sleeve: Case Hardening Steel

DIN 1.0403, ~AISI 10L15

Soft Annealed Gun Metal Finish

Dimensions in MM

18

d1 l1 d2 l2 l3 max.

l 4

max.

Bore Diameter

Mandrel: Heat Treatable Steel

~DIN 1.0728

Special Oil Film Lubrication

3.0 5.0 2.0 36.5 9.0 7.0 3.0 HK030-CK55-111 100

4.0 5.0 2.2 38.0 9.5 8.0 4.0 HK040-CK55-111 100/1000

5.0 6.0 2.8 43.0 11.0 9.5 5.0 HK050-CK55-111 100/1000

6.0 6.5 2.8 43.0 12.0 10.0 6.0 HK060-CK55-111 100/1000

7.0

8.0

7.5

8.5

3.8

4.5

43.0

38.0

13.0

13.5

11.0

11.5

7.0

8.0

+ 0.1

0

HK070-CK55-111

HK080-CK55-111

Standard

100/500

100/500

9.0 9.5 4.5 41.0 14.5 13.0 9.0 HK090-CK55-111 100/500

10.0 10.5 4.5 41.0 15.5 13.5 10.0 HK100-CK55-111 100/250

4.3 5.0 2.2 38.0 9.5 8.0 4.3 HK043-CK55-111 Oversize

5.3 6.0 2.8 43.0 11.0 9.5 5.3 HK053-CK55-111 Version

6.3 6.5 2.8 43.0 12.0 10.0 6.3 HK063-CK55-111

7.3

8.3

9.3

7.5

8.5

9.5

3.8

4.5

4.5

43.0

38.0

41.0

13.0

13.5

14.5

11.0

11.5

13.0

7.3

8.3

9.3

+ 0.1

0

HK073-CK55-111

HK083-CK55-111

HK093-CK55-111

100

10.3 10.5 4.5 41.0 15.5 13.5 10.3 HK103-CK55-111

HK 11 Series

Sleeve: Aluminum Alloy

DIN 3.0615, AlMgSiPb

Plain Finish

Dimensions in MM

d1 l1 d2 l2 l3 max.

l 4

max.

Bore Diameter

Type

Mandrel: Heat Treatable

~DIN 1.0728

Special Oil Film Lubrication

12.0 12.0 6.0 40.0 17.5 15 12.0 + 0.5

0

HK120-CK11-111 Standard 250

Type

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SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

19


20

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


TOOLS

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SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

21


22

HKW-002103 •

HKW-002104 •

HKW-002103 •

HKW-002104 •

HKW-002105 •

TOOLS

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Setting Tools – HK Series

TOOLS

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SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

23


Setting Tools–HK-55

Type KW-010 (shown)

Hydraulic/Pneumatic Tool

Type KW-010 MCS available.

Features a vacuum mandrel collection system.

Air Pressure max. 6.5 bar (95 psi)

Air Consumption per Expander 1 dm3 (61 in3 )

Weight 2.1 kg (4.6 lb.)

24

Type KW-020

Hydraulic/Pneumatic Tool

Air pressure max. 6.5 bar (95 psi)

Weight 2.2 kg (4.9 lb.)

TOOLS

KW-010 KW-020

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Setting Tools–HK-11

Type KW-010 (shown)

Hydraulic/Pneumatic Tool

Type KW-010 MSC available.

Features a vacuum mandrel collection system.

Air Pressure max. 6.5 bar (95 psi)

Air Consumption per Expander 1 dm 3 (61 in3 )

Weight 2.1 kg (4.6 lb.)

Type KW-020

Hydraulic/Pneumatic Tool

Air pressure max. 6.5 bar (95 psi)

Weight 2.2 kg (4.9 lb.)

TOOLS

KW-010 KW-020

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25


26

NOTES

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


LK Series

• 4-12 mm diameter,

•Working pressure to 60 Bar

(870 psi)

• Shortest Installed Length

• Larger working tolerances

0/+0.12 mm

• Installs directly into drilled holes

• Clean mechanical sealing through

positive anchoring

• Quick installation using handy rivet

type tools

• No axial loading imposed on

component

•Available in stainless steel

Contents Page

– LK 600 Series 28

– LK 950 Series 29

– Installation Instructions 30

– Setting Tools 31


LK 600 Series

Sleeve: Stainless Steel

DIN 1.4305, Plain Finish

Special Oil Film Lubrication

One Piece Construction ideal for automated

high production requirements.

28

d1 l1 d2 l2 l3 max.

l 4

max.

Mandrel: Stainless Steel

DIN 1.4305, Plain Finish

Special Oil Film Lubrication

Bore Diameter

4.0 3.7 2.2 36 5.5 4.0 4.0 LK-600-040 100/1000

5.0 4.5 2.95 36 6.9 4.8 5.0 LK-600-050 100/1000

6.0 5.0 3.4 36 7.4 5.3 6.0 LK-600-060 100/1000

7.0

8.0

5.5

6.5

4.2

4.3

34

34

8.0

9.8

5.8

6.8

7.0

8.0

+0.12

0

LK-600-070

LK-600-080

100/500

100/500

9.0 6.5 4.7 34 9.8 6.8 9.0 LK-600-090 100/500

10.0 6.5 5.1 36 9.8 6.8 10.0 LK-600-100 100/500

12.0 7.5 5.9 36 10.8 7.8 12.0 LK-600-120 100/250

Type

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SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


LK 950 Series

Sleeve: Case Hardening Steel

Soft Annealed Gun Finish

One Piece Construction ideal for automated

high production requirements.

d1 l1 d2 l2 l3 max.

l 4

max.

Mandrel: Steel Plain Finish

Special Oil Film Lubrication

Bore Diameter

4.0 3.7 2.2 36 5.5 4.0 4.0 LK-950-040 100/1000

5.0 4.5 2.95 36 6.9 4.8 5.0 LK-950-050 100/1000

6.0 5.0 3.4 36 7.4 5.3 6.0 LK-950-060 100/1000

7.0

8.0

5.5

6.5

4.2

4.3

34

34

8.0

9.8

5.8

6.8

7.0

8.0

+0.12

0

LK-950-070

LK-950-080

100/500

100/500

9.0 6.5 4.7 34 9.8 6.8 9.0 LK-950-090 100/500

10.0 6.5 5.1 36 9.8 6.8 10.0 LK-950-100 100/500

12.0 7.5 5.9 36 10.8 7.8 12.0 LK-950-120 100/250

Type

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29


Installation Instructions LK Series

Drilled Hole

• The drilled hole must be within the tolerances shown on the preceding data sheets.

• Holes must be round within 0.05 mm.

• With hard materials the bore roughness should be from R z = 10 - 30 µm for best results.

• Longitudinal rifles and spiral grooves should be avoided. These influence the sealing effectiveness.

• The bore must be free of oil, grease and chips.

Setting Procedure

30

Fig. 1

Fig. 2

Fig. 3

1. Insert the plug in the tool, making sure that the

sleeve is against the nosepiece. (Fig. 1)

2. After inserting the plug into the hole activate the tool

to expand the plug. The mandrel will break apart

when the proper tension has been reached.

(Fig. 2 & 3)

Note

• The assembly of KOENIG-Expanders should only be

done in a clean working area.

• The sleeve and mandrel of the plug should not be

cleaned or lubricated.

Tools

For trouble free installation of KOENIG-Expanders use the tools and appropriate components according to the data

sheet.

Plug Removal

With KOENIG-Expander LK Series plug removal is possible.

Procedure:

1. Drive the mandrel from the sleeve with a punch.

2. Drill out the sleeve and remove the mandrel.

3. Bore the hole to the next larger Expander diameter per the data sheet.

4. Clear chips, remnants of the sleeve, and oil and grease from the bore.

5. Install a new KOENIG-Expander.

Note: After plug removal always install the next larger size plug.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Setting Tools–LK Series

TOOLS

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SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

31


Setting Tools–LK Series

Type KW-010 (shown)

Hydraulic/Pneumatic Tool

Type KW-010 MCS available.

Features a vacuum mandrel collection system.

Air Pressure max. 6.5 bar (95 psi)

Air Consumption per Expander 1 dm 3 (61 in3 )

Weight 2.1 kg (4.6 lb.)

32

4 LKW-104

Type KW-020

Hydraulic/Pneumatic Tool

Air pressure max. 6.5 bar (95 psi)

Weight 2.2 kg (4.9 lb.)

d1 Nosepiece Jaw Case Jaws Jaw Pusher

Tool

TOOLS

Type Type Type Type Type Type

5 LKW-105 PRG740-11AE PRG540-46E

6 LKW-106 PRG740-7A

7 LKW--107

8 LKW-108

9 LKW-109

HKW 010308

PRG-14

HKW 014208 HKW 010508

10 LKW-110

12 LKW-112 HKW-014210 10X30

KW-010 KW-020

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SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


LP Series

• Mechanical labyrinth sealing

• Satisfactory corrosion protection

• Rated pressure performances up to

60 bar (870 psi)

• Suitable for fully automated

installation

Contents Page

– LP 900 Series 34

– Installation Instructions 35

– Setting Tools 36


LP 900 Series Sealing Plugs

Material: Free Cutting Steel

Nitrocarburized, Lubricated

34

Dimensions in MM

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SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Installation Instructions LP Series

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

35


Setting Tools, LP Series

Tools: Tool Steel

Heat Treated Hardness – HRC50

36

TOOLS

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Assembly Press–LP Series–Pressure and Stroke Control

Type PH-450

Type PH-550

Technical Data PH-450

AUTOMATION

Hydropneumatic Table Press for the installation of MB

and LP Series Koenig Sealing Plugs. Stroke control of

press allows for consistent, repeatable installations to

meet quality system performance goals. On-board

monitoring of installation force with graph printing capabilities

as well as computer data output.

Further Equipment Styles: PH-400 / PH-500

Table Press with stroke control but without

installation force monitoring, graph printing capabilities,

and data output.

Dimensions Width 250 mm

Width (control unit) 470 mm

Height 1,190 mm

Depth 750 mm

Diameter Range 3 –7 mm (.093–.281 in.)

Air Pressure 6 bar

Air Consumption 5.3 L / Stroke

Pressing Force 28 kN

Power Stroke 3 mm

Cylinder Ram ~ 60 mm

Technical Data PH-550

Dimensions Width 250 mm

Width (control unit) 470 mm

Height 1,190 mm

Depth 750 mm

Diameter Range 3 – 14 mm

Air Pressure 6 bar

Air Consumption 16 L / Stroke

Pressing Force 40 kN

Power Stroke max. 16 mm

Cylinder Ram ~ 60 mm

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

37


38

NOTES

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Technical

Information

Engineering:

Design and development

with state-of-the-art

CAD-Design.

Profile Projector –

Measuring Instrument for in-process

control of production.

Contents Page

– Pressure Performance Tests 41

– Pressure Performance

MB 600 42

MB 600, Inch-Version 44

MB 700 46

MB 800 48

Sidex-SK 50

HK 55 52

LK 600 54

LK 950 56

LP 900 58

– Anchorage Principle 60

– Hole Roughness: Requirements 62

– Design Guidelines 63

– Galvanic Corrosion 67

– Chart: Hardness cross reference for

plain and low alloy steels 69

– SI-Units of Measurement 70

– American and British

Units of Measurement 72


40

NOTES

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


T

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

41


42

T

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Pressure Performance MB 600

Installation Requirements

The working pressure specifications on the preceding page are obtainable under the following conditions.








Base Material of the

Installation

High Strength St.

ETG-100

AISI 1144

Free Machining Case

Hard. Stl.

C15 Pb

DIN 1.0403

Cast Iron

GG-25

DIN 1691

Ductile Cast Iron

GGG-50

DIN 1693

Aluminum Alloy

Al Mg Si Pb

DIN 3.0615

AA6262

Aluminum Alloy

Al Cu Mg 2

DIN 3.1354

AA2024

Cast Al Alloy

G-Al Si 7 Mg

3.2371

AA356-T6

Tensile Strength

(avg.) [N/mm 2 ]

Elongation (min.)

[%]

1000 6 865 280

560 6 300 180

250 – – 160

500 7 320 170

340 8 300 90

480 8 380 120

300 4 250 80

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical

characteristics. However, the appropriate installation instructions must be followed.

• Applications for other non-ferrous metals and non-metallic materials upon request.

• Factors which may lower the working pressure capability are:

- anchorage principle

- bore roughness requirements

- design guidelines

Ultimate Strength

(avg.) Rp 0.2 [N/mm 2 ]

Hardness

(min.) HB

Drilled Hole

Tolerance [mm] Roughness R z [µm]

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve

indicated working pressures.

Security Range

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst

pressure Test A and Test B pressure are reduced about 20% after this point.

+ 0.1

0

T

10 to 30

anchorage

in

base metal

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

43


Pressure Performance MB 600, Inch-Version

Sleeve Material: X 10 CrNiS 18 9 Tensile Strength Rm = 640 N/mm 2

DIN 1.4305 Hardness HB = 220

44

p [bar]

1600

1400

1200

1000

800

600

400

200

.093

( 3/32")

➀➁➂➃➅

➎➐

1,400 bar (20,300 psi)

1,200 bar (17,400 psi)

450 bar (6,500 psi)

380 bar (5,500 psi)

.125

( 1/8")

.156

( 5/32")

Proof Pressure Test B

Base Material

.187

( 3/16")

➀➁➂➃➅

➎➐

➀➁➂➃➅

➎➐

.218

( 7/32")

Expander Diameter [in]

.250

( 1/4")

.281

( 9/32")

20,000

15,000

10,000

5,000

T

p [psi]

Max. Allowable Working Pressure = Nominal Pressure

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Pressure Performance MB 600, Inch-Version

Installation Requirements

The working pressure specifications on the preceding page are obtainable under the following conditions.








Base Material of the

Installation

High Strength St.

ETG-100

AISI 1144

Free Machining Case

Hard. Stl.

C15 Pb

DIN 1.0403

Cast Iron

GG-25

DIN 1691

Ductile Cast Iron

GGG-50

DIN 1693

Aluminum Alloy

Al Mg Si Pb

DIN 3.0615

AA6262

Aluminum Alloy

Al Cu Mg 2

DIN 3.1354

AA2024

Cast Al Alloy

G-Al Si 7 Mg

3.2371

AA356-T6

Tensile Strength

(avg.) [N/mm 2 ]

Elongation (min.)

[%]

Ultimate Strength

(avg.) Rp 0.2 [N/mm 2 ]

Hardness

(min.) HB

1000 6 865 280

560 6 300 180

250 – – 160

500 7 320 170

340 8 300 90

480 8 380 120

300 4 250 80

Drilled Hole

T

Tolerance [in.] Roughness R z [µm]

ø .093

from

ø .125

+ 0.002

0

+ 0.004

0

10 to 30

anchorage

in

base metal

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical

characteristics. However, the appropriate installation instructions must be followed.

• Applications for other non-ferrous metals and non-metallic materials upon request.

• Factors which may lower the working pressure capability are:

- anchorage principle

- bore roughness requirements

- design guidelines

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve

indicated working pressures.

Security Range

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst

pressure Test A and Test B pressure are reduced about 20% after this point.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

45


Pressure Performance MB 700

Sleeve Material: Stainless Steel, AISI 303 Tensile Strength Rm = 640 N/mm 2

DIN 1.4305 Hardness HB = 220

p [bar]

46

1600

1400

1200

1000

800

600

400

200

3

1,400 bar (20,300 psi)

1,200 bar (17,400 psi)

450 bar (6,500 psi)

380 bar (5,500 psi)

➀➁➂➃➅

➎➐

4 5 6 7 8 9 10 12 14 16 18 20 22

Proof Pressure Test B

Base Material

➎➐

➀➁➂➃➅

➎➐

➀➁➂➃➅

Expander Diameter [mm]

1,150 bar (16,700 psi)

900 bar (13,000 psi)

350 bar (5,100 psi)

280 bar (4,100 psi)

T

20,000

15,000

10,000

5,000

Max. Allowable Working Pressure = Nominal Pressure

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

p [psi]


Pressure Performance MB 700

Installation Requirements

The working pressure specifications on the preceding page are obtainable under the following conditions.








Base Material of the

Installation

High Strength St.

ETG-100

AISI 1144

Free Machining Case

Hard. Stl.

C15 Pb

DIN 1.0403

Cast Iron

GG-25

DIN 1691

Ductile Cast Iron

GGG-50

DIN 1693

Aluminum Alloy

Al Mg Si Pb

DIN 3.0615

AA6262

Aluminum Alloy

Al Cu Mg 2

DIN 3.1354

AA2024

Cast Al Alloy

G-Al Si 7 Mg

3.2371

AA356-T6

Tensile Strength

(avg.) [N/mm 2 ]

Elongation (min.)

[%]

1000 6 865 280

560 6 300 180

250 – – 160

500 7 320 170

340 8 300 90

480 8 380 120

300 4 250 80

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical

characteristics. However, the appropriate installation instructions must be followed.

• Applications for other non-ferrous metals and non-metallic materials upon request.

• Factors which may lower the working pressure capability are:

- anchorage principle

- bore roughness requirements

- design guidelines

Ultimate Strength

(avg.) Rp 0.2 [N/mm 2 ]

Hardness

(min.) HB

Drilled Hole

T

Tolerance [mm] Roughness R z [µm]

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve

indicated working pressures.

Security Range

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst

pressure Test A and Test B pressure are reduced about 20% after this point.

+ 0.1

0

10 to 30

anchorage

in

base metal

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

47


Pressure Performance MB 800

Sleeve Material: Case Hardening Steel Tensile Strength Rm = 500 N/mm 2

DIN 1.0403 Hardnesss H = 180

p [bar]

48

1600

1400

1200

1000

800

600

400

200

3

1,100 bar (16,000 psi)

1,000 bar (14,500 psi)

350 bar (5,100 psi)

320 bar (4,600 psi)

4 5 6 7 8 9 10 12 14 16 18 20 22

➀➁➂➃➅

➎➐

➎➐

Proof Pressure Test B

Base Material

➎➐

➀➁➂➃➅

➀➁➂➃➅

Expander Diameter [mm]

900 bar (13,000 psi)

800 bar (11,600 psi)

280 bar (4,100 psi)

250 bar (3,600 psi)

T

20,000

15,000

1,000

5,000

Max. Allowable Working Pressure = Nominal Pressure

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

p [psi]


Pressure Performance MB 800

Installation Requirements

The working pressure specifications on the preceding page are obtainable under the following conditions.








Base Material of the

Installation

High Strength St.

ETG-100

AISI 1144

Free Machining

CasehHard. St.

C15Pb

DIN 1.0403

Cast Iron

GG-25

DIN 1691

Ductile Cast Iron

GGG-50

DIN 1693

Aluminum Alloy

Al Mg Si Pb

DIN 3.0615

AA6262

Aluminum Alloy

Al Cu Mg 2

DIN 3.1354

AA2024

Cast Al Alloy

G-Al Si 7 Mg

DIN 3.2371

AA356-T6

Tensile Strength

(avg.)

Rm [N/mm 2 ]

Elongation (min.)

[%)

1000 6 865 280

560 6 300 180

250 – – 160

500 7 320 170

340 8 300 90

480 8 380 120

300 4 250 80

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical

characteristics. However, the appropriate installation instructions must be followed.

• Applications for other non-ferrous metals and non-metallic materials upon request.

• Factors which may lower the working pressure capability are:

- anchorage principle

- bore roughness requirements

- design guidelines

Ultimate Stength

(avg.)

Rp 0.2 [N/mm 2 ]

T

Hardness

Drilled Hole

(min.)

HB Tolerance [mm] Roughness Rz [µm]

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve

indicated working pressures.

Security Range

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst

pressure Test A and Test B pressure are reduced about 20% after this point.

+ 0.1

0

10 to 30

anchorage

in

base metal

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

49


Pressure Performance Sidex-SK

Sleeve Material : Case Hardening Steel Tensile Strength Rm = 500 N/mm 2

DIN 1.0403 Hardness HB = 180

50

➀➁➂➃➅

➎➐

1800

1600

1400

1200

1000

800

600

400

200

4

1,600 bar (23,200 psi)

1,400 bar (20,300 psi)

500 bar (7,200 psi)

450 bar (6,500 psi)

Proof Pressure Test B

Base Material

➀➁➂➃➅

➎➐

➀➁➂➃➅

➎➐

5 6 7 8 9 10

Expander Diameter [mm]

25,000

20,000

15,000

10,000

5,000

p [psi]

T

Max. Allowable Working Pressure = Nominal Pressure

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Pressure Performance Sidex-SK

Installation Requirements

The working pressure specifications on the preceding page are obtainable under the following conditions.








Base Material of the

Installation

High Strength St.

ETG-100

AISI 1144

Free Machining Case

Hard. Stl.

C15 Pb

DIN 1.0403

Cast Iron

GG-25

DIN 1691

Ductile Cast Iron

GGG-50

DIN 1693

Aluminum Alloy

Al Mg Si Pb

DIN 3.0615

AA6262

Aluminum Alloy

Al Cu Mg 2

DIN 3.1354

AA2024

Cast Al Alloy

G-Al Si 7 Mg

3.2371

AA356-T6

Tensile Strength

(avg.) [N/mm 2 ]

Elongation (min.)

[%]

1000 6 865 280

560 6 300 180

250 – – 160

500 7 320 170

340 8 300 90

480 8 380 120

300 4 250 80

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical

characteristics. However, the appropriate installation instructions must be followed.

• Applications for other non-ferrous metals and non-metallic materials upon request.

• Factors which may lower the working pressure capability are:

- anchorage principle

- bore roughness requirements

- design guidelines

Ultimate Strength

(avg.) Rp 0.2 [N/mm 2 ]

Hardness

(min.) HB

Drilled Hole

T

Tolerance [mm] Roughness R z [µm]

+ 0.12

0

• If pressure is applied to both sides of the Sidex-SK plug, allowable working pressure on the insertion side is reduced

by 50%.

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve

indicated working pressures.

Security Range

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst

pressure Test A and Test B pressure are reduced about 20% after this point.

10 to 30

anchorage

in

base metal

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

51


Pressure Performance HK 55

Sleeve Material : Case Hardening Steel, soft annealed Tensile Strength Rm = 350 N/mm 2

DIN 1.0403 Hardness HB = 100

52

p [bar]

1600

1400

1200

1000

800

600

400

200

3

➀➁➂➃➅

➎➐

1,200 bar (17,400 psi)

500 bar (7,200 psi)

350 bar (5,100 psi)

160 bar (2,300 psi)

450 bar (6,500 psi)

4 5 6 7 8 9 10

Proof Pressure Test B

Base Material

➀➁➂➃

➎➏➐

➀➁➂➃

➎➏➐

Expander Diameter [mm]

20,000

15,000

10,000

5,000

p [psi]

T

Max. Allowable Working Pressure = Nominal Pressure

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Pressure Performance HK 55

Installation Requirements

The working pressure specifications on the preceding page are obtainable under the following conditions.








Base Material of the

Installation

High Strength St.

ETG-100

AISI 1144

Free Machining Case

Hard. Stl.

C15 Pb

DIN 1.0403

Cast Iron

GG-25

DIN 1691

Ductile Cast Iron

GGG-50

DIN 1693

Aluminum Alloy

Al Mg Si Pb

DIN 3.0615

AA6262

Aluminum Alloy

Al Cu Mg 2

DIN 3.1354

AA2024

Cast Al Alloy

G-Al Si 7 Mg

3.2371

AA356-T6

Tensile Strength

(avg.) [N/mm 2 ]

Elongation (min.)

[%]

1000 6 865 280

560 6 300 180

250 – – 160

500 7 320 170

340 8 300 90

480 8 380 120

300 4 250 80

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical

characteristics. However, the appropriate installation instructions must be followed.

• Applications for other non-ferrous metals and non-metallic materials upon request.

• Factors which may lower the working pressure capability are:

- anchorage principle

- bore roughness requirements

- design guidelines

Ultimate Strength

(avg.) Rp 0.2 [N/mm 2 ]

Hardness

(min.) HB

Drilled Hole

T

Tolerance [mm] Roughness R z [µm]

• If HK plugs are used to keep channels separate, allowable working pressure on the insertion side is reduced by

50%.

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve

indicated working pressures.

Security Range

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst

pressure Test A and Test B pressure are reduced about 20% after this point.

+ 0.1

0

10 to 30

roughness

anchoring not

effective

*

anchorage

in

base metal

not possible

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

53


Pressure Performance LK 600

54

p [bar]

200

180

160

140

120

100

80

60

40

➀➁➂➃➄➅➆

Base Material

4

180 bar (2,600 psi)

60 bar (870 psi)

Proof Pressure Test B

➀➁➂➃➄➅➆

➀➁➂➃➄➅➆

5 6 7 8 9 10

Expander Diameter [mm]

p [psi]

T

3,000

2,500

2,000

1,500

1,000

Max. Allowable Working Pressure = Nominal Pressure

➀➁➂➃➄ Temperature range for Proof Pressure Test B : -40ºC to +150ºC

➅➆ Temperature range for Proof Pressure Test B : -40ºC to +100ºC

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

12


Pressure Performance LK 600

Installation Requirements

The working pressure specifications on the preceding page are obtainable under the following conditions.








Base Material of the

Installation

High Strength St.

ETG-100

AISI 1144

Free Machining Case

Hard. Stl.

C15 Pb

DIN 1.0403

Cast Iron

GG-25

DIN 1691

Ductile Cast Iron

GGG-50

DIN 1693

Aluminum Alloy

Al Mg Si Pb

DIN 3.0615

AA6262

Aluminum Alloy

Al Cu Mg 2

DIN 3.1354

AA2024

Cast Al Alloy

G-Al Si 7 Mg

3.2371

AA356-T6

Tensile Strength

(avg.) [N/mm 2 ]

Elongation (min.)

[%]

1000 6 865 280

560 6 300 180

250 – – 160

500 7 320 170

340 8 300 90

480 8 380 120

300 4 250 80

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical

characteristics. However, the appropriate installation instructions must be followed.

• Applications for other non-ferrous metals and non-metallic materials upon request.

• Factors which may lower the working pressure capability are:

- anchorage principle

- bore roughness requirements

- design guidelines

Ultimate Strength

(avg.) Rp 0.2 [N/mm 2 ]

Hardness

(min.) HB

• Series LK are not suitable for pressure load applied on the insertion side of plug.

Drilled Hole

T

Tolerance [mm] Roughness R z [µm]

+ 0.12

0

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve

indicated working pressures.

Security Range

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst

pressure Test A and Test B pressure are reduced about 20% after this point.

10 to 30

anchorage

in

base metal

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

55


Pressure Performance LK 950

56

p [bar]

200

180

160

140

120

100

80

60

➀➁➂➃➄➅➆

Base Material

180 bar (2,600 psi)

60 bar (870 psi)

4 5 6 7 8 9 10

Proof Pressure Test B

➀➁➂➃➄➅➆

➀➁➂➃➄➅➆

Expander Diameter [mm]

12

T

2,500

2,000

1,500

1,000

p [psi]

Max. Allowable Working Pressure = Nominal Pressure

➀➁➂➃➄ Temperature range for Proof Pressure Test B : -40ºC to +150ºC

➅➆ Temperature range for Proof Pressure Test B : -40ºC to +100ºC

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Pressure Performance LK 950

Installation Requirements

The working pressure specifications on the preceding page are obtainable under the following conditions.








Base Material of the

Installation

High Strength St.

ETG-100

AISI 1144

Free Machining Case

Hard. Stl.

C15 Pb

DIN 1.0403

Cast Iron

GG-25

DIN 1691

Ductile Cast Iron

GGG-50

DIN 1693

Aluminum Alloy

Al Mg Si Pb

DIN 3.0615

AA6262

Aluminum Alloy

Al Cu Mg 2

DIN 3.1354

AA2024

Cast Al Alloy

G-Al Si 7 Mg

3.2371

AA356-T6

Tensile Strength

(avg.) [N/mm 2 ]

Elongation (min.)

[%]

1000 6 865 280

560 6 300 180

250 – – 160

500 7 320 170

340 8 300 90

480 8 380 120

300 4 250 80

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical

characteristics. However, the appropriate installation instructions must be followed.

• Applications for other non-ferrous metals and non-metallic materials upon request.

• Factors which may lower the working pressure capability are:

- anchorage principle

- bore roughness requirements

- design guidelines

Ultimate Strength

(avg.) Rp 0.2 [N/mm 2 ]

Hardness

(min.) HB

• Series LK are not suitable for pressure load applied on the insertion side of plug.

Drilled Hole

T

Tolerance [mm] Roughness R z [µm]

Diameter

4 to 12mm

+ 0.12

0

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve

indicated working pressures.

Security Range

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst

pressure Test A and Test B pressure are reduced about 20% after this point.

10 to 30

Partial

Anchorage

10 to 30

Anchorage in

base material

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

57


Pressure Performance LP 900

58

p [bar]

200

180

160

140

120

100

80

60

➀➁➂➃➄➅➆

Base Material

180 bar (2,600 psi)

60 bar (870 psi)

4 5 6 7 8 9 10

Proof Pressure Test B

➀➁➂➃➄➅➆

➀➁➂➃➄➅➆

Expander Diameter [mm]

12

T

2,500

2,000

1,500

1,000

p [psi]

Max. Allowable Working Pressure = Nominal Pressure

➀➁➂➃➄ Temperature range for Proof Pressure Test B : -40ºC to +150ºC

➅➆ Temperature range for Proof Pressure Test B : -40ºC to +100ºC

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Pressure Performance LP 900

Installation Requirements

The working pressure specifications on the preceding page are obtainable under the following conditions.








Base Material of the

Installation

High Strength St.

ETG-100

AISI 1144

Free Machining Case

Hard. Stl.

C15 Pb

DIN 1.0403

Cast Iron

GG-25

DIN 1691

Ductile Cast Iron

GGG-50

DIN 1693

Aluminum Alloy

Al Mg Si Pb

DIN 3.0615

AA6262

Aluminum Alloy

Al Cu Mg 2

DIN 3.1354

AA2024

Cast Al Alloy

G-Al Si 7 Mg

3.2371

AA356-T6

Tensile Strength

(avg.) [N/mm 2 ]

Elongation (min.)

[%]

1000 6 865 280

560 6 300 180

250 – – 160

500 7 320 170

340 8 300 90

480 8 380 120

300 4 250 80

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical

characteristics. However, the appropriate installation instructions must be followed.

• Applications for other non-ferrous metals and non-metallic materials upon request.

• Factors which may lower the working pressure capability are:

- anchorage principle

- bore roughness requirements

- design guidelines

Ultimate Strength

(avg.) Rp 0.2 [N/mm 2 ]

Hardness

(min.) HB

Drilled Hole

T

Tolerance [mm] Roughness R z [µm]

Diameter

3 to 12 mm

(see data

sheet)

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve

indicated working pressures.

Security Range

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst

pressure Test A and Test B pressure are reduced about 20% after this point.

10 to 30

anchorage

in

base metal

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

59


Anchorage Principle

60

T

The required bore roughness is directly related to the hardness and the mechanical characteristics of the base

material. Depending on the combination of sealing plug and base material, anchorage takes place either by the

groove profile of the expander sleeve biting into the base material or on anchorage to the surface roughness of

the bore.

NOTE: When selecting a KOENIG Expander the bore roughness must always be adjusted according to the

hardness of the base material.

Anchorage principle related to base material

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Anchorage Principle

Anchorage due to plug sleeve serrations

KOENIG Expander Series MB 800

in aluminum alloy HB = 90

Anchorage due to plug sleeve serrations

KOENIG Expander Series LP 900

in aluminum alloy HB = 90

Anchorage due to plug sleeve serrations

KOENIG Expander Series SK

in aluminum alloy HB=90

Anchorage due to bore roughness

KOENIG Expander Series HK 55

in gray cast iron HB = 160

Anchorage due to plug sleeve serrations

KOENIG Expander Series LK 950

in aluminum alloy HB = 90

T

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

61


Bore Roughness Requirements

62

T

When installing KOENIG-Expanders in hard base material no positive anchoring is possible. So, to attain suitable

working pressures and anchorage, it is necessary to have a bore roughness of Rz=10-30 µm. At a roughness greater

than Rz=10-30 µm leakage might occur.

Pressure performance correlation to bore roughness.

% of test pressure, Test B , and allowable working pressure

100

80

60

40

20

Roughness Profile

Required roughness profile

1 2 3 4 5 6 7 8 9 10 20 30

The ideal bore roughness for anchorage is attained by

drilling with a twist drill or core drill.

Roughness R Z [µm]

(Approximate)

Undesirable roughness profile

By reaming, a one-sided, smooth roughness profile is

created. This is not desirable.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Design Guidelines

T

Wall thickness/distance from edge

As the radial expansion of the KOENIG Expander sleeve occurs, the base material in which it will be anchored

plastically deforms. The resultant strength, as well as the hydraulic pressure and temperature service conditions

depending on the expander type and characteristics of the base material, require minimum wall thickness, or

distance from edge.

The guideline values for minimum wall thickness and distance from edge (Wmin) express these influencing factors.

At these minimum values, only slight deformation on the exterior profile of the base material of less than 20 µm is

likely. This does not affect the function of the KOENIG Expander. Below the guideline values (Wmin ) the possibility

of overloading the base material exists, which can adversely influence the function of the KOENIG Expander. In such

cases tests must be conducted.

Guideline values W min for wall thickness and distance from edge

At KOENIG Expander diameters d1 ≥ 4mm: Wmin = fmin · d1

d1


Design Guidelines

Required Installation Lengths

64

Dimensions in MM

l 3

d 1

l 4

d N

d 1

l 4

d N =d 1

d 1

l 4

d N =d 1

d 1

T

MB Sidex-SK

HK

Threaded Plugs

dN HK 55 HK 11

DIN 908

d1 l3 min l4 min* d1 l4 max d1 l4 max d1 l4 max d1 l4 max

2.0 3.0 3.4 5.0

3.0 4.0 3.8 5.5 3.0 7.0 3.0 6.5

4.0 5.0 5.3 7.0 4.0 6.5 4.0 8.0 4.0 8.0

5.0 6.0 6.3 8.5 5.0 7.5 5.0 9.5 5.0 10.0 M 8x1 11.5

6,0 7.0 7.3 9.5 6.0 8.0 6.0 10.0 6.0 10.0 M 8x1 11.5

7.0 8.0 8.3 11.0 7.0 9.0 7.0 11.0 7.0 10.5 M10x1 12.0

8.0 9.0 9.8 12.5 8.0 10.5 8.0 11.5 8.0 13.5 M10x1 12.0

9.0 10.0 10.8 13.5 9.0 11.0 9.0 13.0 9.0 13.0 M12x1.5 16.0

10.0 12.0 12.8 16.0 10.0 12.5 10.0 13.5 10.0 15.5 M12x1.5 16.0

12.0 14.0 14.5 18.0 12.0 15.0 M14x1.5 16.5

14.0 16.0 16.5 20.0 M16x1.5 16.5

16.0 18.0 18.5 22.5 M18x1.5 17.5

18.0 20.0 21.5 25.5 M20x1.5 19.5

20.0 22.0 24.5 28.5 M22x1.5 19.5

d N = given nominal bore/system bore size

* Installation Lengths MB Series

Comparison

The required installation length (l 4 ) min. for MB plugs is for base materials with hardness greater than HB=90. For

softer materials, deeper installation is required.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

l 4

d N


Design Guidelines

Dimensions in MM

T

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

65


Design Guidelines

66

T

Roundness Tolerance

To assure reliable functioning of the KOENIG-Expander with regard to pressure performance and to assure leak tight

sealing, a roundness tolerance of t=0.05 mm must be held.

By using a double lipped twist drill, the called out hole

and roundness tolerances are reached. Better

tolerances, particularly for larger diameter holes, can be

held by using a triple lipped twist drill.

Conicity of the Bore

Within the effective sealing area of the KOENIG Expander, the bore must be according to the dimensional sheets.

The bore lead in can be beveled up to a depth of 0.25 x d1 (LK: 0.15 x d1) because this area has no significant effect

on the sealing function.

MB SK HK

LP LK

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Galvanic Corrosion

T

In choosing a KOENIG Expander you must consider that the material of the sealing plug and the material of the

production piece can show different electrical potentials. In the presence of an electrolyte (e.g. 5% Water-NaCl

solution), this potential difference causes electrochemical attack on the least noble of the metals in contact - galvanic

corrosion. In this case, either the base material or its surface protection will become the anode and will be

transferred to the pure metal of the cathode. The corrosion speed or the current density will be determined by the

relative surface area or volume of the anode and cathode as illustrated below.

Cathode

Anode

KOENIG-Expander = Cathode

Large Anode Area → Low Current Density at the Anode → Slow Corrosion

KOENIG-Expander = Anode

Small Anode Area → High Current Density at the Anode → Fast Corrosion

Base Material = Anode

Base Material l = Cathode

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

67


Galvanic Corrosion

Effect of Galvanic Corrosion

The following table shows the expected galvanic corrosion behavior of KOENIG Expanders in common base

materials allowing for the relative surface areas of both metals, which influences the speed of corrosion.

Base Material

Steel, carbon/low alloy, plain

Steel, carbon/low alloy, Zn plated, chromate

Steel, carbon/low alloy, phosphatized

Nitrided or case hardening steel behavior depends on the method used

Stainless steel, DIN 1.4305, AISI 303

Stainless steel, DIN 1.4005, AISI 416

Cast iron, GG, DIN 1691, plain

Cast iron, GG, DIN 1691, Zn plated, chromate

Cast iron, GG DIN 1691, phosphatized

Ductile cast iron, GGG DIN 1693, plain

Ductile cast iron, GGG DIN 1693, Zn plated, chromate

Ductile cast iron, GGG DIN 1693 phosphatized

Aluminum alloy, Ws-Nr. 3.3211, AA 6061

Aluminum alloy, Ws-Nr. 3.0615, ~AA 6262

Aluminum alloy, Ws-Nr. 3.1354, AA 2024

Aluminum alloy, Ws-Nr. 3.4365, AA 7075

Cast aluminum alloy, Ws-Nr. 3.2371, AA 356-T6

Cast aluminum alloy, Ws-Nr. 3.2373

Cast aluminum alloy, Ws-Nr. 3.2381

68

KOENIG Expander Series

T

Key to the galvanic corrosion behavior of KOENIG-Expanders in the presence of an electrolytic medium installed in

base materials per the above table:

Not accelerated

Lightly accelerated

Accelerated

Marked acceleration

Suggestions to prevent galvanic corrosion

• Chose materials with no or low potential difference.

• Use corrosion reducing designs, i.e. if possible prevent the accumulation of fluids on the outer surface of the

workpiece.

• By using suitable surface coatings, corrosion attack can be considerably reduced.

Salt spray testing per DIN 50021 can be done in our lab.

MB 600

MB 700

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

MB 800

SK

HK 55

HK 11

LP 900

LK 600

LK 950


Hardness Conversion Table for Hardenable Carbon and Low Alloy Steel.

Taken from DIN 50150-Issued 12/76

Tensile Vickers- Brinell- Rockwell

Tensile Vickers- Brinell- Rockwell

Strength2) Hardness Hardness1)

Hardness Strength2) Hardness Hardness 1) Hardness

N/mm 2 (F ≥ 98 n) HRB HRC HRA

255 80 76

270 85 80.7 41

285 90 85.5 48

305 95 90.2 52

320 100 95 56.2

335 105 99.8

350 110 105 62.3

370 115 109

385 120 114 66.7

400 125 119

415 130 124 71.2

430 135 128

450 140 133 75

465 145 138

480 150 143 78.7

495 155 147

510 160 152 81.7

530 165 156

545 170 162 85

560 175 166

575 180 171 87.1

595 185 176

610 190 181 89.5

625 195 185

640 200 190 91.5

660 205 195 92.5

675 210 199 93.5

690 215 204 94

705 220 209 95

720 225 214 96

740 230 219 96.7

755 235 223

770 240 228 98.1 20.3 60.7

785 245 233 21.3 61.2

800 250 238 99.5 22.2 61.6

820 255 242 23.1 62

835 260 247 (101) 24 62.4

850 265 252 24.8 62.7

865 270 257 (102) 25.6 63.1

880 275 261 26.4 63.5

900 280 268 (104) 27.1 63.8

915 285 271 27.8 64.2

930 290 276 (105) 28.5 64.5

950 295 280 29.2 64.8

965 300 285 29.8 65.2

995 310 295 31 65.8

1030 320 304 32.2 66.4

1060 330 314 33.3 67

1095 340 323 34.3 67.6

1125 350 333 35.5 68.1

T

N/mm 2 (F ≥ 98 n) HRB HRC HRA

1155 360 342 36.6 68.7

1190 370 352 37.7 69.2

1220 380 361 38.8 69.8

1255 390 371 39.8 70.3

1290 400 380 40.8 70.8

1320 410 390 41.8 71.4

1350 420 399 42.7 71.8

1385 430 409 43.6 72.3

1420 440 418 44.5 72.8

1455 450 428 45.3 73.3

1485 460 437 46.1 73.6

1520 470 447 46.9 74.1

1555 480 (456) 47.7 74.5

1595 490 (466) 48.4 74.9

1630 500 (475) 49.1 75.3

1665 510 (485) 49.8 75.7

1700 520 (494) 50.5 76.1

1740 530 (504) 51.1 76.4

1775 540 (513) 51.7 76.7

1810 550 (523) 52.3 77

1845 560 (532) 53 77.4

1880 570 (542) 53.6 77.8

1920 580 (551) 54.1 78

1955 590 (561) 54.7 78.4

1995 600 (570) 55.2 78.6

2030 610 (580) 55.7 78.9

2070 620 (589) 56.3 79.2

2105 630 (599) 56.8 79.5

2145 640 (608) 57.3 79.8

2180 650 (618) 57.8 80

660 58.3 80.3

670 58.8 80.6

680 59.2 80.8

690 59.7 81.1

700 60.1 81.3

720 61 81.8

740 61.8 82.2

760 62.5 82.6

780 63.3 83

800 64 83.4

820 64.7 83.8

840 65.3 84.1

860 65.9 84,4

880 66.4 84.7

900 67 85

920 67.5 85.3

940 68 85.6

Numbers in brackets indicate hardness values, which are

outside the definition area of the standard hardness test, but

actually often used as approximate values.

But the Brinell values in brackets are only used when

measured with a hard metal ball.

1) Calculated as: HB = 0.95 HV

2) The tensile strength values shown in the table are only to be used

as approximate values. To get the exact tensile

strength values a tensile test must be performed.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

69


SI-Units

70

T

The following table gives an overview of the SI units used in this catalog.

NOTE: Units listed in previous conversion tables, are no longer valid according to the international unit system (SI).

Measurement Symbol SI-Unit (Name) Other Valid Units Relationship Between

SI-Units

Length l m (Meter)

Area m2 (Sq. meter) a (Are), ha (Hectare) 1 a = 100 m 2

A

Volume m3 (Cubic meter) l (Liter) 1 l = 1 dm3 V

Time t s (Second)

min (Minute), h (Hour),

d (Day)

1 min = 60 s

1 h = 3600 s

Speed v m/s km/h 1 km/h = 0.2778 m/s

Frequency f Hz (Hertz) 1/s 1 Hz = 1/s

Revolutions n 1/s 1/min

Weight m kg (Kilogramm) g (Gram), t (Ton) 1 t = 1000 kg

Tightness kg/m 3

δ

Force N (Newton) 1 kg m/s2 F

Torque Nm

1 Pa = 1 N/m

Pressure Pa (Pascal)

2

1 bar = 105 Pa

1 mm Hg = 1.3332 · 102 Pa

Mech. Tensile

Strength N/mm2 Pa 1 N/mm2 = 106 Pa

Volumetric Flow m3 M

bar (Bar)

P

mm Hg (Millimeters of

mercury)

σ,τ

R

V /s

°

Temperature T K (Kelvin) °C

Conversion Table

Former units in comparison and relationship to the SI system

Units of Force Mechanical Tensile Strength:

N kp. kgf dyn

1 N 1 0.102 10 5

1 kp. 1 kgf 9.81 1 9.81·10 5

1 dyn 10 –5 1.02·10 6 1

°C = K - 273.15

∆T °C = ∆T K

Pa N/mm 2 kp/mm 2

1Pa=1N/m 2 1 10 –6 1.02·10 –7

1 N/mm 2

10 6

1 0.102

1 kp/mm2 9.81·106 9.81 1

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


Units

Pressure Units for Fluid Power:

1 Pa

(1 N/m 2 )

1 bar

(1 daN/cm 2 )

1 N/mm 2

(1 MPa)

1 daN/mm 2

1 kp/cm 2

(1 at, 1 atü)

Pa

(N/m 2 )

1 10 -5

10 5

10 -6

daN/mm 2

10 -7

1 0.1 10 -2

1.02 · 10 -5 1.02 · 10 -7

1.02 1.02 · 10 -2

10 6 10 1 0.1 10.2 0.102

10 7

9.81 · 10 4

bar

(daN/cm 2 )

N/mm 2

(M Pa)

100 10 1 102 1.02

0.981 9.81 · 10 -2 9.81 · 10 -3

kp/cm 2 )

(at, atü)

kp/mm 2

1 10 -2

1 kp/mm 2 9.81 · 10 6 98.1 9.81 0.981 100 1

SI-Prefixes (decimal multipliers for SI units):

Factor Symbol Name

0,000,001 = 10 -6 µ Micro

0,001 = 10-3 m Milli

0,01 = 10-2 c Centi

0,1 = 10-1 d Deci

1 = 10 0 – –

10 = 10 1 da Deca

100 = 10 2 h Hecta

1,000 = 10 3

k Kilo

1,000,000 = 10 6 M Mega

T

SI-Unit or per standard

approved units.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

71


American and British Measure Units

Conversion of commonly used American (US) and British (UK) units to SI Units

Measurement Name Symbol Conversion

Length mil 1 mil = 25.4 µm

inch in 1 in = 1000 mils = 25.4 mm

foot ft 1 ft = 12 in = 0.3048 m

Area square inch sq in (in2 ) 1 sq in = 6.4516 cm 2

72

square foot sq ft (ft 2 ) 1 sq ft = 144 sq in = 929.03 cm 2

Volume cubic inch cu in (in 3 ) 1 cu in = 16.3871 cm 3

cubic foot cu ft (ft 3 ) 1 cu ft = 28.3168 dm 3

US gallon gal 1 US gal = 3.785 dm 3 = 3.785 l

T

Weight ounce oz 1 oz = 28.3495 g

pound lb 1 lb = 0.453592 kg

Force pound-force lbf 1 lbf = 4.44822 N

ounce-force ozf 1 ozf = 0.278014 N

UK ton-force UK tonf 1 UK tonf = 9964.02 N

US ton-force US tonf 1 US tonf = 8896.44 N

Pressure pound-force per square inch lbf/in2 , psi 1 lbf/in 2 = 1 psi = 6.89476 kPa = 0.0689476 bar

Temperature Degrees Fahrenheit °F °C = (°F -32) · 5 /9

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


NOTES

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

73


Quality Assurance KOENIG-Expander

Quality Assurance per ISO 9001, ISO 14001, and QS-9000 (4th Qtr. 2001) is very important to us.

Koenig (KVT) / Sherex is committed to a system of "Total Quality Management" (TQM) to constantly

improve our quality of service to our customers.

74

Clear specifications

In cooperation with our suppliers

Exact instructions and procedures

For all employees

Controls

For inspection

Process control

In production and assembly

Quality control

Through statistical techniques such as

SPC, Norm charts, etc.

Design control

In development, projects, and revisions.

Employee training

Through regular internal auditing and

implementation of Quality Circles

NOTE: All KOENIG-Expanders are labeled

on their package with a Batch Number

identification. This Batch Number

guarantees traceability of all pertinent

quality characteristics from production

and procurement.

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537


SHEREX INDUSTRIES LTD.

1400 COMMERCE PKWY.

LANCASTER, NY, U.S.A. 14086

PHONE: (716) 681-6250

TOLL FREE: 866-4SHEREX

(866-474-3739)

FAX: (716) 681-0270

E-MAIL: info@sherex.com

WEBSITE: www.sherex.com

SHEREX INDUSTRIES LIMITED

4180 MORRIS DRIVE

BURLINGTON, ON CANADA L7L 5L6

PHONE: (905) 639-7701

FAX: (905) 639-9537

E-MAIL: info@sherex.ca

WEBSITE: www.sherex.ca

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