Challenge Europe - a nuanced approach to manufacturing with bolts, studding and fixings

The manufacturing sourcing and supply process today is more than ever concerned with supporting robust procedures to ensure reliable quality and performance at highly competitive prices. But the greatest concern is probably that of getting it wrong as this is often the greatest cost of all.

It is here that our team here at Challenge Europe can help, even with apparently simple threaded fasteners like flange bolts – used for speed and where people don’t want the inconvenience of a separate washer for load spreading or anti-vibration purposes. Similarly for studding where a longer length is required, e.g. for ceilings, to extend floor anchors or for chemical fixings such as epoxy glue embedded attachments.

All are well understood products but still benefit from expert guidance, as experience as shown.

Standard ex-stock items include flange bolts which are generally found in a more limited range than conventional bolts and set screws – also throughbolt style floor anchors which permit component positioning, hole drilling and insertion of the fixing all in one operation without needing to remove the component.

Conversely, shield anchors do need removal of steelwork in order to drill and place the fixing, but are better in weaker concrete as they are capable of generating a greater wedging force in variable substrates. They are also able to accommodate a variety of different fixings, e.g. various bolt head types.

Modern mechanical fasteners from Challenge Europe

In the modern world there are many issues coming to the fore such as the reduction of chemicals hazardous to your health (RoHS – Restrictions of Hazardous Substances and REACH – Registration, Evaluation, Authorisation and Restriction of Chemicals). In addition industry is continually being charged to reduce wastage and improve recyclability as well improve working environments, health and safety being key issues that most companies come across on a regular basis.

Mechanical fasteners in one form or another have been in existence almost from the cave man days with developments in more recent years enabling them to be used successfully in most types of assembly environments and at the same time satisfying the requirements of safety, quality and cost. They continue to be a simple solution to assembly problems providing a system of positive connection with low risk, which can be easily disassembled. They have no thickness limitation, are not environmentally sensitive and provide through-thickness reinforcement, with low sensitivity to peel stresses and have no major residual stress problems.

Above all they are simple – joint configuration is simple, manufacturing processes are simple, inspection is simple and maintenance is simple. Simplicity can be a major advantage in most applications.

Simplicity however does not mean they are incapable of sophistication with major advantages over chemical fastening adhesives. For example, threaded fasteners are commonly used with a torque adjustable closure force permitting pre-loading of the joint to allow it to adapt to variable loads from engines to couplings.

Similarly, the structural integrity, strength and security of mechanical fasteners can be designed to encompass the needs of vandal-resistance, to accommodate the extreme loads of vandal attack and to resist tools. In our drive for the new it is easy to forget the advantages of the old technologies.

With a mechanical fastener, when it is fixed, it is fixed and with a little thought it stays fixed. You can have confidence in what you feel when you fit it and what you see when you inspect it. So it is worth considering that most mechanical fasteners exhibit a common range of attributes:

They are suited to production – especially where dis-assembly is likely to be needed. Threaded fasteners and rivets are easy to use in the manufacturing environment where everybody has appropriate tools, experience and expertise.

They have predictable, reliable and often very high performance – they are a known quantity from simple and robust (to high specification) materials with positive known characteristics, including sealing and anti-vibration.

They are easy to maintain and are easily removed for maintenance and repair, even small components can be replaced from larger assemblies. Assemblies using mechanical fasteners can generally be taken apart for ease of repair and maintenance, even rivets can be drilled out allowing access in sheet metal fabrications. Whilst there are some adhesives that will allow disassembly this often requires considerable time and the use of chemical solvents to clean and prepare the surfaces for re-assembly.

Mechanical fasteners provide certainty of fixing as they eliminate the risk of faulty and potentially scrap assemblies by providing a visible fixing that is not subject to a failed bond scenario.

Reduced surface preparationgenerally mechanical fasteners require no special preparation of mating surfaces, eliminating the need for cleaning solvents, etc. and provide an immediate fixunlike many adhesives there is no delay in production due to allowances for cure times.

Adjustment during assembly is readily achieved since some assembly jobs entail a trial and error approach, with mechanical fixings you have the provision to adjust as many times as is necessary without being limited by a cure time.

Mating Componentsfasteners don’t have any detrimental effect on mating components as there is no risk of chemical created structural change. In addition dissimilar materials can be joined, although care is recommended to prevent the risk of galvanic corrosion.

They are environmentally friendlydue to their recyclability you don’t have the problems associated with having to safely and legally dispose of chemical waste that could occur with adhesives products. Regarding environmental concerns we find that generally all fasteners are recyclable, either by reuse in their original condition or by melting down. In this respect steel is quite an environmentally friendly material.

Low impact on the work environmentmechanical fasteners have the benefit of being able to be utilised in all weather and environmental conditions that man can survive, no need to provide specialised assembly areas, such as fume extraction or controlled temperature. In addition mechanical fasteners are less messy to use, require less specialised training, and generally don’t require respiratory/allergy monitoring of users.

They have an extended shelf life and maintain their value over timeunlike many adhesive products, mechanical fasteners do not require specialised storage facilities and provided they are kept in a dry environment their shelf life is virtually indefinite.

Likewise for life in service – look after them and they can last many lifetimes – for example the Eiffel Tower, opened in 1889, with 2.5million rivets used in its construction. Then there is the Forth Rail Bridge, opened 1890, 6.5 million rivets, and the Sydney Harbour Bridge opened in 1932, with 6 million rivets used.

Challenge Europe - screws ex-stock and custom

The team here at Challenge Europe are experienced in supporting manufacturing and trade users of ex-stock and custom screws in a very wide variety. In our experience this differentiation of design and material enables us to help customers get the right screw for the job – saving time, saving money, saving waste and ensuring a top quality job first time.

Typically this covers stainless steel machine screws, self-tapping/thread-forming screws and steel chipboard screws. Of increasing popularity are self-drilling types such as SPAX – which have a special thread form to cut into timber without a pilot hole – and HECOFIX screws, also with a range of specialised threads, both especially designed for professional users.

For example, we find that people often use self-tappers in plastic without realising that there are specialist designed-for-plastic screws – and only find out later that ordinary self-tappers can bind in the hole where they snap off or split the component.

Proper advice can cover screw type, hole, sizes, clearances, torque settings etc. So call us here to talk to us about your screw needs.

 

New Hafren range of security fasteners available from Challenge Europe - anti-vandal and anti-tamper screws and nuts

When a manufacturer is considering security issues around fasteners, generally there are three aspects:

  • The ability of the fastener to securely do its job and withstand problems such as vandalism.
  • How secure will the fastener be in service, how for example will it seal or retain components and/or fluids?
  • How confident can I be in my selection and my supply chain?

These are vital matters addressed by Kevin Moorcroft and his team here at Challenge Europe, for example we are delighted to have in our portfolio the Hafren range of security fasteners – a range of anti-vandal, anti-tamper screws and nuts proven in applications from architectural and street furniture, to marine and industrial equipment. Vandal resistant fasteners such as 2 hole headed (otherwise known as pignose or snake eye) A2 stainless screws, bolts and self-tappers provide a versatile and clean look to installations while deterring vandals and keeping installations safe. Likewise, shear-nuts in zinc plated steel, galvanised, A2 and A4 stainless. Other important items include 6-lobe driven threaded fasteners in A2 stainless steel with centre pin, in self-tapping, machine screw, self-drilling, barrel nut and floor anchor formats. Both countersunk and dome headed types are available.

Regarding security of retention and sealing, Challenge Europe offer exceptional performance with Dubo products which flow into the threads of the bolt and the nut, where they create a particularly effective frictional resistance with the bolt. This action prevents rotation of the retaining ring around the bolt, by wrapping around the flats on the nut and thereby effectively prevent the nut from loosening by filling all free spaces, while sealing against leakage. Applications range from use in preventing leakages from transformer oil reservoirs to  more demanding roles within the power generating industry and elsewhere.

Because DUBO Retaining Rings possess plastic-flow characteristics they absorb vibrations arising in the bolt assembly and exhibit excellent sound-deadening properties and durability. Thus they neither deteriorate nor wear and may be re-used again and again without loss of performance.

DUBO Retaining Rings are chemically resistant to Alkalis, to solutions of neutral inorganic salts, also to oils, fats, petrol, benzine, alcohol, acetone, diluted acids, and sea water, they are consequently able to prevent electrolytic corrosion between two different metal surfaces and prevent fatigue in the bolt material while  insulating and protecting the surfaces.

Dubo Toothed Collar Ring drawingA unique addition to the DUBO system is the DUBO-toothed collar ring which is intended for use in combination with high quality steel nuts (8.8). The toothed collar ring enables any desired bolt tension without damaging the DUBO-retaining ring through high bolt and nut loads, this design permits the use of any nut as a locking nut, which can then be re-used. Constraining the DUBO-retaining ring into this toothed-collar ring ensures that optimum deformation of the DUBO-ring is obtained after tightening the nut which provides a secure and long lasting locking and tightening effect according to the DUBO principle.

This high level of product performance is of little value however unless backed by an experienced team working to BS EN ISO standards – such as here at Challenge Europe since manufacturers’ confidence in their supplier is crucial to the reliable consistent output of any production facility. Confidence which stems from the ability to work in partnership with regard stock holding and supply control which may be offered from a central managed site covering production line restocking of fasteners, inventory control – measurement, stock re-ordering, kit and component supply, and single point invoicing. Site management enables a supplier to maintain optimum stock quantities and production system integration ensures supply chain capabilities within preferred production systems, e.g. Kanban, Lineside Supply and Vendor Managed Inventory (VMI).

A process which may additionally include supporting the engineering operation by initiating the supply chain, working from engineering drawings to determine the components/assemblies required. Security and confidence come from partnering design and commissioning new component tooling for improved manufacturing efficiency. Thus by controlling existing tooling we , as your fastener partner are able to audit and maintain an inventory, including a full logistical history for each item. Managing quality control in this way we can take responsibility for the inspection, monitoring and acceptance/rejection of components.

Ultimately as concept consultants we can advise on optimal design-for-production (DFP) values at the product concept stage and provide specification consultancy with pre-production advice on the handling of components, kits and sub-assemblies. This allows greater confidence in the development/production process leading to reliable high quality outcomes.

Further along the product lifecycle into product enhancement, production engineers will want to look at  on-going product improvement – a process that can be made easier as we can suggest components of alternative materials or how to reduce component counts and shorten assembly times.

Contact us here to discuss your fastener needs.

Challenge Europe updated fastenings and fixings brochure

An updated core description of the Challenge Europe portfolio is available free as a download from our website at www.challenge-europe.co.uk/brochure. This document covers the Challenge Europe focus on threaded fasteners and associated accessories.

The quick reference brochure is expected to be handy for designers and installation engineers who need capability in both standard and custom components across the spread of industry from machinery to building, from office to foreshore environments.

Rivets, pins and miscellaneous related products are covered that align with the needs of manufacturing industry and installation contractors at large.

Challenge Europe fulfill the fastener sourcing and supply chain requirements of the manufacturing cycle

It is our philosophy that we can reduce manufacturing component costs and cycle times by supporting all phases of the manufacturing process, from concept through design/development to mainline production. Kevin Moorcroft explains that we achieve this “by involvement in advising the various benefits and pitfalls of specific fasteners at an early stage so that the design engineers can best decide the path to follow. We then carry through with standard samples, custom prototypes and final production specification items, on a customer specific delivery plan – usually to an industry standard such as Kanban, Lineside Supply, JIT or Vendor Managed Inventory (VMI).”

Our primary objective is to understand and satisfy the needs of customers. To this end, the assurance of quality is a recognised fundamental governing all work conducted within the company. Procedures are clearly defined, properly documented and closely monitored to ensure full integration with the overall company policy and its certification to BS EN ISO 9001:2015.

By controlling existing tooling in an on-going relationship, we are able to audit and maintain appropriate levels of inventory, including a full logistical history for each item. Managing quality control in this way we can take responsibility for the inspection, monitoring and acceptance/rejection of components.

Once into the manufacturing cycle as a full production item, the team here at Challenge Europe contribute to on-going product improvement by suggesting and supplying components of alternative materials which can reduce component costs and shorten assembly times.

As concept consultants the team advise on optimal re-design-for-production (DFP) values, while also providing advice on the handling of components, kits and sub-assemblies.

An important part of the whole service package is the provision of specials and custom items which can be readily integrated, along with provision of standard fasteners. This capability is ideal for small quantities and “fiddly” components which can often deflect a design team from their main goal.

Contact us to discuss your manufacturing needs.

Special and custom fastener parts from Challenge Europe now available

Here at Challenge Europe we specialise in small volume manufacturing projects – custom special jobs that are a problem for bigger manufacturers, where it is not cost-effective to program large and expensive automated equipment. This enables us to optimise performance across a customer manufacturing operation with standard products from stock including many specialist fastener items.

However, when standard stock fastenings are not suitable we can offer a custom solution from our own manufacturing facility. This capability is ideal for small quantities and extends to partnering arrangements with fabricators and finishers so that we can cover a wide range of components from specialist threaded fasteners to sheet metal or cast fixings. Our experienced team couple in-house machining with a global sourcing and supply infrastructure, and in-depth expertise of the manufacturing cycle gained from over 30 years in the engineering arena.

This capability enables us to produce components from alternative materials at short notice and to incorporate them into packaged sub-assemblies. In this way customers gain a complete service of high-quality and low-cost on standard mass-produced items and on small quantity specialist components.

Typically this includes: Instrument Carrying Handles, Chrome Handles, Clamp Screws and Stud Rivet Nut Assembly. In addition we offer cut to length studding, vented screws, spacers and general modification work to standard fasteners e.g. shortening to non-standard lengths & cross drilling to take split cotter pins.

Custom specialist machine parts are produced in most metals and sometimes plastics – non-standard items are specials to customer drawings or non-standard sizes to international standards, e.g. an intermediate diameter or length.

Typical related items include instrument carrying handles in standard or custom dimensions for transport of instruments or use on cases, trollies etc., available in black or chrome.

Speak to the team here.

Threaded fasteners need ancillaries - now available from Challenge Europe

Here at Challenge Europe we find that wherever threaded fasteners are used then various ancillary products are often needed. For example, protection of the nut end of a bolt or screw with a plastic dome cap – or protection of the internal hex socket head from filling with dirt by use of a protective cap insert. Both come from sales partner Korrex, who also provide insulating bushes which offer protection from electrolytic corrosion between combinations of differing metals.

Perhaps more generally known are standard rubber and PVC grommets for associated sealing and protection of cables or pipes – along with plastic blanking plugs and screw caps for sealing round or square tubes and holes. Then to tidy it all up when properly screwed together, nylon cable ties are the ultimate – and ubiquitous – fastening ancillary.

Standard and custom specialist washers from Challenge Europe

Here at Challenge Europe, as long-time specialist suppliers to UK manufacturing industry, we are well aware that every application is different – many production needs can be met from our extensive range of standard types but often a custom variant is required.

As our M.D. Kevin Moorcroft explains “we carry a full range of flat, shakeproof, mudguard, copper grip and terminal cup washers, as well as crinkle, sealing, Belleville, cup, spring washers and “O” rings. All of these can be produced to custom specification to suit the needs of UK assemblers. Where vibration and sealing are specific problems then we also offer the Dubo retaining ring and toothed collar ring systems.”

The Dubo ring system is often used in preventing leakages from transformer oil reservoirs ranging to more demanding roles within the power generating industry and elsewhere such as machine tools and hydraulic systems. Complementing the retaining ring is the Dubo toothed collar ring which is intended for use in combination with high quality steel nuts (8.8), making it possible to admit any desired bolt tension. The deformation of the Dubo ring causes the locking and tightening effect according to the dubo principle.

Challenge Europe Rivets make assembly quicker and cheaper

We have a great range of rivets that offer a quick, simple, reliable and low cost ex-stock way to join sections of material – either similar – metal to metal, or dissimilar – metal to plastic. Blind rivets are stocked in depth by our expert team here at Challenge Europe where we aim to partner manufacturers through the design/development/production cycle with standard or custom specifications.

Many rivets are available with a choice of head forms from the standard dome head to large, extra-large and countersunk. A full range of setting tooling is available, including simple handtools for smaller volume work, and sophisticated hydropneumatic equipment to meet intensive production line working. For example, Blind Rivet Nuts which offer the facility to provide an internal thread to the work piece and are set in a similar way to that of a blind rivet. Rivet nuts are available in a comprehensive range of body and head types with material options of steel, stainless steel and aluminium. They provide advantages of being able to be easily set in thin material, but have the same properties as a tapped thread in fuller thickness material.

Blind rivets are offered in a range of fixings designed to allow the riveting operation to be conducted from one side of the workpiece. Variable in type, according to the application, some typical examples are listed below:

  • Open End – Provides strong, low cost fastenings ideal for a wide range of applications within the general engineering industry. Available in aluminium, steel, stainless steel, monel and copper alloy.
  • Closed (Sealed) End – Specifically designed to provide a waterproof seal after the rivet has been set. Available in aluminium, steel, stainless steel, monel and copper alloy.
  • Multigrip – Designed to clamp a wide range of material thicknesses as well as having excellent filling characteristics where hole form proves inconsistent. Additional benefit of allowing reduced rivet inventory. Traditionally available in aluminium, but steel and stainless steel versions have been recently introduced.
  • Structural – Designed to provide high tensile and shear strengths for more demanding applications. Available in steel and aluminium.
  • Grooved – Used in conjunction with fibrous materials (e.g. wood) where upon setting the body of the rivet expands and the grooves bite into the material. Available in aluminium.
  • Load Spreading – Suitable for soft or brittle materials where upon setting the rivet body folds back into segments preventing produce damage. Available in aluminium.
  • Peel – Similar to the Load Spreading rivet in design and application, excepting that the rivet body splits open into a ‘petal’ arrangement upon setting. Available in aluminium.

Contact us for your rivet requirements

1 2 3 4

By continuing to use the site, you agree to the use of cookies. more information

The cookie settings on this website are set to "allow cookies" to give you the best browsing experience possible. If you continue to use this website without changing your cookie settings or you click "Accept" below then you are consenting to this.

Close