New The World‘s Leading Sealing System · 2013. 5. 23. · SE-16494 Kista Tel: ++468 703 01 00...

Koenig Verbindungstechnik

The World‘s Leading Sealing System

2010

Koenig Verbindungstechnik AG

© 2010 by KVT KVT, 8953 Dietikon • T 044.743.33.33 • F 044.740.65.66 • www.kvt-koenig.com • [email protected]

Spanien / SpainItalmatic S.A.ES-20115 AstigarragaTel: ++34 943 33 56 33Fax: ++34 943 33 55 [email protected]

JapanMatsui CorporationJP-Tokyo 106Tel: ++81 33 586 4141Fax: ++81 33 224 [email protected]

KoreaSamjin CorporationKR-Korea 137-876Tel: ++82 2 581 5692Fax: ++82 2 582 [email protected]

Südafrika / South AfricaAlba Hydraulics PTY. Ltd.ZA-1613 EdenglenTel: ++27 11 458 12 00Fax: ++27 11 452 37 [email protected]

Südamerika / South AmericaGEPEFBR-04762-030 São Paulo SPTel: ++55 11 5681 5566Fax: ++55 11 5681 [email protected]

Australien / AustraliaSchiltecAU-NSW 2122 [email protected]

Southern Engineering Services PTY Ltd.AU-NSW 2526 [email protected]

Berendsen Fluid Power PTY Ltd.AU-NSW 2164 Wetherill Park

Indien, China / India, ChinaInmarco Industries PVT Ltd.IN-Mumbai 400059Tel: ++91 22 2850 9991Fax: ++91 22 2850 [email protected]

Finnland / FinlandPolarteknik PMC Oy AbFI-15561 NastolaTel: ++358 38 78 80Fax: ++358 38 78 81 [email protected]

Frankreich / FranceS.E.D.C. IndustrieFR-74304 Cluses CedexTel: ++33 4 50 98 88 82Fax: ++33 4 50 98 00 [email protected]

Grossbritannien / Great BritainBoneham & Turner Ltd.Notts. NG17 5FSGB-Sutton in AshfieldTel: ++44 16 23 44 54 50Fax: ++44 16 23 44 54 [email protected]

Italien / ItalyUnifast SRLIT-10036 Settimo Torinese Tel: ++39 011 816 55 11Fax: ++39 011 816 55 [email protected]

Niederlande / NetherlandsVIBA N.V.NL-2700 AK ZoetermeerTel: ++31 79 341 88 81Fax: ++31 79 341 80 [email protected]

Norwegen / NorwayServi Motion ControlNO-1401 SkiTel: ++47 64 97 97 97Fax: ++47 64 97 98 [email protected]

Schweden / SwedenColly Components ABSE-16494 KistaTel: ++468 703 01 00Fax: ++468 703 98 [email protected]

International

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Deutschland / GermanyKoenig Verbindungstechnik GmbHDE-89186 Illerrieden / UlmTel: ++49 7306 78 20Fax: ++49 7306 22 [email protected] Oesterreich / AustriaKoenig Austria GmbHAT-4481 Asten / LinzTel: ++43 7224 670 90Fax: ++43 7224 677 [email protected]

Polen / PolandKVT-Polska Sp. z o.o.PL-80-557 Gdansk Tel: ++48 58 762 08 88Fax: ++48 58 762 08 [email protected]

Tschechien / CzechiaKVT-CZ s.r.o.CZ-61900 BrnoTel: ++42 547 125 200Fax: ++42 547 125 [email protected]

USAKVT-Koenig LLCUS-Madison CT 06443-2273Tel: ++1 203 245 11 00Fax: ++1 203 245 30 [email protected]

Belgien / BelgiumDejond N.V.BE-2610 Antwerpen ( Wilrijk )Tel: ++32 38 20 34 70Fax: ++32 38 20 35 [email protected]

Dänemark / DenmarkA/S Gunnar HaagensenDK-3450 AllerødTel: ++45 48 17 65 00Fax: ++45 48 17 17 [email protected]


KVT, 8953 Dietikon • T 044.743.33.33 • F 044.740.65.66 • www.kvt-koenig.com • [email protected] © 2010 by KVT

Einzigartiges Verschliess- und Dichtsystem für Bohrungen

Der KOENIG-Expander® ist ein System, das mit absoluter Zuverlässigkeit Bohrungen verschiedenartiger Komponenten der Fluidtechnik ver-schliesst. Gegenüber Methoden – wie Verschlussschrauben mit Dichtscheiben und Dichtmittel, Einpressen von Stiften, Zuschweissen der Bohrungen etc. – zeichnet sich der KOENIG-Expander® durch schnelle, prozessüberwachte Montage sowie grosszügigen Fer-tigungstoleranzen des Bauteils aus. Dank dem ständig wachsenden Sortiment an Baureihen und der Möglichkeit, kundenspezifische Anfertigungen zu realisieren, bietet KVT für jede Anwendung ein geeignetes Verschliess-System an.

Unique sealing and tightening system for holes

The KOENIG-Expander® is a system to seal holes with absolute inte-grity in various components in Mobile Fluid Power Market. Compared to earlier methods, such as threaded plugs with or without sealing software, press-in pins, welding, etc. the KOENIG-Expander® distin-guishes 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, KVT offers a suitable sealing system for every application.

KOENIG-Expander® ermöglichen ein sicheres und dichtes Verschliessen der Bohrungen und verfügen – auch bei extremer Druckbeanspruchung – über ausreichende Sicherheit. Deshalb hat dieses System sich ein breites Anwendungsfeld erschlossen: Steuer- und Regelventile, Anschluss- und Verteilplatten, Pumpen, Motorenkomponenten, Getriebe-Bremskomponenten etc.

The KOENIG-Expander® plug, as designed pressure ratings incorporate minimum Factor of Safety to accommodate for pressure spikes and cyclic pressure loading. As a result of this reliable and leak tight sealing system, the expanders have found broad application on compo-nents such as: hydraulic and pneumatic control valves and manifolds, hydraulic pumps and motors, power transmission components, brake components, etc.

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Automobilbau

• ABS Brems-Systeme• Motor und Getriebe• Lenksysteme• Kraftstoff-Einspritzung

Automotive Industry

• ABSBreak-Systems• Engineandpowertransmission• Powersteering• Fuelinjectionsystems

Flugzeugbau

• Stellantriebe• Fahrwerk• Flugsimulatoren

Aircraft Industry

• Controlgear• Landinggear• Flightsimulators

Werkzeugmaschinen / Sondermaschinen

• Spannvorrichtung• Kühl-Schmiersysteme• Matrizen für Spritzgiessmaschinen

Machine tools / custom equipment

• Clampingdevice• Coolingandlubricatingsystems• Moldsforinjectionmouldingmachines

Mobilhydraulik / Fördertechnik

• Steuer-Antriebseinheiten• Hebebühnen• Baumaschinen

Mobile hydraulics / material handling equipment

• Controlanddriveunits• Liftsandplatforms• Constructionequipment

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Serie MBDie Expansion und Verankerung der Hülse mit der Bohrungswand erfolgt durch Einpressen der Kugel in die Hülsenbohrung. Die Serie MB eignet sich für den Einsatz in Grundwerkstoffen mit geringer bis hoher Härte.

MB SeriesExpansion and anchorage of sleeve in hole wall is achieved by pressing theball intosleeve.TheMBSeriesplug isdesigned foruse inbasematerials of both low to high hardness.

Series SKDie Expansion der Hülse bewirkt ein Zug-Spreizelement mit konischer Partie. Mittels einem Spezialwerkzeug wird die dazu notwendige Axialkraft eingeleitet bis das Spreizelement an der voraus bestimmten Stelle abbricht. Das Rillenprofil am Aussendurchmesser der Hülse hat insbesondere bei Leichtmetallen eine erzwungene Verankerung mit der Bohrungswand zur Folge.

SK SeriesPull/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.

Serie HKDie Konzeption der Serie HK basiert ebenfalls auf dem Zug-/Spreizprinzip. Dank der weichen Hülse wird eine Verankerung über das Rauheitsprofil der Bohrung ermöglicht. Die Serie HK eignet sich besonders für den Einsatz in harten Einbauwerkstoffen.

HK SeriesThe 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 the use in hard materials.

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Serie LKDer Dichtstopfen der Serie LK ist für Anwendungen im Niederdruckbereich bestimmt. Die Verarbeitungs- und Verankerungskonzeption entspricht jener der Serie SK.

LK SeriesThis plug has been designed for applications in the low pressure range. It has an anchorage principle similar to the SK Series plugs.

Serie LPDer Niederdruck-Dichtstopfen der Serie LP wird in eine konische Bohrung eingepresst. Der oberflächengehärtete, jedoch flexible Dichtstopfen verspannt sich mit der Bohrungswand; die labyrinthför-mige Aussenverzahnung verkrallt sich mit der Bohrungswand oder Bohrungsrauheit.

LP SeriesThe low pressure-sealing plug is installed by pressing the plug into a tapered hole. The surface hardened, but flexible plug achieves ancho-rage by gripping with the hole wall.

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Wo kein Weg ist, schaffen wir einen

Ein ausgewiesenes Entwicklungsteam mit modernster technischer Infrastruktur steht Ihnen jederzeit zur Verfügung. Sei es durch kunden-spezifische Untersuchungen sowie Weiter- und Neuentwicklungen des KOENIG-Expanders: Sie finden bei uns stets die optimale Lösung.

Zusammen mit Spezialisten in der Automationstechnik können auch Sie unsere Dienste als Systemanbieter in Anspruch nehmen. Wir helfen Ihnen bei der Evaluation komplexer prozessfähiger Montageautomaten.

If a solution is required, we'll provide one

A proven development team with the most modern technological infra-structure is available to you at any time. Whether through customer-specific tests, new developments or additional enhancements to the KOENIG-Expander®, you can depend on us to find the best solution.

Together with specialists in the field of automotive engineering, you can benefit from our services as a system supplier. We will help you to evaluate complex, process-capable automated assembly systems.

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Safety first, bis ins kleinste Detail

Unsere Qualitätspolitik ist nicht nur eine Philosophie, sondern ein Denken und Handeln aller Mitarbeiter im Dienste unserer Kunden. Als Inhaber des Qualitätszertifikates nach ISO/TS 16949 sowie des Umweltzertifikates nach ISO 14001, ist unsere oberste Prämisse die Sicherstellung der hohen Anforderungen an Produkte, Systeme und Dinstleistungen in Bezug auf:• Eignung• Leistung und Sicherheit• Zuverlässigkeit• Umwelt

Safety first, down to the smallest detail

Ourqualitypolicy isnotmerelyaphilosophy: it is thewayouremp-loyees think and act to best serve our customers. As a holder of the ISO/TS16949qualitycertificateaswellastheISO14001environmen-tal certificate, our top priority is to meet the high demands placed on products, systems and services as they relate to:• Suitability• Service and safety• Reliability• Environment

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KVT Produktepalette

Die KVT-Gruppe gilt international als kompetenter Partner in der Verbindungstechnik. Dank einem breiten Sortiment an mechanischen Befestigern, klebetechnischen Produkten und Verschlüssen bieten wir unseren Partnern optimale Anwendungslösungen an. Unsere Kunden sollen von unserem Know How und unseren Dienstleistungen profitieren:

• Ausgewiesene Spezialisten als Kundenberater im Innen- und Aussendienst• Modernes Informations- und Demonstrationszentrum, Fach- tagungen, Schulungen• Verschiedene chemische und mechanische Labors• Konstruktion kundenspezifischer Verbindungsteile• Ausführliche Dokumentationen• Effizienter Werkzeug- und Maschinenservice, grosses Ersatzteillager• Umfangreiches Sortiment mit grosser Lieferbereitschaft• Zertifiziert in Qualitäts- und Umweltmanagement (ISO 9001 / ISO 14001)• ISO/TS 16949 für KOENIG-Expander

Product Arrangement

The KVT group is known world-wide as a partner in the Fastener Industry. Thanks to the large range of mechanical fasteners, adhesive products, and latches, we can offer to our customers' optimum soluti-ons to their applications. Our customer will profit from our know-how and our services:

• Insideandoutside,accreditedcustomerserviceconsultants.• In-house Product Information and Training Center that offers seminars, courses and demonstrations.• Facilitiesbothchemicalandmechanicaltesting• Abilitytodesignspecialfastenerstocustomerspeci- fications.• Efficienttoolandmachiningservicewithalarge inventory of spare parts• Largeselectionofstockwithexcellentleadtimes• CertifiedQualityandEnvironmentManagement System(ISO9001/ISO14001)• ISO/TS16949forKOENIG-Expandersealingplugs

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Serie MB Seite 11–18

MBSeries Page 11–18

Serie SK Seite 19–25

SK Series Page 19–25

Serie HK Seite 27–35

HK Series Page 27–35

Serie LP Seite 37–40

LPSeries Page37–40

Serie LK Seite 41–47

LKSeries Page 41–47

Technische Seite 49–72Informationen

Technical Page 49–72Information

Dichtstopfen

Sealing Plugs

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Koenig Verbindungstechnik AGKoenig Verbindungstechnik AG


NOTIZEN / NOTES

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• Grosses Lieferangebot von ø 3 bis 22 mm, auch als Inch-Ausführung

• Korrosionsbeständige Ausführung

• Einfache schnelle Montage

• Rein mechanische Abdichtung durch Zwangsverkrallung

• Betriebsdruckleistungen bis 450 bar

• Geeignet für vollautomatische Verarbeitung

• Largerangeofsizes,ø3to22mm,alsoavailableininchversion

• Corrosionresistantexecution

• Fastandeasyinstallation

• Puremechanicalsealingbyforcedanchorage

• Ratedpressureperformancesupto450bar

• Suitableforautomatedinstallation

Serie MB

MB Series

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• Ausführung zum vertieften Setzen

• Sehr schnelle Montage mittels handlichen Werkzeugen

• Direkteinbau in Nennbohrung (Systembohrung)

• Grosszügige Bohrungstoleranz

• Geringe Einbaulänge


• Keine Axialbelastung des Bauteils

• Expandersforrecessedsetting

• Veryfastinstallationbymeansofhandytools

• Installsdirectlyintodrilledhole,noadditionalmachiningrequired

• Largedrilledholetolerance

• Shortinstallationlength


• Noaxialloadingimposedoncomponent

Serie SK

SK Series

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• Expandersforrecessedsetting



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Serie HK

HK Series

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Serie LP

LP Series

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Serie LK

LK Series



• Sehr kurze Einbaumasse

• Schnelle Montage

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• Shortestinstallationlength

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Koenig Verbindungstechnik AGKoenig Verbindungstechnik AG


NOTIZEN / NOTES

48



Page

• Pressure Performance Tests 50

• Base Material / Conditions 51

• Pressure Performance 52 MB Series SK / HK Series LP / LK Series

• Installation Instructions 55

• Anchorage Principle 61

• Bore Roughness Requirements 63

• Design Guidelines 64

• Calvanic Corrosion 68

• Hardness Conversion Table for 70 Hardenable Carbon and Low Alloy

• SI-Units 71

• American and British 72 Measure Units

Contents

Technical Information

49



Pressure Performance Tests–KOENIG-Expander

Test Ⓐ Pressure Test To Failure

In Test Ⓐ the KOENIG-Expander is subject to increasing static pressure until plug blowout occurs. These tests are done by KVT for functional testing during manufacturing runs. Each production lot (Batch No.) undergoes these tests.

Pre

ssur

e

0 Time

SPS-Control Unit

PE

Digital Pressure Gauge

Pressure Intensifier

KOENIG-Expander Test Piece

Static Blowout Pressure Arrangement

Test Ⓑ Temperature/Pressure Cycling

In Test Ⓑ the KOENIG-Expander is subject to a long term test simulating practical conditions. This determines the pressure which can be applied (lower limit) without plug blowout, with intermittent pressure and varying temperature.

Duration: 170 h (Long term test)Drill Hole: Tolerances, roundness, and roughness per data sheets Plain surface Distance from edge per data sheets.

Pre

ssur

e

0 Time

Pressure Intensifier

KOENIG-Expander Test Pieces

RecorderControl Unit

Cooling / Heating Chamber

Time

Tem

p.

I+

PE

Cooling / Heating Chamber

Conditions

Temperature: 2 hours at +100 °C, 2 hours at –40 °C Series LK and LP partiell 2 hours at +150 °C, 2 hours at –40 °CTemperature change: between 30 and 45 minutes

Pressure: intermittent 2 minutes at 0 bar, 3 minutes at test pressure.

50



Base Material / Conditions

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

• 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 cast aluminium, magnesium alloy, 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 guidlines

• 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 Ⓑ pressure) allows for uncontrollable variations. For instance, dynamic loading at 1 million cycles and a frequency of 3–4 Hz has shown that burst pressure Test Ⓐ and Test Ⓑ pressure are reduced about 20% after this point.

Base Materialof the Installation

Tensile Strength(avg.) Rm [N/mm2]

Elongation (min.)A5 [%]

Ultimate Strength(avg.) Rp0.2 [N/mm2]

Hardness(min.) HB

①High Strength St.ETG-100AISI 1144

1'000 6 865 280

②Free Machining CaseHard. Stl. C15Pb1.0403

560 6 300 180

③Cast IronEN-GJL-250EN 1561

250 – – 160

④Ductile Cast IronEN-GJS-500-7EN-1563

500 7 320 170

⑤Aluminium-AlloyAlCuMg23.1355 / AA2024

480 8 380 120

⑥Aluminium-AlloyAlMgSiPb3.0615 / ~AA6262

340 8 300 90

⑦Cast Al AlloyG-AlSi7Mg3.2371 / AA356-T6

300 4 250 80

51



Pressure Performance

SeriesMB 600

Base material of the Installation

ETG-100

C15Pb

EN-GJL-250

EN-GJS-500-7

AlCuMg2

AlMgSiPb

G-AlSi7Mg

ø 3–101’400 bar / 20’300 psi

450 bar / 6’500 psi1’200 bar / 17’400 psi

380 bar / 5’500 psi

ø 12–141’000 bar / 14’500 psi

350 bar / 5’100 psi900 bar / 13’000 psi280 bar / 4’100 psi

Hole Tolerance 0 / +0,1 mm

Roughness RZ 10–30µm Anchorage in base metal

SeriesMB 600

Inch


ETG-100

C15Pb

EN-GJL-250

EN-GJS-500-7

AlCuMg2

AlMgSiPb

G-AlSi7Mg

ø 0,093–0,2811’400 bar / 20’300 psi

450 bar / 6’500 psi1’200 bar / 17’400 psi

380 bar / 5’500 psi

Hole Tolerance ø 0,093 0 / +0,002 Inch from ø 0,125 0 / +0,004 Inch


SeriesMB 700


ETG-100

C15Pb

EN-GJL-250

EN-GJS-500-7

AlCuMg2

AlMgSiPb

G-AlSi7Mg

ø 3–101’400 bar / 20’300 psi

450 bar / 6’500 psi1’200 bar / 17’400 psi

380 bar / 5’500 psi

ø 12–221’150 bar / 16’700 psi




SeriesMB 850


ETG-100

C15Pb

EN-GJL-250

EN-GJS-500-7

AlCuMg2

AlMgSiPb

G-AlSi7Mg

ø 3–101’100 bar / 16’000 psi

350 bar / 5’100 psi1’000 bar / 14’500 psi

320 bar / 4’600 psi

ø 12–22900 bar / 13’000 psi280 bar / 4’100 psi

800 bar / 11’600 psi250 bar / 3’600 psi



Proof Pressure Test ⒷMax. allowable Working Pressure = Nominal Pressure

52




SeriesSK


ETG-100

C15Pb

EN-GJL-250

EN-GJS-500-7

AlCuMg2

AlMgSiPb

G-AlSi7Mg

ø 4–101’600 bar / 23’200 psi

500 bar / 7’200 psi1’400 bar / 20’300 psi

450 bar / 6’500 psi



SeriesHK


ETG-100

C15Pb

EN-GJL-250

EN-GJS-500-7

AlCuMg2

AlMgSiPb

G-AlSi7Mg

ø 3–101’200 bar / 17’400 psi


Hole

Tolerance 0 / +0,1 mm

Roughness RZ 10–30µmRoughness anchoring not effective

Anchorage in base metal not possible

If SK plugs are used to keep channels separated, allowable working pressure on the insertion side is reduced by 50%.

If HK plugs are used to keep channels separated, allowable working pressure on the insertion side is reduced by 50%.


53



SeriesLP


ETG-100

C15Pb

EN-GJL-250

EN-GJS-500-7

AlCuMg2

AlMgSiPb

G-AlSi7Mg

ø 4–12180 bar / 2’600 psi

60 bar / 850 psi180 bar / 2’600 psi

60 bar / 850 psi

Hole Tolerance as per specification sheet


SeriesLK 600


ETG-100

C15Pb

EN-GJL-250

EN-GJS-500-7

AlCuMg2

AlMgSiPb

G-AlSi7Mg

ø 4–12180 bar / 2’600 psi

60 bar / 850 psi180 bar / 2’600 psi

60 bar / 850 psi



SeriesLK 950


ETG-100

C15Pb

EN-GJL-250

EN-GJS-500-7

AlCuMg2

AlMgSiPb

G-AlSi7Mg

ø 4–16180 bar / 2’600 psi

60 bar / 850 psi180 bar / 2’600 psi

60 bar / 850 psi


Roughness RZ 10–30µm * **

Temperature range for Proof Pressure Test Ⓑ: –40 °C bis +150 °C Temperature range for Proof Pressure Test Ⓑ: –40 °C bis +100 °C

Temperature range for Proof Pressure Test Ⓑ: –40 °C bis +150 °C Temperature range for Proof Pressure Test Ⓑ: –40 °C bis +100 °C


Temperature range for Proof Pressure Test Ⓑ: –40 °C bis +150 °C * partial anchorage in base material Temperature range for Proof Pressure Test Ⓑ: –40 °C bis +100 °C ** anchorage in base material

KOENIG-Expander Sealing Plugs series LK are not suitable for pressure load applied on the insertion side of the plug.For special release contact KVT.


54



Installation Instruction for MB Series

Drilled Hole

• The drilled hole must be within the tolerances shown on the preceding dimensional sheets.• The counterbored hole (d2) must be properly sized for the through hole (d3) according to the dimensional sheets.• Holes must be round within 0.05 mm.• With hard materials the bore roughness should be from RZ = 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

• 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.

• Cleaning/degreasing of plugs before installation, only spray cleaning with air drying allowed. (No dipping and vacuum drying).

PressSmall 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.

F

SX

d1

Installation Chart

Fig. 1

Fig. 2

Fig. 3

MB 600 / MB 700 / MB 850 Series

d1 [mm] 3 4 5 6 7 8 9 10 12 14 16 18 20 22

S [mm] Stroke (approx. values) 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] ±0,2Position of top of ball

relative to top of sleeve0,4 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

MB 600 Series Inch-Version

d1 [in] .093 .125 .156 .187 .218 .250 .281

S [in] Stroke (approx. values) .031 .047 .059 .079 .094 .109 .118

X [in]Position of top of ball

relative to top of sleeveFlush to .012 below the sleeve

F

55



Installation Instructions MB Series

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 DrillMB 600-093 A Ball HRC ~55: Carbide Tipped DrillMB 600-125 A to 281 A Ball HB ~200: High Speed Steel DrillMB 700-030 to 220 Ball HRC ~45: Carbide Tipped DrillMB 850-040 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-Diameter 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 size plug.

56



Installation Instruction SK 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 RZ = 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

• Insert the plug in the tool, making sure that the sleeve is against the nosepiece (Fig. 1).

• 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 and 3).

Note:

• The assembly of KOENIG-Expanders should only be done in a clean working area.

• Sleeve and mandrel of the plug should not be cleaned or lubri-cated.

Tools

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

Plug Removal

With KOENIG-Expander 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.

Fig. 1

Fig. 2

Fig. 3

57



Installation Instruction HK 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 RZ = 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


• 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 rea-ched (Fig. 2 and 3).

• When correctly installed, the tapered portion of the mandrel will be below the sleeve surface (Fig. 3). A projecting mandrel indicates an over tolerance hole or too thin

wall thickness.

Note:



Tools


Plug RemovalWith KOENIG-Expander HK 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.


Fig. 1

Fig. 2

Fig. 3

58



Fig. 1

F

Fig. 2

Fig. 3

Installation Instruction LP Series

Drilled Hole

• The drilled hole must be within the tolerances shown on the dimensional sheets.• The cone rate 1:12 must be kept as per specification sheet.• Holes must be round within 0.05 mm.• With hard materials the bore roughness should be from RZ = 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

• With the setting hole facing out, the LP-plug is inserted in the cone bore. The top sleeve should not be above the surface of the base material (Fig. 1).• The LP-plug can now be pressed in with the setting tool. Corresponding approximate values for stroke S are from the table below (Fig. 2).• Installed LP-plug (Fig. 3).

Note:

• Use the proper size setting tool for the KOENIG-Expander according to the data sheet.• Through washing of the LP-plugs before installation, higher setting force might occur.

Press

• It is preferred to limit travel when using a press because insertion force is difficult to control.

• Recommended setting speed is 5 mm/sec.The KOENIG-Expander assuring an optimum orientation, it works perfectly with automatic processing.

Plug Removal

With KOENIG-Expander LP Series plug removal is possible. The plug can be drilled out with a high speed steel drill.

Procedure:1. Drill out, in one process, to the next larger diameter, nominal diameter d4 according to the data sheet.2. Drill the taper hole with a reamer up to diameter d3 according to the data sheet.3. Clear chips, remnants of the sleeve, and oil and grease from the bore.4. Install a new KOENIG-Expander.


S

FInstallation Chart

Series LP 900 – 040 050 060 070 080 090 100 120

S [mm]±0.25

Stroke (average value)

1.0 1.3 1.3 1.5 1.8 1.8 2.0 2.0

in steel, grey cast nodulized cast ironin aluminium wrought alloy, aluminium-cast material

59



Installation Instruction LK Series

Drilled Hole

• The drilled hole must be within the tolerances shown on the dimensional sheets.• Holes must be round within 0.05 mm.• With hard materials the bore roughness should be from RZ = 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


• 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 and 3).

Note:



Tools


Plug Removal

With KOENIG-Expanders 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.


Fig. 1

Fig. 2

Fig. 3

60



Anchorage Principle

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 the base material

KOENIG-Expander

Hard

ness

HB

Hard base material: To achieve the allowable working pressure, anchorage to the bore roughness of the base material is required. Roughness RZ = 10 to 30 µm.

Soft base material: Anchorage to the bore of the base material occurs automatically due to the serrations on the sleeve ofthe KOENIG-Expander.

Transition zone: To achieve the allowable working pressure, anchorage to the bore roughness of the base material is required. Roughness RZ = 10 to 30 µm.

Soft base material: Anchorage is not possible with the HK Series. Such combinations are not allowed for high pressure applications.

Transition zone: To provide for the allowable pressure rating, the serration of the sleeve, anchors into the base material.

61



Anchorage Principle

Sufficient anchorage due to plug sleeve serrations KOENIG-Expander Series LK 950in aluminum alloy HB = 90

Anchorage due to plug sleeve serrationsKOENIG-Expander Series LP

in aluminum alloy HB = 90

Anchorage due to bore roughnessKOENIG-Expander Series HKin gray cast iron HB = 160

Anchorage due to plug sleeve serrations KOENIG-Expander Series SKin aluminum-alloy HB = 90

Anchorage due to plug sleeve serrationsKOENIG-Expander Series MB 850

in aluminum-alloy HB = 90

62



Bore Roughness Requirements

When installing KOENIG-Expanders in hard base material no positive anchoring is possible. So, to attain suitable working pressures and ancho-rage, it is necessary to have a bore roughness of RZ = 10–30 µm. At a roughness greater than RZ = 30 µm leakage might occur.

100

80

60

40

20

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

Pressure performance correlation to bore roughness.

% o

f tes

t pre

ssur

e, T

est Ⓑ

, and

allo

wab

le w

orki

ng p

ress

ure

Roughness Rz [µm](Approximate)

Roughness Profile

Required roughness profile Undesirable roughness profile

The ideal bore roughness for anchorage is attained by drilling with a twist drill or core drill.

By reaming, a one-sided, smooth roughness profile is created. This is not desirable.

63



Design Guidelines

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.

Distance to external wall Distance to exterior wall Wall thickness between bores

WminWmin

d1

d1

Wmin

d 1

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 Wmin for wall thickness and distance from edge

At KOENIG-Expander diameters Series MB / SK / HK and LP d1 ≥4 mm: Wmin = fmin · d1

d1 < 4 mm: Wmin = fmin · d1 + 0,5 mm

At KOENIG-Expander diameters Series LK d1 ≥5 mm: Wmin = fmin · d1

d1 = 4 mm: Wmin = fmin · d1 + 0,5 mm

Basematerial

① ② ③ ④ ⑤ ⑥ ⑦Description ETG 100 C15Pb EN-GJL-250 EN-GJS-500-7 AlCuMg2 AlMgSiPb G-AlSi7Mg

Avg. tensile strength Rm [N/mm2] 1000 560 250 500 480 340 300

Min. elongation A5 [%] 6 6 – 7 8 8 4

Avg.ultimate strength Rp 0,2 [N/mm2] 865 300 – 320 380 300 250

Koenig-Expander Series Factor fmin

MB 600 0,6 0,8 1,0 0,8 0,8 1,0 1,0

MB 600, Inch-Version 0,6 0,8 1,0 0,8 0,8 1,0 1,0

MB 700 0,6 0,8 1,0 0,8 0,8 1,0 1,0

MB 850 0,5 0,6 1,0 0,6 0,6 1,0 1,0

SK 0,5 0,6 1,0 0,6 0,6 1,0 1,0

HK 0,4 0,5 0,8 0,5 0,5 0,8 0,8

LP 0,3 0,3 0,5 0,3 0,4 0,5 0,5

LK 600 0,3 0,3 0,6 0,5 0,4 0,5 0,5

LK 950 0,3 0,3 0,6 0,5 0,4 0,5 0,5

64



Design Guidelines

Required Installation Lengths

dN = given nominal bore / system bore size

* Installation Lengths MB Series

The required installation length (l4) min. for MB plugs is for base materials with hardness greater than HB=90. For softer materials, deeper installation is required.

dN

MB Series SK Series HK Series Treaded Plugs DIN 908

d1 l3 min l4 min * 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

4,0 5,0 5,3 7,0 4,0 6,5 4,0 8,0

5,0 6,0 6,3 8,5 5,0 7,5 5,0 9,5 M8x1 11,5

6,0 7,0 7,3 9,5 6,0 8,0 6,0 10,0 M8x1 11,5

7,0 8,0 8,3 11,0 7,0 9,0 7,0 11,0 M10x1 12,0

8,0 9,0 9,8 12,5 8,0 10,5 8,0 11,5 M10x1 12,0

9,0 10,0 10,8 13,5 9,0 11,0 9,0 13,0 M12x1,5 16,0

10,0 12,0 12,8 16,0 10,0 12,5 10,0 13,5 M12x1,5 16,0

12,0 14,0 14,5 18,0 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

l

1

3

l 4

dN

d1

d1dN=

l 4

d1

d1N =

l 4

d

l 4

d1

dN

65



Design Guidelines

Required Installation Lengths

dN = given nominal bore / system bore size

dN

LP Series LK Series Threaded Plugs DIN 908

d1 l3 min d1 l4 max d1 l4 max

4,0 4,40 7,0 4,0 4,0

5,0 5,40 8,0 5,0 4,8 M8x1 11,5

6,0 6,40 8,5 6,0 5,3 M8x1 11,5

7,0 7,40 8,5 7,0 5,8 M10x1 12,0

8,0 8,45 9,5 8,0 6,8 M10x1 12,0

9,0 9,60 10,0 9,0 6,8 M12x1,5 16,0

10,0 10,65 11,0 10,0 6,8 M12x1,5 16,0

12,0 12,75 12,0 12,0 7,8 M14x1,5 16,5

14,0 14,0 8,7 M16x1,5 16,5

16,0 16,0 11,5 M18x1,5 17,5

l 4

d1

dNN

l 2

d

1d d1

d1N=

l 4

d

66



Design Guidelines

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 dia-meter 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 dimesional 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.

d1

Sea

lC

ylin

dric

alN

o S

eal

max

. 0.2

5 x

d 1

d1

Sea

lC

ylin

dric

alN

o S

eal

max

. 0.2

5 x

d 1

d1

Seal

Cyl

indr

ical

No

Seal

max

. 0.2

5 x

d 1

d1

Sea

lbe

vele

dN

o S

eal

d1

Seal

Cyl

indr

ical

No

Seal

max

. 0.1

5 x

d 1

67



Galvanic Corrosion

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 contract - 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

Base Material = Anode

Large Anode Area Low Current Density at the Anode Slow Corrosion

Small Anode Area High Current Density at the Anode Fast Corrosion

KOENIG-Expander = Anode

Base Material = Cathode

68



Galvanic Corrosion

Effect of Galvanic Corrosion

The following table shows the expected galvanic corrosion behavior of KOENIG-Expanders in common base materials allowing for therelative surface areas of both metals, which influences the speed of corrosion.

Key to the galvanic corrosion behavior of KOENIG-Expanders in the presence of an electrolytic medium installed in base materials per the above table:

Accelerated

Lightly accelerated

Not accelerated

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.

Base material

KOENIG-Expander Series

MB

600

MB

700

MB

850

SK HK LP LK 6

00

LK 9

50

Steel, carbon/low alloy, plain

Steel, carbon/low, Zn plated, chromate

Steel, carbon/low alloy, phospatized

Nitrided or case hardening steel behavior depends on the method used

Stainless steel, X 8 CrNiS 18-9, 1.4305, AISI 303

Stainlesss steel, X 12 CrS 13, 1.4005, AISI 416

Cast iron, EN 1561, plain

Cast iron, EN 1561, Zn plated, chromate

Cast iron, EN 1561, phosphatized

Ductile cast iron, EN 1563, plain

Ductile cast iron, EN 1563, Zn plated, chromate

Ductile cast iron, EN 1563, phosphatized

AlMg1SiCu 3.3211 AA-Norm 6061

AlMgSiPb 3.0615 AA-Norm ~6262

AlCuMg2 3.1355 AA-Norm 2024

AlZnMgCu1.5 3.4365 AA-Norm 7075

G-AlSi7Mg 3.2371 AA-Norm 356-T6

G-AlSi9Mg 3.2373

G-AlSi10Mg 3.2381

69



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 HV2) The tensile strength values shown in the table are only to be used as approximate values. To get the exact tensile strenght values a tensile test must be performed.

Zugfestigkeit2)

N/mm2

Vickershärte

(F ≥98 n)

Brinellhärte1)

Rockwellhärte Zugfestigkeit2)

N/mm2

Vickershärte

(F ≥98 n)

Brinellhärte1)

Rockwellhärte

HRB HRC HRA HRB HRC HRA

255270285305320

80859095

100

76,080,785,590,295,0

41,048,052,056,2

11551190122012551290

360370380390400

342352361371380

36,637,738,839,840,8

68,769,269,870,370,8

335350370385400

105110115120125

99,8105109114119

62,3

66,7

13201350138514201455

410420430440450

390399409418428

41,842,743,644,545,3

71,471,872,372,873,3

415430450465480

130135140145150

124128133138143

71,2

75,0

78,7

14851520155515951630

460470480490500

437447

(456)(466)(475)

46,146,947,748,449,1

73,674,174,574,975,3

495510530545560

155160165170175

147152156162166

81,7

85,0

16651700174017751810

510520530540550

(485)(494)(504)(513)(523)

49,850,551,151,752,3

75,776,176,476,777,0

575595610625640

180185190195200

171176181185190

87,1

89,5

91,5

18451880192019551995

560570580590600

(532)(542)(551)(561)(570)

53,053,654,154,755,2

77,477,878,078,478,6

660675690705720

205210215220225

195199204209214

92,593,594,095,096,0

20302070210521452180

610620630640650

(580)(589)(599)(608)(618)

55,756,356,857,357,8

78,979,279,579,880,0

740755770785800

230235240245250

219223228233238

96,7

98,1

99,5

20,321,322,2

60,761,261,6

660670680690700

58,358,859,259,760,1

80,380,680,881,181,3

820835850865880

255260265270275

242247252257261

(101)

(102)

23,124,024,825,626,4

62,062,462,763,163,5

720740760780800

61,061,862,563,364,0

81,882,282,683,083,4

900915930950965

280285290295300

268271276280285

(104)

(105)

27,127,828,529,229,8

63,864,264,564,865,2

820840860880900

64,765,365,966,467,0

83,884,184,484,785,0

9951030106010951125

310320330340350

295304314323333

31,032,233,334,335,5

65,866,467,067,668,1

920940

67,568,0

85,385,6

Hardness Conversion Table for Hardenable Carbon and Low Alloy Steel

70



SI-Units

SI-Prefixes (decimal multipliers for SI units):

Measurement SI-Units Additional legal Units Relationship betweenSI-Units

Space and Time

Length m (Meter)

Area m2 (Square meter) a (Are)ha (Hectare)

1 a = 100 m2

1 ha = 10'000 m2

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

Time s (Second) min (Minute) 1 min = 60 s

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

Velocity m/s km/h 1 km/h = 0,2778 m/s

Mechanics

Weight kg (Kilogram) g (Gram)t (Tonne)

1 t = 1'000 kg

Force N (Newton) 1 N = 1 kg m/s2

Mech. Tension N/m2 1 N/mm2 = 1MPa1 MPa = 106 Pa

Pressure Pa (Pascal) bar (Bar)mmHg (Millimeter Mercury)

1 Pa = 1 N/m2

1 bar = 105 Pa1 mmHg = 1,33322·102 Pa

Temperature

Temperature K (Kelvin) ° C (Degree centigrade) Temp. [° C] = Temp. [K] -273,15Temp. difference 1 °C = 1 K

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 = 100 – –

10 = 101 da Deca

100 = 102 h Hecta

1'000 = 103 k Kilo

1'000'000 = 106 M Mega

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American and British Measure Units

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

Measurement Name Symbol Conversion

Length inch in 1 in = 25,4 mm

Area square inch sq in (in2) 1 sq in = 6,4516 cm2

Volume cubic inchUS gallon

cu in (in3)US gal

1 cu in = 16,3871 cm3

1 US gal = 3,785 dm3

Weight ouncepound

ozlb

1 oz = 28,3495 g1 lb = 0,453592 kg

Froce pound-forceounce-forceUK ton-forceUS ton-force

lbfozfUK tonfUS tonf

1 lbf = 0,44822 N1 ozf = 0,278014 N1 UK tonf = 9964,02 N1 US tonf = 8896.44 N

Pressure pound-force per square inch ibf/in2, psi 1 lbf/in2 = 1 psi = 6,89476 kPa = 0,0689476 bar

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

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