PEM 256 Press In Inserts For Castings And Soft Metals User Guide

PEM 256 Press In Inserts For Castings And Soft Metals User Guide

Product Specifications

• Product Name: CKTM Press-In Inserts
• Usage: For Castings and Soft Metals
• Thread Size: Unified and Metric
• Material: Stainless Steel
• Thread Code: CKS
• Length Code: 1 or 2
• Length A: Varies based on thread size
• After Knurl E: Varies based on thread size
• Pilot C: Varies based on thread size
• Straight Hole Dia. D: Varies based on thread size
• Min. Sheet Thickness: Varies based on thread size

PEM® CASTSERT™ PRESS-IN INSERTS

For Castings and Soft Metals HRB 70 / HB 125 or less
PEM® 300 Series Stainless Steel CASTSERT™ inserts provide strong, durable metal threads in soft metals and die-cast alloys. The simple press-in and rapid installation process for these inserts uses a flat punch and anvil to install all sizes and lengths, approximately 80% faster than other methods.

• Designed for flush installation with flat punch and anvil into blind holes or thru-holes
• Process cost savings vs. coil inserts or thread tapping
• Installed into drilled holes or as-cast holes with low draft angle
• Pilot for rapid seating and self-alignment
• Symmetric for auto-feed capability

Fastener drawings and models are available at www.pemnet.com. Custom sizes are available on special order. Contact us for more information.

All dimensions are in inches.

Unified|

Thread Size

| Type|

Thread Code

|

Length Code

| Length A

±.005

| After Knurl E

Nom.

| Pilot C

Max.

| Min. Sheet Thickness R| Hole Size in Material (1)|
---|---|---|---|---|---|---|---|---|---|---
Straight Hole Dia.

D

+.003 –.000

| Min. Dia. H

of Tapered Hole (2) **at Length R**

| Min. Dist. Hole C/L to Edge (3)|
Stainless Steel|
.086-56

(#2-56)

| CKS| 256| 1| .125| .196| .179| .130| .188| .180| .151|
2| .250| .255|
.112-40

(#4-40)

| CKS| 440| 1| .175| .228| .209| .180| .219| .210| .175|
2| .300| .305|
.138-32

(#6-32)

| CKS| 632| 1| .200| .259| .240| .205| .250| .241| .198|
2| .375| .380|
.164-32

(#8-32)

| CKS| 832| 1| .250| .295| .266| .255| .281| .267| .225|
2| .475| .480|
.190-32

(#10-32)

| CKS| 032| 1| .300| .358| .329| .305| .344| .330| .272|
2| .525| .530|
.250-20 (1/4-20)| CKS| 0420| 1| .375| .452| .423| .380| .438| .424| .343|
2| .625| .630|

All dimensions are in millimetres.

Metric| Thread Size x Pitch| Type| ****

Thread Code

| ****

Length Code

| Length A

±0.13

| After Knurl E

Nom.

| Pilot C

Max.

| Min. Sheet Thickness R| Hole Size in Material (1)|
---|---|---|---|---|---|---|---|---|---|---
Straight Hole Dia.

D

+0.08

| Min. Dia. H

of Tapered Hole (2) **at Length R**

| Min. Dist. Hole C/L to Edge (3)|
Stainless Steel|
M2.5 x 0.45| CKS| M2.5| 1| 3.18| 4.98| 4.55| 3.3| 4.76| 4.57| 3.83|
2| 6.35| 6.48|
M3 x 0.5| CKS| M3| 1| 4.45| 5.79| 5.31| 4.57| 5.56| 5.33| 4.44|
2| 7.62| 7.75|
M4 x 0.7| CKS| M4| 1| 6.35| 7.49| 6.76| 6.48| 7.15| 6.78| 5.72|
2| 12.07| 12.19|
M5 x 0.8| CKS| M5| 1| 7.62| 9.09| 8.37| 7.75| 8.73| 8.38| 6.92|
2| 13.34| 13.46|
M6 x 1| CKS| M6| 1| 9.53| 11.48| 10.74| 9.65| 11.11| 10.77| 8.71|
2| 15.88| 16|

1. Blind holes to include .050”/1.27mm min. of hole clearance for material build up during install.
2. Draft hole performance will vary greatly depending on length of engagement of the knurl over the installed length. For best results, recommend use of 3 degree or less total draft and design hole as close to H as possible at depth R to optimize length and depth of knurl engagement.
3. Centerline-to-edge constraints are highly dependent on panel material and may have different failure modes depending on panel ductility. It is highly recommended to test for center-line to edge constraints in your specific application.

Custom sizes are available on special order. Contact us for more information.

• CK-2 PennEngineering
• www.pemnet.com

Part Number Designation

(1) HRB – Hardness Rockwell “B” Scale. HB – Hardness Brinell.

Material and Finish Specifications

 | Threads| Fastener Material| Standard Finish| For Use in Castings and Soft Metals: (1)
---|---|---|---|---

Type

| International, ASME B1.1, 2B / ASME B1.13M, 6H| 300 Series Stainless Steel| Passivated and/or Tested per ASTM A380| HRB 70 / HB 125

or less

CKS| •| •| •| •
Part Number Code for Finishes| None|

Installation

1. Prepare properly sized mounting hole in the sheet or leave as-cast tapered holes with low draft angle within the requirements shown on page 2.
2. Set the fastener into the mounting hole, seating the fastener using the pilot.
3. With installation punch and anvil surfaces parallel, apply squeezing force until the head of the insert contacts the sheet material.

Installation Tooling

Unified| Type| Anvil Dimensions (in.)| HAEGER® Part Number
---|---|---|---
A| B| C| Anvil| Punch
CKS| 3| 2.5| 1| H-108-0020L| H-108-0020L
Metric| Type| Anvil Dimensions (mm)| HAEGER® Part Number
---|---|---|---
A| B| C| Anvil| Punch
CKS| 76.2| 63.5| 25.4| H-108-0020L| H-108-0020L

Installation Note
For best results we recommend using a HAEGER® machine using a flat punch and anvil to install all CastSert™ inserts due to the required high force stroke equal to the part length.

Product Usage Instructions

Installation Preparation

1. Prepare a properly sized mounting hole in the sheet or leave as-cast tapered holes with a low draft angle within the requirements shown on page 2.

Installation Steps

2. Set the fastener into the mounting hole, ensuring that the fastener is seated using the pilot.
3. With the installation punch and anvil surfaces parallel, apply squeezing force to securely install the press-in insert.

For Additional HAEGER® and PEMSERTER® Tooling Information / Part Numbers

Performance Data(1)

Unified|

Thread Code

|

Length Code

| Test Sheet Material
---|---|---|---
ADC12 Die Cast Aluminum (A383 Equivalent)
Installation (lbs.)| Pullout (lbs.)| Torque-out (in. lbs.)
256| 1| 920| 65| 19
2| 1415| 135
440| 1| 1100| 75| 36
2| 1615| 145
632| 1| 1700| 180| 54
2| 2200| 280
832| 1| 1820| 220| 74
2| 3415| 530
032| 1| 2810| 250| 144
2| 4114| 670
0420| 1| 5010| 570| 273
2| 6710| 1345

1. Published installation forces are for general reference. Actual set-up and confirmation of complete installation should be made by observing proper seating of fastener as described in the installation steps. Installation force and torque-out values reported are averages when all proper installation parameters and procedures are followed. Variations in mounting hole size, sheet material, and installation procedure may affect performance. Performance testing this product in your application is recommended. We will be happy to provide technical assistance and/or samples for this purpose.

Metric|

Thread Code

|

Length Code

| Test Sheet Material
---|---|---|---
ADC12 Die Cast Aluminum (A383 Equivalent)
Installation (kN)| Pullout (N)| Torque-out (N•m)
M2.5| 1| 4.1| 300| 2.2
2| 6.3| 600
M3| 1| 4.9| 340| 4.1
2| 7.2| 660
M4| 1| 8.1| 800| 8.4
2| 15.2| 2100
M5| 1| 12.5| 1120| 16.3
2| 18.3| 3000
M6| 1| 22.3| 2550| 30.8
2| 30.3| 6000

Notes:

• Performance data in drilled straight hole condition with recommended hole tolerances in JIS H 5302 Grade ADC12 Die-cast Aluminum.
• ADC12 material hardness recorded at Hardness 70 HB (Hardness Brinell 70).
• Performance data collected from a sample size of 28 pieces from production lot.
• Grade 12.9 Socket Head Cap Screws failed in Torque for all samples. Torque-out data shown is average bolt breakage.
• Pullout data varies greatly part to part as common with cast metals. Published data is the minimum force to pull insert out of sheet in the 28 piece sample.

To prevent jack-out, it is very important that the clearance hole of the mating component is sized correctly. The clearance hole should be larger than the assembly screw, yet smaller than the outside diameter of the insert so that the insert, not the host panel, carries the compressive load. CastSert inserts can also jack-out when mating hardware bottoms out in a blind application. To ensure bottoming out does not occur, the proper length of mating hardware must be selected. All pullout tests were conducted as shown in the diagram labeled “normal mating configuration”. If possible in application, mating from the side opposite of installation such as shown in the “optimal mating configuration” will increase pullout performance. For additional pull- out performance in thru-hole applications, loading the joint opposite the side of installation would essentially provide pull-out equal to the installation force.

All PEM® products meet our stringent quality standards. If you require additional industry or other specific quality certifications, special procedures and/or part numbers are required. Please contact your local sales office or representative for further information. Regulatory compliance information is available in Technical Support section of our website. Specifications subject to change without notice. See our website for the most current version of this bulletin.

Frequently Asked Questions

Q: Are custom sizes available for the CKTM Press-In Inserts?
A: Yes, custom sizes are available on special orders. Please contact us for more information.

Q: Where can I find fastener drawings and models for the CKTM Press-In Inserts?
A: Fastener drawings and models can be found on our website at www.pemnet.com.

Q: What is the recommended hardness for use in castings and soft metals?
A: The recommended hardness is HRB 70 / HB 125 or less.

North America: Danboro, Pennsylvania USA
E-mail: [email protected] 
Tel: +1-215-766-8853
800-237-4736 (USA)

Europe: Galway, Ireland
E-mail: [email protected]
Tel: +353-91-751714

Asia/Pacific: Singapore
E-mail: [email protected] 
Tel: +65-6-745-0660

Shanghai, China:
E-mail : [email protected]
Tel: +86-21-5868-3688
Visit our PEMNET™ Resource Center at www.pemnet.com
Technical support e-mail: [email protected]
CK-4 PennEngineering www.pemnet.com

References

• PEM - PennEngineering | Homepage

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