A p p l i c a t i o n s L a b o r a t o r y T e s t i n g R e p o r t

A T F , I n c o r p o r a t e d

3 5 5 0 W e s t P r a t t A v e n u e L i n c o l n w o o d , I l l i n o i s 6 0 7 1 2

P h o n e ( 8 4 7 ) 6 7 7 - 1 3 0 0

Performance Evaluation of DELTA PT® 40 in the FCA DS 20” Wheel

Project Number: 15002

Submitted To:

[Company]

Test Engineer: Carson McVay

Date:

1/28/2015

2

Table of Contents Introduction .................................................................................................................................................. 3

Testing Summary .......................................................................................................................................... 4

Screws ....................................................................................................................................................... 4

Application ......................................................................................................................... 4

Tests Conducted (see Procedures on page 5 for test details) .................................................................. 4

Procedure ...................................................................................................................................................... 5

Test Preparation........................................................................................................................................ 5

Drive & Strip Torque ................................................................................................................................. 5

Tightening Torque ..................................................................................................................................... 5

Repeat Assembly ....................................................................................................................................... 5

Drive and Strip Torque Explanation .............................................................................................................. 6

Test Results ................................................................................................................................................... 7

Dimensional Analysis ................................................................................................................................ 7

Drive & Strip Torque ................................................................................................................................. 9

Tightening Torque ................................................................................................................................... 11

Repeat Assembly ..................................................................................................................................... 11

Pull Out Testing ....................................................................................................................................... 12

Pull Out Fixture Set Up ............................................................................................................................ 12

Fastener Dimensions ............................................................................................................................... 13

Pull Out Forces ........................................................................................................................................ 13

Example Force Result .............................................................................................................................. 14

Conclusions ................................................................................................................................................. 15

3

The ATF, Inc. Applications Lab, on behalf of , initiated project number 005 to evaluate the performance

of a DELTA PT® 40 in FCA DS 20” wheel. Drive and Strip Torque Tests were conducted to determine

margin of safety for installation and to calculate the optimal tightening torque. Repeat Assembly Tests

were performed to evaluate the long term performance of the joint after several installations

I n tr od u c t io n

4

Screws

DELTA PT® 40 x 1.46 x 17 TORX® Round Washer Head

ATF Part Number: P3121003

Size: 4.0 mm diameter; 17 mm length

Head Style: Round Washer Head

Drive Style: TORX®

Plating: GMW 3200

Material: 1022 Steel, Neutral hardened to RC 33-39

Application

FCA DS 20” Wheel Applique

Boss Material: PC ABS

Average Hole Diameter: 3.50 mm

Tests Conducted (see Procedures on page 5 for test details) Drive and Strip Torque Test Tightening Torque Determination Repeat Assembly Pull Out Testing

T e s t i ng S u mma r y

5

Test Preparation To ensure accuracy, a random sample of fasteners were selected for measurement. The pertinent

dimensions of the fasteners include the major thread diameter, overall length and head diameter.

Likewise, the application piece bosses were measured to ensure stability for testing. The pertinent

boss dimensions include hole diameter and hole depth.

Drive & Strip Torque Driving torque and stripping torque are important in determining a joint’s safety of assembly. Drive

and strip torque testing is conducted by driving the fasteners into the pilot holes of each boss with an

Atlas Copco electric driver, turning at a free speed of 400 rpm, until the joint fails. The torque is

measured continuously throughout the driving process. The measuring apparatus consists of an Atlas

Copco Tensor S4/S7 running ToolsTalk PF3000 for data acquisition. The software then collects and

translates signals from the transducer into a torque vs. time graph. This graph is interpreted to

determine the precise maximum driving and stripping torque.

Tightening Torque The tightening torque is the torque at which it is recommended the application be assembled. The

tightening torque should be sufficiently high so as to fully drive the screw and generate clamp load, yet

low enough to avoid stripping and long term boss damage. An adequate safety factor to compensate

for the repeat accuracy of the driver system must also be considered.

Repeat Assembly Repeat assembly testing is conducted to evaluate the performace of the fasteners after being serviced

multiple times. Each fastener is driven into the test boss using an Atlas Copco electric driver, turning

at a free speed of 600 RPM. The fastener is tightened to the tightening torque ten times. The Break-

loose torque is measured on the first, fifth and tenth assemblies. On the eleventh assembly the fastener

is driven until the joint fails due to stripping.

Pr o c e d u re

6

D r i v e a n d S tr i p To r q u e E xp l a na t io n

7

Dimensional Analysis Application: FCA DS 20" Wheel

Boss Material: PC ABS

Applique

1 Hole Ø -

Bottom- [mm]

2 Hole Ø -

Bottom- [mm]

3 Hole Ø -

Bottom- [mm]

A 3.48 3.48 3.45

B 3.45 3.45 3.48

C 3.48 3.48 3.45

D 3.48 3.48 3.45

E 3.48 3.45 3.45

F 3.48 3.45 3.45

G 3.48 3.45 3.48

H 3.48 3.48 3.48

I 3.45 3.48 3.45

J 3.48 3.45 3.45

K 3.48 3.45 3.45

L 3.45 3.45 3.45

Average 3.47 3.46 3.46

3σ Maximum 3.51 3.51 3.50

3σ Minimum 3.43 3.42 3.42

Std. Deviation 0.01 0.02 0.01

T e s t R es u l t s

8

Fastener: DELTA PT® 40 x 1.46 x 17 TORX® Round Washer Head

Specimen

No. Major Ø

[mm]

Shank Length [mm]

1 4.04 16.86

2 4.04 16.79

3 4.00 16.59

4 4.00 16.96

5 4.00 16.96

6 4.01 17.04

7 4.00 16.97

8 4.00 16.94

9 4.00 16.98

10 4.01 16.98

11 4.03 16.94

12 4.03 17.02

13 4.00 16.90

14 4.03 17.01

15 4.03 16.96

16 4.02 17.00

17 4.03 16.87

18 4.02 17.18

19 4.00 17.01

20 4.03 16.90

21 4.02 16.95

22 4.01 17.14

23 4.00 16.87

24 4.02 17.01

25 4.00 17.09

26 4.01 17.00

27 4.00 17.05

28 4.03 17.10

29 4.02 17.10

30 4.02 17.10

Average 4.02 16.98

3σ Maximum 4.06 17.32

3σ Minimum 3.97 16.63

Std. Dev 0.01 0.11

9

Drive & Strip Torque

Application: 20" Dodge Ram Wheel Fastener: DELTA PT® 40 x 1.46 x 17 TORX® Round Washer Head ATF Part #: P3121003

Applique No. Boss 1

Driving Torque [Nm]

Boss 1 Stripping Torque [Nm]

Boss 2 Driving Torque

[Nm]

Boss 2 Stripping Torque [Nm]

Boss 3 Driving Torque

[Nm]

Boss 3 Stripping Torque [Nm]

A 0.45 2.43 0.48 2.28 0.51 2.67

B 0.42 2.40 0.49 1.93 0.47 2.42

C 0.45 2.51 0.55 1.94 0.50 2.63

D 0.40 2.79 0.54 1.83 0.52 2.59

E 0.48 2.65 0.48 2.38 0.52 2.63

F 0.50 2.73 0.50 2.09 0.48 2.55

G 0.46 2.70 0.48 2.52 0.46 2.55

H 0.46 2.42 0.51 2.49 0.49 2.82

I 0.50 2.84 0.48 2.54 0.50 2.48

J 0.48 2.88 0.49 2.64 0.48 2.87

Average 0.46 2.64 0.50 2.26 0.49 2.62

3σ Maximum 0.56 3.18 0.58 3.15 0.55 3.04

3σ Minimum 0.36 2.09 0.42 1.38 0.43 2.20

Std. Deviation 0.03 0.18 0.03 0.29 0.02 0.14

3σ minimum strip-to-drive ratio: 3.75

2.39

3.97

10

Combined Driving Torque [Nm]

Combined Stripping Torque [Nm]

0.45 2.43 0.42 2.40 0.45 2.51 0.40 2.79 0.48 2.65 0.50 2.73 0.46 2.70 0.46 2.42 0.50 2.84 0.48 2.88 0.48 2.28 0.49 1.93 0.55 1.94 0.54 1.83 0.48 2.38 0.50 2.09 0.48 2.52 0.51 2.49 0.48 2.54 0.49 2.64 0.51 2.67 0.47 2.42 0.50 2.63 0.52 2.59 0.52 2.63 0.48 2.55 0.46 2.55 0.49 2.82 0.50 2.48 0.48 2.87 0.48 2.51 Average

0.58 3.32 3σ Maximum 0.39 1.69 3σ Minimum 0.03 0.27 Std. Deviation

2.93 3σ minimum strip-to-drive ratio:

11

Tightening Torque Recommended Driver Settings:

2-stage Tightening 1st stage target torque: 0.90±0.10 Nm (speed = 400 rpm)

2nd stage target torque: 1.14±0.25 Nm (speed = 100 rpm)

Repeat Assembly

Application: 20" Dodge Ram Wheel

Fastener: DELTA PT® 40 x 1.46 x 17 TORX® Round Washer Head

ATF Part #: P3121003

Specimen No.

1st Assembly 5th Assembly 10th Assembly

lnstallation Torque [Nm]

Breakloose Torque [Nm]

lnstallation Torque [Nm]

Breakloose Torque [Nm]

lnstallation Torque [Nm]

Breakloose Torque [Nm]

1 1.17 1.15 1.15

2 1.15 1.15 0.84 1.19 0.93

3 1.16 1.01 1.17 0.82 1.15 0.76

4 1.15 1.07 1.15 0.84 1.17 0.74

5 1.17 0.92 1.17 0.94 1.18 0.91

6 1.16 0.97 1.15 0.78 1.15 0.69

Average 1.16 0.99 1.16 0.84 1.17 0.81

3σ Maximum 1.19 1.18 1.19 1.02 1.22 1.13

3σ Minimum 1.13 0.80 1.13 0.67 1.11 0.48

Std. Deviation 0.01 0.06 0.01 0.06 0.02 0.11

12

Pull Out Testing The purpose of this testing was to evaluate the pull-out force of the DELTA PT® 40 in the PC ABS boss

material. Testing was conducted using the previously calculated tightening torque strategy. Each of the

fasteners tested were successfully installed into each of the bosses tested with the recommended

strategy. After the fasteners were installed into the boss, the boss was cut away from the material as to

fit in to the testing fixture.

The fastener for the application tested is 17mm in length and the thickness of the capture material is

estimated to be 5mm, yielding a result of 12 mm of thread engagement into the boss material. For the

test set up, the thickness of the capture material was increased to 9.50mm. A very similar DELTA PT® 40

was used for the pull out testing as was used for Drive and Strip testing. The ATF part chosen for the

testing was part P3121002. This is a DELTA PT® 40 x 23mm. This part has the same hardness and finish as

the part tested on the application. With the increased length of this part and the different capture

material (test rig) the engagement was able to remain at approximately 12mm.

The figure shown below depicts the testing that was performed. Each fastener was measured and

documented prior to testing to ensure accuracy for testing. The pertinent measurements for each of

these fasteners are also detailed in the table on the next page.

Pull Out Fixture Set Up

13

Fastener Dimensions ATF Part# P3121002

Description Delta 40 x 23

Sample # Head (mm) Thread (mm) Shaft (mm)

1 8.62 4.01 22.52

2 8.65 4.01 22.51

3 8.70 4.00 22.56

4 8.62 4.02 22.46

5 8.62 4.00 22.60

Pull Out Forces Test # Pull Out Force (N)

1 155

2 119

3 120

4 145

5 112

14

Example Force Result

Trial 5 Pull Out Force Graph

15

The objective for this series of testing was to evaluate the performance of a DELTA PT® 40 in the FCA

DS 20” wheel Applique.

The results of the Drive and Strip Torque Tests show that there is an adequate margin of safety available

for installation of the DELTA PT® 40 into the PC ABS inserts (3σ min. strip to drive ratio > 2). The

recommended driver settings are detailed below. Moreover, the fasteners can be reinstalled at least 10

times with the same driver settings without damage/failure of the joint components. Therefore, use of

the DELTA PT® 40 in this insert design is highly recommended; no issues with assembly are foreseen at

this time.

Recommended Driver Settings

Fastener: DELTA PT® 40 x 1.46 x 17 TORX® Round Washer Head

ATF Part #: P3121003

Application: FCA DS 20” Wheel

Driver Settings: 2-stage Tightening

1st Target Torque: 0.90±0.10 Nm (speed = 400 rpm)

2nd Target Torque: 1.14±0.25 Nm (speed = 100 rpm)

Liability Statement The information and technical advice contained herein is given to the best of our knowledge according to

the state of technology at the time of this test. It is presented to our customers with the intention of

aiding them in improving their product. Please understand that since differences exist between the

laboratory and mass production, we cannot guarantee a specific performance or accept any liability.

C o n c l us io n s