presspress - seekpartfile.seekpart.com/keywordpdf/2011/3/31/201133191424404.pdf · equivalent hex...

6-1/2" MTX Tensioners on aninjection molding machine.

APPLICATIONS

T H E S O L U T I O N T O B O LT I N G P RO B L E M S

APPLICATIONSPRESSPRESS

P. O . B o x 6 8 3 • 1 0 0 0 G r e g g S t . • C a r n e g i e , PA 1 5 1 0 6( 4 1 2 ) - 2 7 9 - 11 4 9 • FA X ( 4 1 2 ) - 2 7 9 - 11 8 5 • 1 - 8 0 0 - 3 4 5 - B O LT ( 2 6 5 8 ) U S A

E - M a i l : b o l t i n g @ s u p e r b o l t . c o m • w w w. s u p e r b o l t . c o m

S u p e r b o l t p r o d u c t s a r e p r o t e c t e d b y t r a d e m a r k r i g h t s a n d o n e o r m o r e U . S . p a t e n t s :R E 3 3 4 9 0 ; 4 , 8 4 6 , 6 1 4 ; 5 , 0 8 3 , 8 8 9 ; 6 , 1 9 9 , 4 5 3 ; 6 , 3 8 1 , 8 2 7 ; 6 , 11 2 , 3 9 6 ; 6 , 2 6 3 , 7 6 4 ; o t h e r

p a t e n t s p e n d i n g a n d c o r r e s p o n d i n g f o r e i g n p a t e n t s .

2 column, 4,500 ton hydraulic open die forgingpress.The press columns are tightened by 20" dia. Superbolt Torquebolts that are approximately40 ft. long.These are the largest Torquebolts in the world.

7" mechanical tensioners secure tie rods on an injection molding machine.

2,000 ton Panel Press. Superbolt Tensionerseliminated tooling accessibility problems.

6-3/4" tensioners on hydraulicpress eliminates loosening of nuts which caused column failures in the past.

Forging press columns tensioned by 16-1/2" Superbolt split nuts.

Other Applications:

An Old Problem:

The Simple Solution:

Superbolt has been proven again and again in the field, solving thousands of bolting problems and improving your bottom line. The following pages details a few of the applications in your industry.

How They Work:

The hardened washer is installed first to protect the joint surface. TheTorquenut™ is spun on hand tight, for positioning. Easy turn jackbolts "push" the nut body up, tightening the existing bolt or stud in pure tension.

The strength of a screw fastener increases with the square of its diameter. The torque required increases with the third power. Bolts with a diameter greater than 1 inch cannot be effectively torqued to capacity with hand tools. To achieve high preload levels, some form of high energy equipment is required. Slugging wrenches and crane wrenches are dangerous and thermal tightening can be unsafe and time consuming. Hydraulic wrenching can be expensive, time consuming, innacurate and it often leads to thread galling problems. Hydraulic tensioning also shares some of these problems and adds problems with field retrofit.

Superbolt Tensioners are designed as direct replacements for standard bolting. They can be threaded onto a new or existing bolt, stud, threaded tie rod or shaft. With Superbolt Tensioners, bolting is fast, safe, easy and accurate - only hand tools are required!

Superbolt vs. Hydraulic Wrench: With a hydraulic wrench one would need 18,925 ft•lb of torque to stress a 3" stud to 428,400 lbs using a hex nut. With a 3" MTX Supernut, only 114 ft•lbs on each of the jackbolts is needed to produce the same bolt load!

Torque vs. Preload Comparison ChartThread DiameterEquivalent Hex Nut torquePreload (lbs)Superbolt Jackbolt torque

10"165,656 lb•ft1,125,000 lbs234 lb•ft

15"795,150 lb•ft3,000,000 lbs310 lb•ft

20"2,385,450 lb•ft6,750,000 lbs350 lb•ft

An Old Problem:

The Simple Solution:

Superbolt has been proven again and again in the field, solving thousands of bolting problems and improving your bottom line. The following pages details a few of the applications in your industry.

How They Work:

The hardened washer is installed first to protect the joint surface. TheTorquenut™ is spun on hand tight, for positioning. Easy turn jackbolts "push" the nut body up, tightening the existing bolt or stud in pure tension.

The strength of a screw fastener increases with the square of its diameter. The torque required increases with the third power. Bolts with a diameter greater than 1 inch cannot be effectively torqued to capacity with hand tools. To achieve high preload levels, some form of high energy equipment is required. Slugging wrenches and crane wrenches are dangerous and thermal tightening can be unsafe and time consuming. Hydraulic wrenching can be expensive, time consuming, innacurate and it often leads to thread galling problems. Hydraulic tensioning also shares some of these problems and adds problems with field retrofit.

Superbolt Tensioners are designed as direct replacements for standard bolting. They can be threaded onto a new or existing bolt, stud, threaded tie rod or shaft. With Superbolt Tensioners, bolting is fast, safe, easy and accurate - only hand tools are required!

Superbolt vs. Hydraulic Wrench: With a hydraulic wrench one would need 18,925 ft•lb of torque to stress a 3" stud to 428,400 lbs using a hex nut. With a 3" MTX Supernut, only 114 ft•lbs on each of the jackbolts is needed to produce the same bolt load!

Torque vs. Preload Comparison ChartThread DiameterEquivalent Hex Nut torquePreload (lbs)Superbolt Jackbolt torque

10"165,656 lb•ft1,125,000 lbs234 lb•ft

15"795,150 lb•ft3,000,000 lbs310 lb•ft

20"2,385,450 lb•ft6,750,000 lbs350 lb•ft

Problem: Due to the nature of big presses, large diameter columns must be used to distribute the extremely high working loads generated. However, the torque required to prestress these columns is almost impossible to achieve with conventional bolting methods.

Traditionally, sledgehammers, overhead cranes, or stud heaters are used. These methods are inaccurate, ineffective, time consuming and are a safety hazard. Sufficient and accurate preload is difficult to achieve on small presses and nearly impossible on larger presses. If the columns are not properly prestressed, fatigue fractures can occur.

Solution: Superbolt® Torquenuts® are designed as direct replacements for the OEM nuts, and are being used by press OEM companies, press repair shops, and end users. Only ordinary hand torque wrenches are required to properly prestress any size press column.

The entire operation can be performed safely by a single man in a fraction of the time it takes to use traditional tightening methods. The Mesta Press shown required less than 6 hours installation time with only 1 man for all 8 nuts vs. the 2-1/2 full days it previously took with additional personnel.

Removal is also a simple task. Torquenuts will not gall the main column thread during removal. Once the preload is relieved by loosening the jackbolts, the Torquenut easily spins off!

Press Columns:

Problem: This customer traditionally used the press force to prestress the columns. To remove the nuts,

the press is loaded to 110% of the press rated load and the split

column nuts are removed. In this case, there was a failure in the

hydraulic cylinder and the press could not be used to unload the

column nuts. The nuts were burned off, which took 2 days.

Superbolt® Solution: The old cast steel split column nuts were replaced with split Supernut® tensioners. The preload was achieved by loading the press to 110% of working load and some additional preload was achieved by torquing the jackbolts of the tensioners to 100 ft•lbs. Without hydraulic help from the main cylinder, the jackbolts would have to be torqued to 460 ft•lbs to achieve equivalent total preload of 3,5000,000 lbs. The Torquenut halves were held together with 1-1/2" high powered Superbolt® Torquebolts. In the future, the column Torquenuts can be unloaded without the hydraulic help of the main cylinder by simply untorquing the jackbolts.

4,250 Ton Aluminum Extrusion Press:

18" Superbolt Torquenut creates 2,625,000 lbs. of preload with only 275 ft•lbs of torque.

3250 Ton Mesta Forging Press. 18" Thrust Collar Style Torquenuts (no column threads).

5,000 Ton Forging Press with 20" diameter Superbolt MT Tensioners.

Before: Preload = 2,625,000 lbs. Hex Nut Torque = 695,756 ft•lb.

After: Preload = 2,625,000 lbs. Superbolt Jackbolt Torque = 275 ft•lb.

Hydraulic Presses High Pressure Piping:

Hydraulic Line - Main Ram.

Main Hydraulic Line - Pre-fill and Decompression Valve.

2,500 Ton Forging Press with 15-3/4" diameter Superbolt Tensioners.

Problem: Due to the nature of big presses, large diameter columns must be used to distribute the extremely high working loads generated. However, the torque required to prestress these columns is almost impossible to achieve with conventional bolting methods.

Traditionally, sledgehammers, overhead cranes, or stud heaters are used. These methods are inaccurate, ineffective, time consuming and are a safety hazard. Sufficient and accurate preload is difficult to achieve on small presses and nearly impossible on larger presses. If the columns are not properly prestressed, fatigue fractures can occur.

Solution: Superbolt® Torquenuts® are designed as direct replacements for the OEM nuts, and are being used by press OEM companies, press repair shops, and end users. Only ordinary hand torque wrenches are required to properly prestress any size press column.

The entire operation can be performed safely by a single man in a fraction of the time it takes to use traditional tightening methods. The Mesta Press shown required less than 6 hours installation time with only 1 man for all 8 nuts vs. the 2-1/2 full days it previously took with additional personnel.

Removal is also a simple task. Torquenuts will not gall the main column thread during removal. Once the preload is relieved by loosening the jackbolts, the Torquenut easily spins off!

Press Columns:

Problem: This customer traditionally used the press force to prestress the columns. To remove the nuts,

the press is loaded to 110% of the press rated load and the split

column nuts are removed. In this case, there was a failure in the

hydraulic cylinder and the press could not be used to unload the

column nuts. The nuts were burned off, which took 2 days.

Superbolt® Solution: The old cast steel split column nuts were replaced with split Supernut® tensioners. The preload was achieved by loading the press to 110% of working load and some additional preload was achieved by torquing the jackbolts of the tensioners to 100 ft•lbs. Without hydraulic help from the main cylinder, the jackbolts would have to be torqued to 460 ft•lbs to achieve equivalent total preload of 3,5000,000 lbs. The Torquenut halves were held together with 1-1/2" high powered Superbolt® Torquebolts. In the future, the column Torquenuts can be unloaded without the hydraulic help of the main cylinder by simply untorquing the jackbolts.

4,250 Ton Aluminum Extrusion Press:

18" Superbolt Torquenut creates 2,625,000 lbs. of preload with only 275 ft•lbs of torque.

3250 Ton Mesta Forging Press. 18" Thrust Collar Style Torquenuts (no column threads).

5,000 Ton Forging Press with 20" diameter Superbolt MT Tensioners.

Before: Preload = 2,625,000 lbs. Hex Nut Torque = 695,756 ft•lb.

After: Preload = 2,625,000 lbs. Superbolt Jackbolt Torque = 275 ft•lb.

Hydraulic Presses High Pressure Piping:

Hydraulic Line - Main Ram.

Main Hydraulic Line - Pre-fill and Decompression Valve.

2,500 Ton Forging Press with 15-3/4" diameter Superbolt Tensioners.

Supernut™ Tensioners on 400 mm (Approx. 15.75") Columns for 1,500 Ton Underground Hydraulic Forging Press.

Hydraulic Forging Press:

Problem:

The Press Sticks in a Down Position:-Must loosen the tie rods to release the press.-Time consuming, expensive and hazardous 8-12 hours downtime.

Rebuild, Repair or Adjustment of Press:-Thread galling and tie rod damage.-Requires heating rods, slug wrenches and heavy impact wrenches.

Solution:

Superbolt® Multi-Jackbolt Tensioners:-Backing off jackbolts loosens press sufficiently to free it from down positions.-Jackbolts used to develop preload in pure tension.-Requires simple hand tools, eliminating unsafe, time consuming bolting methods.-Greatly reduces installation and removal times -Eliminates thread galling and stud damage.

Stamping Press:

Extruding Press:

Press Anchorbolts:

•3" - 8 tpi Anchorbolt on 2,000 Ton Hydraulic Press

Preload = 379,000 lbsJackbolt Torque = 205 ft•lbs(Note: Hex Torque = 16,750 ft•lbs)

•3-1/2" - 8 tpi Anchorbolt on 1,500 ton Hydraulic Press

Problem: The press columns failed twice since 1978 and had to be totally replaced. The insurance company did not want to insure the press anymore unless the machine was correctly pretensioned.

Solution: The press was modified. The existing columns were checked and can be reused. On both sides the columns are stretched by Superbolt patented Multi-Jackbolt tensioners. The higher preload can now safely take up the heavy loads of the machine. There has not been one failure since the press has been modified .

Installation: Complete reconstruction including 6 pieces MT-S355x12/W-Special.

Other Applications:

1200 ton Hepburn Bale Press oil leaks stopped by using Superbolt® Tensioners.

2500 Ton Structural Foam Injection Molding Press.

Williams and White 1390 Ton Particle Board Press.

Supernut™ Tensioners on 400 mm (Approx. 15.75") Columns for 1,500 Ton Underground Hydraulic Forging Press.

Hydraulic Forging Press:

Problem:

The Press Sticks in a Down Position:-Must loosen the tie rods to release the press.-Time consuming, expensive and hazardous 8-12 hours downtime.

Rebuild, Repair or Adjustment of Press:-Thread galling and tie rod damage.-Requires heating rods, slug wrenches and heavy impact wrenches.

Solution:

Superbolt® Multi-Jackbolt Tensioners:-Backing off jackbolts loosens press sufficiently to free it from down positions.-Jackbolts used to develop preload in pure tension.-Requires simple hand tools, eliminating unsafe, time consuming bolting methods.-Greatly reduces installation and removal times -Eliminates thread galling and stud damage.

Stamping Press:

Extruding Press:

Press Anchorbolts:

•3" - 8 tpi Anchorbolt on 2,000 Ton Hydraulic Press

•3-1/2" - 8 tpi Anchorbolt on 1,500 ton Hydraulic Press

Problem: The press columns failed twice since 1978 and had to be totally replaced. The insurance company did not want to insure the press anymore unless the machine was correctly pretensioned.

Solution: The press was modified. The existing columns were checked and can be reused. On both sides the columns are stretched by Superbolt patented Multi-Jackbolt tensioners. The higher preload can now safely take up the heavy loads of the machine. There has not been one failure since the press has been modified .

Installation: Complete reconstruction including 6 pieces MT-S355x12/W-Special.

Other Applications:

1200 ton Hepburn Bale Press oil leaks stopped by using Superbolt® Tensioners.

2500 Ton Structural Foam Injection Molding Press.

Williams and White 1390 Ton Particle Board Press.

6-1/2" MTX Tensioners on aninjection molding machine.

APPLICATIONS

THE S O LUTIO N TO B O LTING P RO B LEMS

APPLICATIONSPRESSPRESS

P. O . B o x 6 8 3 • 1 0 0 0 G r e g g S t . • C a r n e g i e , PA 1 5 1 0 6( 4 1 2 ) - 2 7 9 - 11 4 9 • FA X ( 4 1 2 ) - 2 7 9 - 11 8 5 • 1 - 8 0 0 - 3 4 5 - B O LT ( 2 6 5 8 ) U S A

E - M a i l : b o l t i n g @ s u p e r b o l t . c o m • w w w. s u p e r b o l t . c o m

S u p e r b o l t t e n s i o n e r s a r e p r o t e c t e d b y t r a d e m a r k r i g h t s a n d o n e o r m o r e U . S . p a t e n t s : 6 , 1 9 9 , 4 5 3 ; 6 , 3 8 1 , 8 2 7 ; 6 , 11 2 , 3 9 6 ; 6 , 2 6 3 , 7 6 4 ; 7 , 6 3 7 , 7 0 6 ; 7 , 7 7 5 , 5 5 9

o t h e r p a t e n t s p e n d i n g a n d c o r r e s p o n d i n g f o r e i g n p a t e n t s .

2 column, 4,500 ton hydraulic open die forging press. The press columns are tightened by 20" dia. Superbolt® Torquebolts that are approximately 40 ft. long. These are the largest Torquebolts in the world.

7" mechanical tensioners secure tie rods on an injection molding machine.

2,000 ton Panel Press. Superbolt Tensionerseliminated tooling accessibility problems.

6-3/4" tensioners on hydraulicpress eliminates loosening of nuts which caused column failures in the past.

Forging press columns tensioned by 16-1/2" Superbolt split nuts.

Other Applications:

presspress - seekpartfile.seekpart.com/keywordpdf/2011/3/31/201133191424404.pdf · equivalent hex...

Documents