Thread-forming in metal

HELICOIL®

Assembly of thread inserts

Creating high-strength fastenings

There are plenty of options: from simple manual installation tools and standard tools through to complete systems.

Our assembly solutions are designed as fully automatic or semi-automatic workstations. Depending on your requirements, parts can be handled by the operator, by a handling system, by a rotary indexing system or by a transfer system.

Take a look at our assembly solutions.

 


Method / principle

HELICOIL® thread inserts create high-strength, wear-resistant, heat-resistant threads of highest precision by transferring the force from flank to flank into the pilot thread. The reduced diameter of the HELICOIL® Plus in the first thread ensures that the thread insert can be screwed in like a screw.
Installing HELICOIL® thread inserts is easy and cost-effective, because there are only a few basic rules to follow. For efficient assembly, whether for a single application or for high-volume production, we offer a wide choice of installation tools – from manual to automated.
The HELICOIL® system combines conformance to standards with easy installation.

Applications

HELICOIL® can be found in the automotive sector, in aerospace, and in general industry. Our installation tools are used for repairs and maintenance, in small and medium-scale production with hand-operated assembly tools, and in automated high-volume production.

HELICOIL® Plus thread inserts comply with a variety of requirements and industry standards, including those in the aerospace industry, and feature other approvals as well as suitability tests, e.g. in the field of power plant technology.

 

Product benefits
  • Reduced assembly time
  • High process reliability
  • Assembly systems, tools and products from a single source – from manual to automated
  • Available for imperial and metric dimensions and for custom designs

Installation process

 

Core hole drilling

Standard twist drills are used. For suggested diameters and core hole depths, please refer to our catalogues "HELICOIL® Plus – The thread technology for high-strength fastenings" – Metric threads (0100) / Imperial threads (0101).
Use a 90° cutter for countersinking and deburring before thread cutting. External diameter of the countersink = DHC + 0.1 mm.

HELICOIL® installation process – Core hole drilling
 

Thread cutting

System-specific original HELICOIL® taps should be used for cutting the HELICOIL® Plus pilot thread. For recommended hand and machine taps, please refer to our catalogues "HELICOIL® Plus – The thread technology for high-strength fastenings" – Metric threads (0100) / Imperial threads (0101). Use HELICOIL® plug gauges to check the trueness to gauge of the pilot thread.

HELICOIL® installation process – Thread cutting
 

Inserting the thread insert

Installation is possible using manual or mechanical installation tools or automated systems. Screw the HELICOIL® Plus thread insert onto the installation mandrel with the driver tang facing downwards (1), insert it into the prewinder (2) or place it on the fly-over tool (3), and place the tool on the tapped hole.

HELICOIL® installation process – Thread insert positioning
 

Installation

Screw in the thread insert by turning the mandrel (1), spindle (2) or fly-over tool (3) by hand or by operating the drive. It must be installed at least 0.25 P below the surface.

HELICOIL® installation process – Installation
 

Tang break-off

To create a through-hole thread, the driver tang must be broken off at the notch. This is done using a tang break-off tool (1 and 2). For thread sizes M 14 or bigger with a fine or standard screw thread, the driver tang can be removed using long-nose pliers (3). For blind-hole threads, there is no need to remove the tang, provided that the maximum screw-in depth t3 of the screw is observed.

HELICOIL® installation process – Tang break-off

Thread preparation

System-specific original HELICOIL® taps should be used for cutting the HELICOIL® Plus pilot thread.

We supply a range of appropriate hand and machine taps.

Hand taps

Suitable for through-hole and blind-hole tapping.

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Machine taps

For through-hole and blind-hole tapping.

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Combined drilling and cutting tools

For cutting HELICOIL® pilot threads in damaged or stripped metric coarse and fine threads.

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Mechanical thread former

Non-cutting production of internal threads for blind-hole and through-hole threads.

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Plug gauges

For checking the trueness to gauge of pilot threads created with a thread-cutting tool, we can provide plug gauges in diameters M 2 to M 36 x 3.

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Installation mandrels

The installation mandrels in different types are designed for installing HELICOIL® Plus and HELICOIL® Tangfree Free Running and Screwlock.

HELICOIL® Plus

Installation mandrel for installing HELICOIL® Plus Free Running and Screwlock, dimensions M 2 to M 24.
With hexagon head DIN 3126 – E 6.3 / DIN ISO 1173.

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HELICOIL® Tangfree

Installation mandrel for installing HELICOIL® Tangfree Free Running and Screwlock, dimensions M 3 to M 14.
With hexagon head DIN 3126 – E 6.3 / DIN ISO 1173.

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Tools with installation mandrel

For processing HELICOIL® Plus and HELICOIL® Tangfree thread inserts.

There are essentially three different types of installation tools. The choice depends on the number of HELICOIL® thread inserts to be processed, the location of the tapped holes in the workpiece, and the thread size.

Battery-operated

Type B-S 206

For M 2 to M 6 thread inserts.

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Battery-operated

Type B-S 824

For M 7 to M 24 thread inserts.

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Electric

Type E-S 206

For M 2 to M 6 thread inserts.

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Electric

Type E-S 410

For M 4 to M 10 thread inserts.

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Pneumatic

Type P-S 412

For M 4 to M 12 thread inserts.

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Pneumatic

Type P-S 1216

For M 12 to M 16 thread inserts.

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Tools with prewinder

For processing HELICOIL® Classic, HELICOIL® Plus and HELICOIL® Tangfree thread inserts.

Pitch-controlled manual installation tools for processing loose and magazined HELICOIL® thread inserts.

Electric

Type E-PSG

For HELICOIL® Plus and HELICOIL® Tangfree in sizes M 2.5 to M 6 for medium and large-scale production.

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Pneumatic

Type P-PSG 256 / 714 / 1626

For the loose processing of HELICOIL® Classic and HELICOIL® Plus in sizes M 2.5 to M 26 x 1.5.

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Pneumatic

Type P-PSG 256 SF / 714 SF

For the magazined processing of HELICOIL® Classic and HELICOIL® Plus in sizes M 2.5 to M 10 (STRIPFEED®).

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Manual tools

For HELICOIL® Classic and HELICOIL® Plus thread inserts

The manual tools are available with and without pitch control.

Type H-PSG

Manual tool with prewinder for M 2 to M 36 x 3 thread inserts.

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Type H-M

Fly-over tool with depth stop for M 18 to M 36 thread inserts.

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Tang break-off tools

For quick and easy tang break-off on HELICOIL® Classic and HELICOIL® Plus thread inserts.
Manual

Tang break-off mandrel

Tang break-off mandrel available for sizes M 2 to M 12.

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Mechanical

Type TB-M

Mechanical tang break-off tool with spring tension, available for sizes M 2 to M 12.

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Pneumatic

Type TB-P

Pneumatic tang break-off tool with thrust trigger, available for sizes M 3, M 4 to M 8 and M 10 and M 12.

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Extraction tools

For the manual and mechanical disassembly of HELICOIL® thread inserts
Manual / mechanical

Extraction tool

A tool for the manual and mechanical disassembly of HELICOIL® thread inserts. The only difference is in the size range: M 3 to M 5 and M 6 to M 14.

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Accessories

Parallel-arm stand type S

For HELICOIL® installation tools. Fast and reliable positioning, especially for smaller sizes.

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Automatic installation tools

Automatic processing of HELICOIL® thread inserts.

Automation

Just as important as the high quality standard is the cost-effective installation of HELICOIL® thread inserts.
To this end, we offer modules for integration into automatic processes and complete systems.

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Downloads

Find out more: related downloads.

If you would like to know more, simply download the relevant brochures.

Title Language Version File Download
HELICOIL®
Metric thread inserts for metals
English 0100/16.02 2927 kB / PDF
English 0100/16.02 2927 kb / PDF
HELICOIL®
Imperial thread inserts for metals
English 0101/15.01 3494 kB / PDF
English 0101/15.01 3494 kb / PDF
The Blue Book
Aerospace Buyer’s Directory
To HELICOIL® Wire Thread Inserts
English 0130/16.02 522 kB / PDF
English 0130/16.02 522 kb / PDF
HELICOIL® Tangfree
The tangfree coil thread insert for a high-strength thread
English 0150/14.02 1355 kB / PDF
English 0150/14.02 1355 kb / PDF
E-PSG and ES-410
Electrical installation tool for HELICOIL® thread inserts
English 0170/12.02 331 kB / PDF
English 0170/12.02 331 kb / PDF

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