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Thread-forming in metal

HELICOIL®

There are plenty of options, from simple manual installation tools to standard tools to fully automated complete systems.

Installation mandrel for HELICOIL® Smart – The thread insert with tang that does not have to be broken off.

Thread-forming in metal

Creating high-strength fastenings

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

Method and principle

The HELICOIL® installation process

HELICOIL® thread inserts create high-strength, wear-resistant, heat-resistant thread of the highest precision by transferring the forces from flank to flank into the pilot thread. The reduced diameter of the HELICOIL® Plus in the first turn ensures that the thread insert can be installed 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 provide a broad range of manual and automated installation tools.

The HELICOIL® system combines conformance to standards with easy installation.

The installation steps in detail

Core hole drilling

You can use a standard twist drill. 
Use a 90° cutter for countersinking and deburring before thread cutting. External diameter of the countersink = DHC + 0.1 mm.

HELICOIL® core hole drilling

Thread cutting

You should use our system’s original HELICOIL® taps to cut the HELICOIL® Plus pilot thread. Use HELICOIL® plug gauges to verify that pilot thread is true-to-gauge.

HELICOIL® thread-cutting

Thread forming

Use a thread former to quickly and easily produce a chipless internal thread.

HELICOIL® thread forming

Thread installation

You can carry out the installation with a manual installation tool, an automatic installation tool or a fully automated solution.

HELICOIL® Plus Free Running Thread insert for metals

Interested?

Order HELICOIL® thread inserts online now

In the eShop, you will find the latest information on price and availability, technical data sheets and CAD downloads, as well as our varied range of branded products and standard parts.

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Find the right solution for your application

HELICOIL® taps

System-specific original HELICOIL® taps should be used for cutting the HELICOIL® Plus pilot thread. We supply a range of suitable manual and automatic taps.

  • Hand taps

    • For machining materials with a strength rating up to 700 N/mm2.
    • Only suitable for blind holes if sufficient tapping space is present.
    • Minimum requirement is 1d deeper that the fully cut-out thread length.
    Manual taps in our eShop
  • Machine taps

    Depending on your application, you can choose from various machine taps.

    Machine taps in our eShop
  • Combined drilling and cutting tools

    Combined drilling and tapping tool 0142.0 for HELICOIL® holding threads in damaged metric coarse and fine threads. Pre-drilling (tap drilling) is not required.

    Combined drilling and cutting tools in the eShop
  • Mechanical thread former

    HELICOIL® forming tap for the chipless production of tolerance class 5H (6H mod.) holding threads for HELICOIL® thread inserts. The forming tap features lubrication grooves to provide for proper lubrication also for large depths.

    Discover mechanical thread formers in our eShop
  • Plug gauges

    Plug gauge to check if holding threads for HELICOIL® thread inserts which have been produced with a threading tool are true to gauge.

    Plug gauges in our eShop

HELICOIL® installation mandrels

Installation mandrels in various shapes for installation of HELICOIL® Plus, HELICOIL® Tangfree – Free Running and Screwlock, and HELICOIL® Smart Free Running.

  • HELICOIL® Plus

    Suitable for the following tools

    • Electrical installation tools – type E S 206 and E S 410
    • Battery-operated installation tools – type B S 206 and B S 824
    • Pneumatic installation tools – P S 412 and P S 1216


    Advantages

    • Quick changeover
    • Reduced tool costs
    • Pick-and-place processing is possible 
       
    HELICOIL® Plus in our eShop
  • HELICOIL® Tangfree

    Suitable for the following tools

    • Electrical installation tools – Type E‑S 206 and E‑S 410
    • Battery-operated installation tools – Type B‑S 206 and B‑S 824
    • Pneumatic installation tools – P‑S 412 and P‑S 1216
    HELICOIL® Tangfree in our eShop
  • HELICOIL® Smart

    Installation mandrel with depth stop for installation of HELICOIL® Smart Free Running in dimensions from M 4 to M 12.

    Suitable for the following tools

    • Pneumatic installation tools – P‑S 408S, P‑S 10S and P‑S 12S

HELICOIL® tools with installation mandrel

For processing HELICOIL® Plus, HELICOIL® Tangfree and HELICOIL® Smart thread inserts. Essentially there are 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.

  • Type P-S 408S

    Technical data

    • Idle speed: 1500 rpm at p = 6.3 bar (adjustable via air pressure)
    • Air consumption: 5.5 l/s at p = 6.3 bar
    • Torque: M = 4.5 Nm
    • Tool holder: 1/4" hexagon socket with radial bearing
    • Weight: 0.8 kg

    Size-specific HELICOIL® Smart installation mandrels with depth stop must be ordered separately.

  • Type P-S 10S

    Technical data

    • Idle speed: 600 rpm at p = 6.3 bar (adjustable via air pressure)
    • Air consumption: 5.5 l/s at p = 6.3 bar
    • Torque: M = 7 Nm
    • Tool holder: 1/4" hexagon socket with radial bearing
    • Weight: 1.1 kg

    Size-based HELICOIL® Smart installation mandrels with depth stop must be ordered separately.

  • Type P-S 12S

    Technical data

    • Idle speed: 380 rpm at p = 6,3 bar (adjustable via air pressure)
    • Air consumption: 5.5 l/s at p = 6.3 bar
    • Torque: M = 10 Nm
    • Tool holder: 1/4" hexagon socket with radial bearing
    • Weight: 1.1 kg

    Size-based HELICOIL® Smart installation mandrels with depth stop must be ordered separately.

  • Type B-S 206

    Technical data

    • Idle speed: 2‑stage 200 rpm & 600 rpm, reversible
    • Torque: 21-step adjustability 0.3 – 2.9 Nm / max. 4.4 Nm
    • Tool holder: 1/4" hexagon socket
    • Weight incl. battery: 0.5 kg
    • Battery: 3.6 V / 1.5 Ah / Charge time 30 min.

    The appropriate installation mandrel must be ordered separately.

    Type B-S 206 in our eShop
  • Type B-S 824

    Technical data

    • Idle speed:
      • Stage 1 / variable 65 – 450 rpm, reversible
      • Stage 2 / variable 200 – 1450 rpm, reversible
    • Torque: 19-step adjustability 1 – 6.9 Nm / max. 31.9 Nm
    • Tool holder: self-centering chuck 1.0 – 13 mm
    • Weight incl. battery: 2.0 kg
    • Battery: 15.6 V / 3 Ah / Charge time 45 min.

    The appropriate installation mandrel must be ordered separately.

    Type B-S 824 in our eShop
  • Type E-S 206

    Technical data

    • Idle speed: 720 rpm
    • Output voltage: 35 V DC
    • Torque: M = 0.45 – 0.95 Nm
      (infinitely variable shut-off\\\ clutch)
    • Tool holder: 1/4" hexagon socket with radial bearing
    • Weight: 0.31 kg

    The appropriate installation mandrel must be ordered separately.

  • Type E-S 410

    Technical data

    • Idle speed: 1200 rpm (variable adjustment) – automatic reversal when reaching the screw-in depth
    • Torque: 0.9 – 3 Nm (variable adjustment of the torque setting on control device)
    • Tool holder: quick-change chuck 1/4" hexagon socket with radial bearings for installation mandrel
    • Weight: 0.57 kg

    The appropriate installation mandrel must be ordered separately.

    Type E S 410 in our eShop
  • Type E-S 412

    Technical data

    • Idle speed: 1500 rpm at p = 6.3 bar
      (adjustable via air pressure)
    • Air consumption: 5.5 l/s at p = 6.3 bar
    • Torque: M = 1.2 to 4,5 Nm
      (variable adjustment shut-off clutch)
    • Tool holder: 1/4" hexagon socket with radial bearing
    • Weight: 0,8 kg                                           
    Type P-S 412 in our eShop
  • Type P-S 1216

    Technical data

    • Idle speed: 950 rpm at p = 6.3 bar
      (adjustable via air pressure)
    • Air consumption: 5.5 l/s at p = 6.3 bar
    • Torque: M = 1.2 to 5.5 Nm
      (variable adjustment shut-off clutch)
    • Tool holder: 1/4" hexagon socket with radial bearing
    • Weight: 0.8 kg

    The appropriate installation mandrel must be ordered separately.

    Type P-S 1216 in our eShop

HELICOIL® 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.

  • Type E-PSG

    Technical data

    • Idle speed: 1200 rpm
      (variable adjustment) – automatic reversal on reaching the screw-in depth
    • Torque: 0.9 – 3 Nm (variable adjustment of the torque setting on control device)
    • Tool holder: Connection for P‑PSG 256 prewinders
    • Weight: 0.75 kg

    The exchange unit is determined according to the HELICOIL® type and size.

    Type E-PSG in our eShop
  • Type E-PSG 256 Quick Exchange

    The complete tool consists of a control unit, an electric motor (type Pluto 3) including Quick Exchange System, a BitBox with size-related adapter and a basic tool.

    Advantages

    • Fast change of exchange units for various HELICOIL® types, dimensions and lengths
    • Saves time
    • Brushless motor for clean room applications
    • Compact and transportable tool

    The exchange unit and the BitBox are determined by HELICOIL® type and size.

  • Type P-PSG 256/ 714/ 1626

    The installation tool has a reversible compressed air motor and a size-related exchange unit.
    The HELICOIL® installation depth is adjusted by changing compensation discs.
    The tool is recommended for medium and large-scale production.

    Type P-PSG 256/ 714 /1626 in our eShop
  • Type P-PSG 256SF/ 714SF

    The installation tool has a reversible compressed air motor and a size-related exchange unit.
    The HELICOIL® installation depth is adjusted by changing compensation discs.
    The tool is recommended for medium and large-scale production.

    Type P-PSG 256SF/ 714SF in our eShop

HELICOIL® manual tools

For HELICOIL® Classic and HELICOIL® Plus thread inserts The manual tools are available with and without pitch control.

  • Type H-PSG

     

    Thread mandrel, pitch-controlled and with depth stop.

     

    HELICOIL® hand tools in our eShop
  • Typ H-M

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

    HELICOIL® hand tools in our eShop

HELICOIL® tang break-off tools

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

  • Tang break-off mandrel

    Standard HELICOIL® tang break-off tool for tang removal without loss of performance. Easy-to-use, economical and fitting for HELICOIL® Plus and HELICOIL® Classic thread inserts with lengths between 1 d and 2 d.

    Tang break-off mandrel in our eShop
  • Type TB-M

    TB-M mechanical HELICOIL® tang break-off tool for tang removal without loss of performance. Easy-to-use, economical and fitting for HELICOIL® Plus and HELICOIL® Classic ranging from 1 d to 2 d.

    Type TB-M in our eShop
  • Type TB-P

    TB-P pneumatic HELICOIL® tang break-off tool for tang removal without loss of performance. Easy-to-use, economical and fitting for HELICOIL® Plus and HELICOIL® Classic thread inserts with lengths between 1 d and 2 d.

    Type TB-P in our eShop

HELICOIL® extraction tool

For the manual and mechanical extraction of HELICOIL® thread inserts

  • Extraction tool

    Manual disassembly can be carried out using a tap wrench or ratchet; mechanical disassembly with a cordless screwdriver.
    Other dimensions on request.

     

    Extraction tool in our eShop

HELICOIL® Accessories

  • Parallel-arm stand, type S

    Advantages

    • Rationalisation
    • Fast and reliable positioning, particularly for smaller dimensions
    • Easy handling, fatigue-free work
       

    Technical data

    • Working radius: 130 mm – 450 mm
    • Working height: 50 mm – 450 mm
    • Weight without tool: 8 kg
    • Torque absorption: max. 15 Nm

Automation

HELICOIL® Automatic installation tools

Cost-effective installation of HELICOIL® thread inserts is just as important as their high quality standard. Our range includes modules for integration into automatic processes and complete systems.

Do you have specific requirements? If so, please contact us!

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Boellhoff Helicoil

Videos

The HELICOIL® technology

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