How to Avoid Sheet Metal Hardware Problems

The necessity for permanently attached fasteners will invariably arise when designing sheet metal parts on a regular basis. When we refer to a fastener in this article, we are specifically referring to the kind of fasteners known as clinch fasteners. Working with them can simplify your assembly, help you save money, and improve the effectiveness of your designs. You might experience some hardware issues along the road, though. In order to shorten iterations and assist you in reaching a workable design more quickly, we aim to spare you from some of those hardware headaches.

Incorporating Fasteners into Sheet Metal Parts

Why is it important how a fastener interacts with a material? because of the installation method for clinch fasteners. The substance of the sheet flows around the fastener when it is pressed into the sheet, locking it in place.

Consider the hardness of the material you are working with when you are designing your part. Steel sheets often accept hardware made of hardened steel. Aluminum can take most hardware types, however there are certain special concerns for aluminum. Stainless steel will need hardened stainless hardware.

The Special Case for Aluminum

Aluminum appears to be the most straightforward material to attach hardware to on paper, and in some ways, it is. Technically, aluminum sheets may be attached to hardware made of aluminum, steel, or stainless steel. Despite this, if you ordered steel hardware and your quote calls for stainless or aluminum, you might be shocked. Due to the galvanic interaction between steel and aluminum, one of the two dissimilar metals will corrode dangerously quickly when they come into contact. When moisture, condensation, or immersion are present, this is significantly worsened. The incompatibility of steel with any aluminum coating further restricts installation alternatives and increases the chance of plating damage during hardware installation. Compared to alloy steel, stainless steel is more inert and less vulnerable to galvanic corrosion. Even chromating is possible, but anodizing is not. We are likely to suggest stainless steel or aluminum hardware for aluminum parts due to these two factors. Plan to use stainless or aluminum hardware for your aluminum parts to save time on iteration and quoting.

Dealing with Stainless Steel Fastener Supplies

Hardened stainless hardware, which should not be confused with regular stainless hardware (PEM hardware's type-code will include a 4 or P, for example: SP-M4-2 or BSO4-832-6) is required for stainless steel parts. The type-code will have an additional S for PEM hardware, for instance: BSOS-832-6 or FHS-M3-8. The issue here is accessibility. The hardened stainless steel hardware is frequently either out of stock or not produced at all. Hardened steel is not at all accessible for hardware types like tie downs (TD), right angle fasteners (RA), and SNAP TOP fasteners (SSC).

Panel fasteners, for example, are extremely scarce hardware kinds. Many require a minimum purchase of 5,000 units and are custom orders. Check the inventory status on PEM's website before developing a stainless steel item. There is one reliable workaround we can use for panel fasteners: fasteners with a flare. Since the sheet material does not flow to hold the screw in place, these are not clinch fasteners. Instead, these are inserted beneath a countersunk hole, and the hardware is secured in place by a sleeve that is flared into the countersink.

How to Avoid Sheet Metal Hardware Problems

It's time to consider placement after selecting the appropriate hardware. There are many factors to take into account in this situation, including how your components fit, if it can be installed where you want it, how close it is to other features, and how that gear is secured. Modeling at the proper size hole and dropping it into your assembly file are not the only options. Planning for these elements will improve your iteration pace and quotation accuracy if you want to get it right.

Hardware Nearness: As seen in the aforementioned video, the substance enters the hardware to produce the clinching motion. This flowing action won't happen if the hardware is too close to an edge, hole, or cutout; instead, the material will bulge and flow away from the hardware rather than securing it in the sheet. On PEM's website, this parameter is shown as the Min. Distance C/L to edge. It will be easier to ensure that your hardware is firmly fastened to the sheet if you adhere to this minimum distance.

Here are two parts with almost the same design: but one is good, and one is bad. The one of the left doesn't leave enough space close to the edges. A bit of vibration or a nasty jostle could cause that edge to break. The one on the right, though, offers plenty of space, making it more likely to survive manufacturing and last a long time.

The assumption that you can simply tack weld the hardware you want and it will function as intended if you can't find a perfect clinch fastener to meet your part geometry, material, or thickness is a prevalent fallacy about clinch fasteners. But that's not the case, regrettably. Clinch fasteners are made and fastened in a different way than weld nuts and studs. They are created to withstand the intense heat produced by welding and are composed of various materials. Clinch fasteners don't fit into this category. They have not been tested as welded fasteners and are not intended to withstand that level of heat. The fasteners' placement or intended functionality cannot be guaranteed. Be prepared for a departure from this standard procedure, but be aware that we do not provide this as an option.

Hardware, Installation, and Limitations

The goal is to cut costs and accelerate iteration times. Clinch nuts may give you headaches to work with. We've talked about how to steer clear of such headaches, which will also cut down on costs and revision time. Your connection with clinch fasteners will be successful if you are aware of the hardware, the installation limitations, and certain manufacturing best practices. Don't forget that PEM's website is a great resource for details on both installation procedures and particular gear. Additionally, they have the crucial inventory lookup function, which will let you know if the hardware you wish to use is indeed readily available. Use the appropriate hardware for your parts with the assistance of our team at any time to finish projects quickly, affordably, and correctly the first time.