Helicoil Problems
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Posted by: wander909 ® 11/05/2009, 19:28:30 Author Profile eMail author Edit

I'm a Quality Engineer for an assembly line in a manufacturing company. Pretty much all of the components we assemble contain helicoil inserts and there seems to be a massive failure rate. The point of failure is typically as the bolt passes through the helicoils locking feature. This problem is not limited to any one supplier, thread size, bolt type etc... On a number of seperate components I've exmined the process and this appears to be sound - the thread is re-tapped post processing, prior to inserting the helicoil, thus removing any contamination, yet still we see frequent failures. I'd just like to know if anyone else has experienced this kind of problem and if they've managed to resolve it. Is there a known problem with helicoils, and is a high failure rate just a given?

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: Helicoil Problems
: Helicoil Problems -- wander909	Post Reply	Top of thread	Engineering Forum

Posted by: AVIB ® 11/07/2009, 13:59:18 Author Profile eMail author Edit

Hello , I understand that you refer to the Inserter when you say bolt ? If this is the case then use a new tool and count how many inserts are ok up to the first failure .(SPC-Stati.Proc.Contr.) Then you know when you have to replace the Inserter. Also the re-tap process is not a good practice. AVIB

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: Helicoil Problems
: Helicoil Problems -- wander909	Post Reply	Top of thread	Engineering Forum

Posted by: Kelly Bramble ® 11/05/2009, 19:56:35 Author Profile eMail author Edit

Welcome to Engineers Edge wander909! Can you clarify which threaded insert (helicoil) you are using? Got a picture? You wrote "helicoils locking feature" and I'm not sure which feature this is on a standard Helicoil" threaded insert. Tanged threaded inserts should have the installation tang feature removed after the insert is installed. I do know that many manufacturing organizations prefer tang-less inserts as these are easier to remove in the event of damage or rework.

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: : Helicoil Problems -- Kelly Bramble	Post Reply	Top of thread	Engineering Forum

Posted by: Kelly Bramble ® 11/06/2009, 12:48:21 Author Profile eMail author Edit

To repair a helicoil insert see - http://www.engineeringmotion.com/videos/354/save-a-helicoil-after-installation

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: : Helicoil Problems
: : Helicoil Problems -- Kelly Bramble	Post Reply	Top of thread	Engineering Forum

Posted by: steve frank ® 11/05/2009, 21:44:42 Author Profile eMail author Edit

Can you give us more information on the failure? Did the threaded insert strip with the fastener, did the insert pull out of the material? Also, what kind of material are you placing the inserts into? We use a lot of steel threaded inserts (PEM serts typically) with our carbon composite projects and have never had any problems with them. Steve Frank Modified by Administrator at Fri, Nov 06, 2009, 08:12:03

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: : : Helicoil Problems -- steve frank	Post Reply	Top of thread	Engineering Forum

Posted by: wwdaugherty ® 11/06/2009, 08:04:48 Author Profile eMail author Edit

Ditto on the tangless inserts. The only way to fly... That sounds like an installation/ process problem on the face of it. As the others said, there are many modes of failure and you were not very specific.

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