Eliminating need for post-paint operations reduces regulatory compliance costs
 The AKH FAS-NER SYSTEM is a simple punch and die operation that automatically feeds, punches, inserts and locks a self-piercing FAS-NER to produce a solid joint all in one operation. |
Throughout the course of history, manufactures had to live with the expensive and cumbersome operations of welding, placement of mechanical fasteners and finishing operations.
With an increasing quest for efficiency by reducing operating expenses and increasing capacity, many of the traditional processes are being re-examined.
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One process that is not only a bottleneck but also one that carries considerable regulatory compliance is the finishing of the product.
By eliminating the need for post-paint operations the costs of regulatory compliance is reduced, plus manufactures save the capital burden of the painting facilities in addition to labor costs associated with handling, cleaning, spraying, and drying operations.
By utilizing pre-painted materials, the manufacture eliminates one of the largest bottlenecks and allows products to hit the market quicker and at lower manufacturing cost.
Advantages Eliminating Post-Painting Process
- Decrease of work-in-process.
- Decrease in floor space for product inventory.
- Increase in the consistency of the product appearance.
In North America, industries such as major appliances, automotive vehicles, garage and entry doors, office products, lighting fixtures and construction are taking the lead in manufacturing with pre-painted materials.
After the decision to move to pre-painted materials, the next question to answer is, “How can we join our pre-painted materials”?
They can be joined by using numerous mechanical fasteners, adhesives and cold forming methods.
To maximize the benefits of pre-paint the method of joining should not mare the finish or require secondary operations to cover the exposed fastener. With the pre-paint the use of thermal processing is not feasible.
Cold forming processes (i.e. orbital / radial riveting, staking, and clinching) may destroy the integrity of the coating and in-turn may require a secondary process to prevent or inhibit corrosion.
The use of adhesive bonding has gained acceptance over the years. By distributing the load across a larger cross section, an adhesive bond has an advantage of providing a stronger joint, over other traditional joining methods. It also provides a leak free joint.
Disadvantages Of Bonding
- Many adhesives have an unpleasant odor.
- Possible irritant to the respiratory tract, eyes, and skin.
- May require operators to wear additional personal protection devices.
- Assemblies may need to be cured or stay for extended period of time in fixtures.
- May require an additional fastening method to maintain alignment during curing.
- Surface preparation – additional labor may need to be spent on material prep to allow successful bonding to pre-paint.
- Disposal of the adhesive.
- Clean-up and the containment of spills.
Traditional mechanical fasteners (i.e. bolts, screws, rivets) usually require a pre-drilled or pre-punched hole to insert the fastener. The through hole is commonly placed during the stamping / forming operation.
Cost associated with the maintenance of the punch and matrix is often over-looked. Down time or rework caused from a broken punch can also be costly.
Other Pitfalls Of Mechanical Fasteners
- Fasteners often required skilled operators to ensure the proper torque has been achieved.
- Cross threading.
- Not always tamper-proof.
- Foreign objects wedge into holes preventing insertion.
One style of mechanical fastening that has an edge over the aforementioned is the AKH FAS-NER SYSTEM.
The AKH FAS-NER SYSTEM is a simple punch and die operation that automatically feeds, punches, inserts and locks a self-piercing FAS-NER to produce a solid joint all in one operation.
The self-piercing AKH FAS-NER is inserted directly into pre-painted material without the need for pre-punched holes, saving time and labor spent on tooling maintenance and adds flexibility of running multiple applications across the same AKH FAS-NER SYSTEM.
AKH FAS-NER SYSTEM Advantages
- One single action provides the punching, inserting and locking of the FAS-NER.
- Provides a flush joint.
- Dissimilar materials may be joined together.
- Dissimilar material thickness and, multiple layers can be joined.
- Multiple FAS-NERS may be installed in a single operation.
- FAS-NER may be inserted at various attitudes.
- Eliminates post process grinding, cleaning and finishing.
- Consistent joint due to less process variables.
- The FAS-NER can be colored matched to the pre-painted material.
- Does not produce harmful fumes and is environmentally safe.
- A clean and quite operation.
AKH Systems range from a single hit machine to completely automated multi-head, multi-hit turnkey systems.
Several product applications at the Trane facility in Cullen, LA, are currently being produced using the AKH FAS-NER, along with pre-painted material. Commercial size air handlers that in the past were spot-welded and then post painted are now being produced with the combination of pre-painted material and the Painted AKH FAS-NER.
According to Skipper Martin, manufacturing engineer at Trane’s Cullen facility, “We have experienced more consistency in the strength of the joint as well as the appearance.”
“Beyond that, appearance is favorable due to the AKH FAS-NER being flush with the sheet metal surface, and their color has been selected to match that of the pre-painted steel. Also, the process is much more user friendly and doesn’t take years to ‘master the art’ as with spot welding.”
Appearance is a huge factor when dealing with pre-painted material, so the AKH FAS-NER can be coated to match the pre-painted materials color along with setting flush with the surface.