More than just cold forming

The often complex forming of the wire on a multistage header is frequently followed by a large number of further work steps. Blind rivet studs are welded by laser or mechanically crimped, and inside or outside threads are formed in all conceivable formats.

At the request of the customer, various sealants can be applied (mechanically or by spraying) or contours are modified by secondary machining. In order to protect expensive parts from scratches during industrial assembly, a special partial scratch protection coating can be applied.

HONSEL offers a world of secondary processing possibilities that is constantly being expanded and optimised.


Tolerance practically zero

The automotive industry accepts only minimal tolerances. Suppliers have to constantly ensure that every product supplied meets these stringent specifications. Less than 0.07 mm – that is the concentricity tolerance that HONSEL can guarantee the automotive customer. And HONSEL is less tolerant also when it comes to coil lengths: A coil may deviate in length by only +/- 0.05 mm. HONSEL customers appreciate this precision.


Barrel finishing

During the hardening process, scale forms on the outside of the stud because the glowing hot metal reacts with the oxygen in the air. These thin residues from the oxidation process can be vibration polished so that the stud has a glossy surface again.

At the same time, barrel finishing reduces the friction coefficient (RZ) of the studs – a precondition for longer service lives of the finished products. As with all other process steps, HONSEL attaches great importance here again to being able to carry out barrel finishing in-house.


Crimping

Using this special assembly process, sleeves and bolts of the Rifbolt blind rivet studs are undetachably joined together with perfect corrosion protection. In view of their great success, several crimp machines are already in operation. These are genuine in-house developments by the HONSEL experts – from the idea, through the design and production right up to the maintenance in daily multi-shift operation.


Surfaces

In order meet the high demands on corrosion protection, HONSEL has set up a wide-ranging partner network together with leading companies from the surface coating sector. In areas with the highest demand for corrosion protection, not only zinc coatings but also zinc-nickel coatings are used for HONSEL blind rivet nuts and studs.

Together with the partners and by agreement with leading automobile manufacturers, HONSEL can always recommend the optimum corrosion protection for an application and supply zinc-nickel coatings in accordance with the following standards (selection):

Volkswagen-GruppeVW 13750 TL 244
Mercedes-BenzDBL 8451
BMWGS 90010
PorschePN 11011
OpelGME 00252
FordFord WSS-M21P51

Drilling

Whenever the cold extrusion technology comes up against its limits, particularly for studs, HONSEL has created a possibility of producing a wide variety of shaft forms with one drilling process in the form of fully automated drilling machines.


Laser welding

A great development advance at HONSEL was the ultra-modern laser welding process. Rifbolt blind rivet studs have been produced in an in-house laser chamber using this manufacturing process for many years. In addition to the machine for large volumes in industrial series production, a separate hand-held laser welding station offers the possibility of fast prototype production.


Heat treatment

Following the policy of keeping central production processes in-house, HONSEL has acquired vast know-how in a multitude of heat treatment techniques over the years.

This has led to the development of the very successful “hochfest”(high strength) product range that enables HONSEL to modify lightweight materials in such a way that in some areas their strength is significantly higher than that of the normal standard versions. In this way substantially higher mechanical requirements can be fulfilled, at the same time exploiting weight and cost advantages.


Turning / milling

Various ultramodern lathes and milling machines are available not only for the growing prototype production, but also for special series production. The focus for HONSEL is always on offering the customer the most efficient production method, depending on the required tolerances, or on combining different processes.


Rolling/pointing

The latest rolling and pointing machines enable HONSEL to produce a wide variety of screw variants. Not only our house brand, Rifbolt blind rivet stud, but also numerous special parts with outside thread are constantly expanding the HONSEL product portfolio.


Assembly

The assembly of different components is playing an increasingly important role in many areas of the company. The company offers a range of possibilities, starting with the classic assembly of blind rivet pin and sleeve, through the joining of blind rivet sleeve and screws for blind rivet studs, right up to the application of various sealants.

Today HONSEL delivers a wide range of different screw/sleeve combinations in large quantities to the automotive industry under the name HONSEL Power Fastener.

Consultation

The HONSEL experts from all the departments in our company are at your disposal with advice and assistance and will be happy to support you in meeting your requirements. Ask us!

Automation

HONSEL automation has development and production operations at its Fröndenberg facility. Every single step of the production process, from the customer briefing to the initial CAD-designs, the prototypes and the ready-to-manufacture products

Responsibility

The guiding principles are our compass and form the basis for our guidelines and behaviour within HONSEL Umformtechnik.