Trilobular thread-forming system

DIN 7500

DIN 7500 The Thread-Forming Screw

Cost-efcient application Increased strength of fastened joint Metric, regular thread High-vibration resistance

The Thread
Thread-forming screws according DIN 7500can be driven into malleable materials without the need for tapping the mating thread.

How it works?
Conventional, Tapped Hole 1 Grain ow interrupted, not work hardened 1 Produces chips and shavings

1 1

There is play in threads Irregular thread ank surface

Thread is Formed by the Screw 1 Grain ow redirected, work-hardened 1 Produces no chips 1 There is no play in the mating threads

1 1

Smooth thread ank surface No additional locking elements needed

Simple reliable - fast

Advantages
Thread forming screws form their mating threads eliminating the need for tapping. The thread formed is a regular thread (metric or inch), meaning, thread-forming screws can be replaced with conventional screws. Naturally, thread-forming screws may be used in tapped holes as well. Thus, the product range can be optimised.

Drill pilot hole

No need for tapping

Drive screw in

Tighten screw

Costs reduced by 20 to 30%

Conventional fastening technology Screw DIN 7985 M4x10, 4.8, zinc plated with ribbed lock washers M4 Purchase screw Purchase lock washer Keep screw in inventory Keep lock washer in inventory Produce pilot hole: - drill - die-cast - punch Tapping Chips removal Cleaning Inspecting, handling Temporary storage Install of screw Install of lock washer Multifunctional fastening technology Thread-forming screw DIN 7500 form C M4x10, steel zinc plated Purchase screw Purchase lock washer Keep screw in inventory Keep lock washer in inventory Produce pilot hole: - drill - die-cast - punch Tapping Chips removal Cleaning Inspecting, handling Temporary storage Install of screw Install of lock washer

cost savings

cost savings

cost savings

Based on years of experience, using thread-forming screws can reduce costs by up to 30%.

cost savings

DIN 7500 I BOSSARD

DIN 7500 Simple, Reliable, Fast

The Trilobular Screw Thread
A B C S Tapered screw point max. 4 P Load-bearing length Total length Thickness of material 4 thread pitches (max. 4xP). The tapered portion of the thread can not be fully loaded, which must be taken into account, when screw length is determined.

The trilobular thread shape facilitates thread forming. The tapered point eases thread engaging and initial thread forming. The maximum taper length equals

Materials, Corrosion Protection

Thread-forming screws are normally made of zinc plated, case-hardened steel. The surface may be coated with wax or a similar lubricant to reduce the driving torque. The screws can therefore be installed into all malleable metals up to a maximum hardness of 135 HB (tensile strength Rm = 450 N/mm2 ~ 65000 psi). On the other hand, thread-forming screws made from stainless steel A2 can only be used to fasten aluminum and non-ferrous metals.

Assembly
Ideally, thread forming screws are installed using automated fastening systems or manual power drivers with torque transducers (max. 1000 rpm). To start the thread forming process, screws must be slightly pressed into the pilot hole. Screws can be removed and re-installed at anytime for servicing and repair work.
1 2 1 2 Installation with manual power driver Installation with semi-automatic screwdriver

Screw installation without countersink (small bulge)

Application Guidelines
Thread-forming displaces material, thus a small bulge is produced at the holes entrance. This may prevent parts from being tightly fastened. A 90 chamfer, with a depth of 0.5 to 1 x the thread pitch, will avert that. A shallow relief bore will do the same. By putting a relief bore at the entrance of the pilot hole, the thread engagement of the individual assembled parts can be kept constant. This way, driving torques can be kept the same, assuming
Extruded hole

the screw diameter and material are the same. In thin sheet metals an extruded hole will increase pull-out force. Thread-forming screws are highly vibration resistant.

Relief bore

With countersinking, screw not yet installed

BOSSARD I DIN 7500

Technical Support and Testing

Whether a certain type of thread-forming screw is suitable for a given malleable material (steel, aluminum or non-ferrous metal) should be tested and evaluated through application testing. Bossard engineers carry out application testing to assess thread forming screws, sizes M2.5 to M8, for specic customer applications. Findings and recommendations are then documented in a test report; the test reports typically include clear guidelines in terms of driving and tightening torques, pilot hole geometry, hole diameter and engagement length.
1 4 2 3 4 Driving in = thread-forming Head bearing area Tightening Stripping or breaking

Torque [Nm]

Time [sec]

Data Thread pitch Tightening torque max. Breaking torque min. Tensile force min. Thickness of material 2 and smaller 4 6 8 10 12 14 (Nm) (kN) (mm)

Nominal diameter M2 0,4 M2,5 0,45 M3 0,5 M3,5 0,6 M4 0,7 M5 0,8 M6 1 M8 1,25

Information Concerning Pilot Holes

Thread-forming screws can be installed in blind holes as well as through holes. Type and strength of material of the mating components, hole geometry and size, and engagement length are decisive for a proper installation. That information can be found in the tables to the left.

ca. 80% of the breaking torque 0,5 1,65 1 2,7 1,5 4 2,3 5,4 3,4 7 7,1 11,4 12 16 29 29

(mm) Pilot hole H11 for steel, HRB 77 max.; drilled or punched 1,8 1,85 2,25 2,3 2,35 2,7 2,75 2,75 3,2 3,2 3,2 3,6 3,65 3,7 3,7 4,5 4,55 4,6 4,65 4,65 5,4 5,45 5,5 5,55 5,55 7,25 7,25 7,4 7,4 7,5 7,5 7,5

Pilot Holes for Aluminum Die-Cast

t1 (mm): The hole entrance is furnished with a chamfer to: facilitate the die casting process, Strengthen the casting pin, ease the locating of holes (screw is guided into hole), prevent material build-up on the hole entrance, enable the use of cost-efcient nominal screw lengths
Nominal diameter d1 1) d2 1) d3 1)
1)

t2 / t3 (mm): Load-bearing engagement length, taper angle maximum 1.

M2 (mm) (mm) (mm) 1,9 1,75 1,8 0 0,04

M2,5 2,36 2,2 2,27 0 0,06

M3 2,86 2,67 2,76 0 0,06

M3,5 3,32 3,11 3,23 0 0,075

M4 3,78 3,54 3,64 0 0,075

M5 4,77 4,5 4,6 0 0,075

M6 5,69 5,37 5,48 0 0,075

M8 7,63 7,24 7,35 0 0,09

+ (mm)
Tolerance

for d1, d2, d3 t1 x 45 t2

2) 2)

(mm) (mm) (mm) (mm)

Tolerance

variable, minimum 1 x thread pitch P 4,3 0,2 0 2 5,3 0,2 0 2,5 6 0,2 0 3 6,9 0,6 0 3,5 7,8 0,5 0 4 9,2 0,5 0 5 11 0,5 0 6 14 0,5 0 8

for t2 t3

(mm) (mm)

All design recommendation should be veried through application testing.

DIN 7500 I BOSSARD

The Thread-Forming Screw DIN 7500 Product overview

Thread-Forming Screw Head DIN 7985 with Pozidriv cross recessed pan
1 BN 2724

d1 d2 max. k max.

M2,5 5 2,12 1 2,6 min. 1,27 1,52

M3 6 2,52 1 3 1,68 1,93

M4 8 3,25 2 4,3 1,9 2,36

M5 10 3,95 2 5 2,64 3,1

M6 12 4,75 3 6,7 3,02 3,48

d1 4 5 6 8 10 L 12 16 20 25 30 40

M2,5
11 11 11 11 11 11 11 11

M3

M4

M5

M6

case hardened, zinc plated, waxed

1 BN 4908

11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11

d
m~ t max.

INOX A2, waxed

Hexalobular pan head thread forming screws ~Form C Head ~DIN 7985
1 BN 13916

d1 d2 max. k max.

M2 4 1,72 X6 0,8 1,8

M2,5 5 2,12 X8 1,2 2,4

M3 6 2,52 X10 1,3 2,8

M4 8 3,25 X20 1,8 3,9

M5 10 3,95 X25 2 4,5

M6 12 4,75 X30 2,4 5,6

M8 16 6,15 X40 3,3 6,8

d1 3 4 5 6 8 10 L 12 16 20 25 30 35 40

M2
1 1 1 1 1 1 1

M2,5

M3

M4

M5

M6

M8

case hardened, zinc plated, waxed

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

c
t max. A~

Hexalobular pan head thread forming screws ~Form C Head ISO 14583
1 BN 5653

d1 d2 max. k max.

M2,5 5,0 2,1 X8 1,04 2,4

M3 5,6 2,4 X10 1,27 2,8

M4 8,0 3,1 X20 1,66 4,0

M5 9,5 3,7 X25 1,91 4,5

M6 12,0 4,6 X30 2,42 5,6

d1 4 5 6 8 10 L 12 16 20 25 30

M2,5
1 1 1 1 1 1

M3

M4

M5

M6

INOX A2, waxed

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

c
t max. A~

BOSSARD I DIN 7500

Thread forming screws with Pozidriv cross recessed cheese head with metric head
1 BN 2723

d1 d2 max. k max.

M2,5 4,5 1,9 1 2,4 min. 1,1 1,35

M3 5,5 2,3 1 2,9 1,6 1,85

M4 7 2,9 2 4,3 1,9 2,35

M5 8,5 3,7 2 4,7 2,3 2,75

M6 10 4,3 3 6,3

d1 6 8 10 12 L 16 20 25 30

M2,5
1 1 1 1 1

M3
1 1 1 1 1 1

M4
1 1 1 1 1 1 1

M5

M6

case hardened, zinc plated, waxed

1 1 1 1 1 1 1 1 1 1 1 1

d
m~ t max.

2,5 2,97

Thread forming screws with Pozidriv cross recessed at head with metric thread
1 BN 3327

d1 d2 max. k max.

M2,5 4,7 1,5 1 2,5 min. 1,22

M3 5,6 1,65 1 2,8 1,48 1,73

M4 7,5 2,2 2 4 1,6 2,06

M5 9,2 2,5 2 4,4 2,05 2,51

M6 11 3 3 6,1 2,46 2,92

d1 5 6 8 10 L 12 16 20 25 30

M2,5
11 11 11 11 11 11

M3

M4

M5

M6

Case-hardened zinc plated, waxed

1 BN 4919

11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11

d
m~ t

INOX A2, waxed

max. 1,47

Hexalobular at head thread forming screws with metric thread

1 BN 11288

d1 d2 max. k max.

M2 3,8 1,2 X6 0,7 1,8

M2,5 4,7 1,5 X8 1 2,4

M3 5,6 1,65 X10 1 2,8

M4 7,5 2,2 X20 1,4 3,9

M5 9,2 2,5 X25 1,5 4,5

M6 11 3 X30 1,9 5,6

M8 14,5 4 X40 3,3 6,8

d1 3 4 5 6 8 10 L 12 16 20 25 30 35 40

M2
1 1 1 1 1 1 1

M2,5

M3

M4

M5

M6

M8

Case-hardened zinc plated, waxed

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

c
t max. A~

DIN 7500 I BOSSARD

Hexalobular at head thread forming screws with metric thread

1 BN 13278

d1 d2 max. k max.

M2,5 4,7 1,5 X8 0,79 2,4

M3 5,5 1,65 X10 0,83 2,8

M4 8,4 2,7 X20 1,53 4

M5 9,3 2,7 X25 1,51 4,5

M6 11,3 3,3 X30 1,78 5,6

d1 5 6 8 10 L 12 16 20 25 30

M2,5
1 1 1 1 1

M3

M4

M5

M6

INOX A2, waxed

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

c
t max. A~

Thread forming screws hex head with ange and metric head
1 BN 3326

d1 d2 max. k max.

M4 8,9 4,23 0,65 7

M5 10,4 5,25 0,8 8

M6 13 6,25 1,05 10

M8 17 8,35 1,35 13

d1 6 8 10 12 L 16 20 25 30

M4
11 11 11 11 11 11 11

M5

M6

M8

Case-hardened zinc plated, waxed

1 BN 10812

11 11 11 11 11 11 11 11 11 11 11 11 11 1 1 1 1

c max. s

INOX A2, waxed

DIN 7500 I BOSSARD

Hexalobular pan head thread forming screws with ribs and metric thread
1 BN 14551

d1 d2 max. k max. n

M3 6 2,52 0,6 X10

M4 8 3,25 1

d1 5 6 8 L 10 12 16

M3
1 1 1

M4

Case-hardened zinc plated, waxed

1 1 1 1

X20 1,9

t max.

1,2

Electrical Grounding without Extra Cost - Thanks to Grounding Screws with Nibs
This screw is furnished with nibs underneath the head. The nibs generate electrical contact by penetrating the coated surface of the clamped components. These nibs also increases vibration resistance.

1 Thread-forming grounding screws 2 Cost-savings example of light xture assembly

BOSSARD I DIN 7500

www.bossard.com

09/07 25/1