anchorage principle the required bore roughness is directly related to the hardness and the mechanical characteristics of the base material depending on the combination of sealing plug and base material anchorage takes place either by the groove profile of the sealing plug biting into the base material mb sidex -sk series lp or on anchorage to the surface roughness of the bore sidex-sk lk mb series in hard materials note when selecting a plug the bore roughness must always be adjusted according to the hardness of the base material anchorage principle related to base material to achieve the allowable working pressure anchorage to the bore roughness of the base material is required roughness rz 10 to 30 µm 300 280 260 hardness hb 300 280 hard base material mb 600 mb 700 lk 500 260 240 220 hardness hb 240 220 200 180 160 140 120 100 80 60 soft base material lk 950 lp 900 mb 850 sidex -sk anchorage to the bore of the base material occurs automatically due to the serrations on the sleev
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installation details for mb series setting force mb 600/700 mb 850 mb 600 inch version f kn 80 70 60 50 40 30 20 b a f kn 80 70 60 50 40 30 20 10 3 4 5 6 7 8 9 10 12 d1 14 16 18 20 22 mm 4 5 6 7 8 9 10 12 d1 14 16 18 20 22 mm b a f kn 16 14 12 10 8 6 4 2 b a 10 0 093 125 156 187 218 250 281 in d1 measured in steel with a tensile strength of 1,000 n/mm2 when installing in material with less strength the values are less a force with minimum bore diameter tolerance b force with maximum bore diameter tolerance plug removal mb series plug removal is possible the plug can be drilled out with a carbide tipped drill or with a high speed steel drill mb mb mb mb mb 600-030 600-093 600-125 700-030 850-040 to 140 a a to 281a to 220 to 220 ball hb 200 ball hrc 55 ball hb 200 ball hrc 45 ball hrc 45 high speed steel drill carbide tipped drill high speed steel drill carbide tipped drill carbide tipped drill procedure plug diameter 6mm or .250 in drill out in one process to the next larger diamet
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mb 600 series inch version sealing plugs sleeve stainless steel din 1.4305 aisi 303 hardness hb 220 ball stainless steel din 1.4034 aisi 420 093 dia din 1.4301 aisi 304 125 to .281 dia sleeve and ball clear passivated to mil s 5002 aerospace quality dimensions in inches type mb 600-093 a mb 600-125 a mb 600-156 a mb 600-187 a mb 600-218 a mb 600-250 a mb 600-281 a pressure performance d1 .0933/32 .1251/8 .1565/32 .1873/16 .2187/32 .2501/4 .2819/32 l1 .100 .138 .150 .193 .225 .260 .285 l2 .120 .170 .195 .260 .300 .350 .380 d2 .0937 002 0 d3 l3 max min .062 .095 .093 .125 .125 .130 x .1250 004 0 004 .1562 0 0 .1875 004 .0 .156 .152 .187 .187 .218 .212 .250 .250 to max .2187 004 0 .012 0 .2500 004 .2812 004 0 base material minimum hardness hb high strength stl etg-100 ansi 1144 free machining case hard stl c15 pb cast iron gg-25 din 1691 din 1.0403 ductile cast iron ggg-50 din 1693 aluminium alloy al cu mg 2 din 3.1354 aa2024 aluminium alloy al mg si pb din 3.0615 aa62
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new application plugs mb-e type for volume requirements special applications available upon approval of application high pressure plugs 2,500 bar hp500-040/m5 type 1 type 2 sleeve case hardened steel 1.0403 gun metal finish lubricated ball bearing steel 1.0616 plain finish lubricated sleeve case hardened steel 1.0403 zinc plated clear passivated ball bearing steel 1.0616 plain finish lubricated sealing diameter 4mm thread m5x0.5mm working pressure 2500 bar the high pressure plug must be installed by a process controlled device 13
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sidex-sk series sleeve case hardened steel din 1.0403 aisi 10l 15 gunmetal finish hardness hb 180 mandrel heat treated forging steel 1.7033 cold forged this range forged steel replaces the hk range with the exception of 3mm hk030-ck55-111-ak sidex-sk series · · · · · · dimensions in mm type d1 l1 d2 l2 l3 max l4 max working pressure to 500 bar 7,250 psi shorter installed length larger working tolerances 0 0.12mm installs directly into drilled holes clean mechanical sealing through positive anchoring quick installation using rivet type tools bore diameter d sk 550-f-040 sk 550-f-050 sk 550-f-060 sk 550-f-070 sk 550-f-080 sk 550-f-090 4.0 5.0 6.0 7.0 8.0 9.0 4.5 5.5 6.5 7.5 8.5 9.5 10.5 2.50 3.00 3.40 4.10 4.20 4.50 4.75 39 41 43 43 40 43 45 9.0 10.0 12.0 14.0 15.0 17.0 19.0 6.5 7.5 8.0 9.0 10.5 11.0 12.5 4.0 5.0 6.0 7.0 8.0 9.0 10.0 +0.12 0 sk 550-f-100 10.0 pressure performance base material minimum hardness hb high strength st etg-100 aisi 1144 free machining case hard stl c15 pb c
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lk series low pressure applications up to 60 bar l2 d1 l1 l3 l4 sleeve case hardened steel din 1.0403 soft annealed gun finish mandrel free cutting steel or cold forming steel plain finish spec oil film lubrication type lk 950-040 lk 950-050 lk 950-060 lk 950-070 lk 950-080 lk 950-090 lk 950-100 lk 950-120 d1 4.0 5.0 6.0 7.0 8.0 9.0 10.0 12.0 l1 3.7 4.5 5.0 5.5 6.5 6.5 6.5 7.5 d2 d2 2.2 2.95 3.4 4.2 4.3 4.7 5.1 5.9 l2 36 36 36 34 34 34 36 36 l3 max 5.5 6.9 7.4 8.0 9.8 9.8 9.8 10.8 l4 max 4.0 4.8 5.3 5.8 6.8 6.8 6.8 7.8 bore-diameter 4.0 5.0 6.0 7.0 8.0 9.0 10.0 12.0 +0.12 0 also available lk950-160 16mm forged mandrel or turned on low quantities sleeve stainless steel din 1.4305 aisi 303 plain finish special oil film lubrication mandrel stainless steel plain finish lk600 now available upon application type lk 600-040 lk 600-050 lk 600-060 lk 600-070 lk 600-080 lk 600-090 lk 600-100 lk 600-120 d1 4.0 5.0 6.0 7.0 8.0 9.0 10.0 12.0 l1 3.7 4.5 5.0 5.5 6.5 6.5 6.5 7.5 d2 2.2 2.95 3.4 4.2 4.
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lp series sealing plug material free cutting steel din 1.0718 nitrocarburized 1:12=4,77 0.25o d3 o 0,05 d1 l2 min installed d2 l1 d4 type d1 d2 l1 d3 min d4 +0.1 -0.3 l2 min lp 900-040 lp 900-050 lp 900-060 lp 900-070 lp 900-080 lp 900-090 lp 900-100 lp 900-120 4.4 5.4 6.4 7.4 8.45 9.6 10.65 12.75 3.7 4.7 5.7 6.7 7.7 9.0 10.0 12.0 5 6 6 6 7 7.5 8.5 9.5 4.55 5.55 6.55 7.55 8.6 9.75 10.8 12.9 4 5 6 7 8 9 10 12 7 8.0 8.5 8.5 9.5 10.0 11.0 12.0 pressure performance series lp d1 mm 4-12 etg-100 aisi 1144 c15pb 1.0403 1 gg-25 din 1691 ggg-50 din 1693 pb 2 aicumg2 3.1354 aimgsipb g-aisi7mg 3.2371 3.0615 p test b 1 p test b pressure 180 bar pb 2 pressure 60 bar 180 bar 60 bar 1 proof pressure 2 max allowable working pressure · · · · 21 press fit grooved labyrinth sealing surface direct installation in hydraulic through holes ideal for automated installation applicable for metals and plastics
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setting tools settings tool kw-010-mcs settings tools sidex-sk series tool head nose piece type skw-104 skw-105 skw-106 skw-107 skw-108 skw-109 skw-110 jaw case type prg-740-11ae prg-740-11ae prg-740-11ae hk-010308 hk-010308 hk-010308 hk-010308 jaws type prg-540-46e prg-540-46e prg-540-46e hk-014208 hk-014208 hk-014208 hk-014208 jaw pusher type prg-14 prg-14 tool type kw010 kw010 d1 4.0 5.0 6.0 7.0 8.0 9.0 10.0 type skw-040 skw-040 skw-060 skw-070 skw-080 skw-080 skw-080 prg-740-7a kw010 hk-010508 hk-010508 hk-010508 hk-010508 kw010 kw020-b kw020-b kw020-b kw020-b tool kw-010-mcs needs to be switched off when using plugs 7mm hydraulic/pneumatic tool tool with mandrel collecting system air pressure 6-5 bar weight 2.1 kg setting tool kw-020-b settings tools for lk series d1 tool head type nose piece type lkw-104 lkw-105 jaw case type jaws type pusher type prg-14 tool type 4 5 6 7 8 9 10 12 lkw-040 prg 740-11ae prg 540-46e kw-010-1 prg-740-7a hkw-010308 hkw-014208 hkw-010508 kw-020-b lkw
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pressure performance tests koenig sealing plugs test a pressure test to failure in test a the koenig plug is subject to increasing static pressure until plug blowout occurs these tests are done by kvt for functional testing during manufacturing runs each production lot batch no undergoes these tests koenig plug test piece test b temperature/pressure cycling in test b the koenig plug is subject to a long term test simulating practical conditions this determines the pressure which can be applied lower limit without plug blowout with intermittent pressure and varying temperature conditions temperature 2 hours at 100°c 2 hours at -40°c temperature change between 30 and 45 minutes duration drill hole pressure intermittent 2 minutes at 0 bar 3 minutes at test pressure 170 h long term test tolerances roundness and roughness per data sheets plain surface distance from edge per data sheets koenig plug test piece base material 0f the installation tensile strength avg n/mm2 elongation min
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industry applications aerospace control gear landing gear flight simulators automotive brake systems power transmissions engine transmissions power steering systems fuel injection systems hydraulics and pneumatics control and drive units valves pumps jacks lifts cylinders 30
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boneham and turner ltd n ew p re m i se s oddicroft industrial estate oddicroft lane sutton in ashfield nottinghamshire ng17 5fs telephone +44 01623 445 450 fax +44 01623 445 451 sales@boneham.co.uk www.boneham.co.uk
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