Thread-forming in metal

HELICOIL®

There are plenty of options, from simple manual installation tools to standard tools to fully automated complete systems.

Thread-forming in metal

Creating high-strength fastenings

Our assembly solutions are designed as fully automatic or semi-automatic workstations. Depending on your requirements, parts can be handled by the operator, a handling system, a rotary indexing system or a transfer system. Take a look at our assembly solutions.

Method and principle

The HELICOIL® installation process

HELICOIL® thread inserts create high-strength, wear-resistant, heat-resistant thread of the highest precision by transferring the forces from flank to flank into the pilot thread. The reduced diameter of the HELICOIL® Plus in the first turn ensures that the thread insert can be installed like a screw.

Installing HELICOIL® thread inserts is easy and cost-effective, because there are only a few basic rules to follow. For efficient assembly, whether for a single application or for high-volume production, we provide a broad range of manual and automated installation tools.

The HELICOIL® system combines conformance to standards with easy installation.

The installation steps in detail

Core hole drilling

You can use a standard twist drill.
Use a 90° cutter for countersinking and deburring before thread cutting. External diameter of the countersink = DHC + 0.1 mm.

Thread cutting

You should use our system’s original HELICOIL® taps to cut the HELICOIL® Plus pilot thread. Use HELICOIL® plug gauges to verify that pilot thread is true-to-gauge.

Thread forming

Use a thread former to quickly and easily produce a chipless internal thread.

Thread installation

You can carry out the installation with a manual installation tool, an automatic installation tool or a fully automated solution.

HELICOIL® Plus Free Running Thread insert for metals

Find the right solution for your application

HELICOIL® taps

System-specific original HELICOIL® taps should be used for cutting the HELICOIL® Plus pilot thread. We supply a range of suitable manual and automatic taps.

Hand taps
For machining materials with a strength rating up to 700 N/mm2.

Only suitable for blind holes if sufficient tapping space is present.

Minimum requirement is 1d deeper that the fully cut-out thread length.
Machine taps

Depending on your application, you can choose from various machine taps.
Combined drilling and cutting tools

Combined drilling and tapping tool 0142.0 for HELICOIL® holding threads in damaged metric coarse and fine threads. Pre-drilling (tap drilling) is not required.
Mechanical thread former

HELICOIL® forming tap for the chipless production of tolerance class 5H (6H mod.) holding threads for HELICOIL® thread inserts. The forming tap features lubrication grooves to provide for proper lubrication also for large depths.
Plug gauges

Plug gauge to check if holding threads for HELICOIL® thread inserts which have been produced with a threading tool are true to gauge.

HELICOIL® installation mandrels

Installation mandrels in various shapes for installation of HELICOIL® Plus, HELICOIL® Tangfree – Free Running and Screwlock, and HELICOIL® Smart Free Running.

HELICOIL® Plus
Suitable for the following tools

Electrical installation tools – type E S 206 and E S 410

Battery-operated installation tools – type B S 206 and B S 824

Pneumatic installation tools – P S 412 and P S 1216

Advantages

Quick changeover

Reduced tool costs

Pick-and-place processing is possible
HELICOIL® Tangfree
Suitable for the following tools

Electrical installation tools – Type E‑S 206 and E‑S 410

Battery-operated installation tools – Type B‑S 206 and B‑S 824

Pneumatic installation tools – P‑S 412 and P‑S 1216
HELICOIL® Smart
Installation mandrel with depth stop for installation of HELICOIL® Smart Free Running in dimensions from M 4 to M 12.

Suitable for the following tools

Pneumatic installation tools – P‑S 408S, P‑S 10S and P‑S 12S

HELICOIL® tools with installation mandrel

For processing HELICOIL® Plus, HELICOIL® Tangfree and HELICOIL® Smart thread inserts. Essentially there are three different types of installation tools. The choice depends on the number of HELICOIL® thread inserts to be processed, the location of the tapped holes in the workpiece, and the thread size.

Type P-S 408S
Technical data

Idle speed: 1500 rpm at p = 6.3 bar (adjustable via air pressure)

Air consumption: 5.5 l/s at p = 6.3 bar

Torque: M = 4.5 Nm

Tool holder: 1/4" hexagon socket with radial bearing

Weight: 0.8 kg

Size-specific HELICOIL® Smart installation mandrels with depth stop must be ordered separately.
Type P-S 10S
Technical data

Idle speed: 600 rpm at p = 6.3 bar (adjustable via air pressure)

Air consumption: 5.5 l/s at p = 6.3 bar

Torque: M = 7 Nm

Tool holder: 1/4" hexagon socket with radial bearing

Weight: 1.1 kg

Size-based HELICOIL® Smart installation mandrels with depth stop must be ordered separately.
Type P-S 12S
Technical data

Idle speed: 380 rpm at p = 6,3 bar (adjustable via air pressure)

Air consumption: 5.5 l/s at p = 6.3 bar

Torque: M = 10 Nm

Tool holder: 1/4" hexagon socket with radial bearing

Weight: 1.1 kg

Size-based HELICOIL® Smart installation mandrels with depth stop must be ordered separately.
Type B-S 206
Technical data

Idle speed: 2‑stage 200 rpm & 600 rpm, reversible

Torque: 21-step adjustability 0.3 – 2.9 Nm / max. 4.4 Nm

Tool holder: 1/4" hexagon socket

Weight incl. battery: 0.5 kg

Battery: 3.6 V / 1.5 Ah / Charge time 30 min.

The appropriate installation mandrel must be ordered separately.
Type B-S 824
Technical data

Idle speed:

Stage 1 / variable 65 – 450 rpm, reversible

Stage 2 / variable 200 – 1450 rpm, reversible

Torque: 19-step adjustability 1 – 6.9 Nm / max. 31.9 Nm

Tool holder: self-centering chuck 1.0 – 13 mm

Weight incl. battery: 2.0 kg

Battery: 15.6 V / 3 Ah / Charge time 45 min.

The appropriate installation mandrel must be ordered separately.
Type E-S 206
Technical data

Idle speed: 720 rpm

Output voltage: 35 V DC

Torque: M = 0.45 – 0.95 Nm
(infinitely variable shut-off\\\ clutch)

Tool holder: 1/4" hexagon socket with radial bearing

Weight: 0.31 kg

The appropriate installation mandrel must be ordered separately.
Type E-S 410
Technical data

Idle speed: 1200 rpm (variable adjustment) – automatic reversal when reaching the screw-in depth

Torque: 0.9 – 3 Nm (variable adjustment of the torque setting on control device)

Tool holder: quick-change chuck 1/4" hexagon socket with radial bearings for installation mandrel

Weight: 0.57 kg

The appropriate installation mandrel must be ordered separately.
Type P-S 412
Technical data

Idle speed: 1500 rpm at p = 6.3 bar
(adjustable via air pressure)

Air consumption: 5.5 l/s at p = 6.3 bar

Torque: M = 1.2 to 4,5 Nm
(variable adjustment shut-off clutch)

Tool holder: 1/4" hexagon socket with radial bearing

Weight: 0,8 kg
Type P-S 1216
Technical data

Idle speed: 950 rpm at p = 6.3 bar
(adjustable via air pressure)

Air consumption: 5.5 l/s at p = 6.3 bar

Torque: M = 1.2 to 5.5 Nm
(variable adjustment shut-off clutch)

Tool holder: 1/4" hexagon socket with radial bearing

Weight: 0.8 kg

The appropriate installation mandrel must be ordered separately.

HELICOIL® tools with prewinder

For processing HELICOIL® Classic, HELICOIL® Plus and HELICOIL® Tangfree thread inserts. Pitch-controlled manual installation tools for processing loose and magazined HELICOIL® thread inserts.

Type E-PSG
Technical data

Idle speed: 1200 rpm
(variable adjustment) – automatic reversal on reaching the screw-in depth

Torque: 0.9 – 3 Nm (variable adjustment of the torque setting on control device)

Tool holder: Connection for P‑PSG 256 prewinders

Weight: 0.75 kg

The exchange unit is determined according to the HELICOIL® type and size.
Type E-PSG 256 Quick Exchange
The complete tool consists of a control unit, an electric motor (type Pluto 3) including Quick Exchange System, a BitBox with size-related adapter and a basic tool.

Advantages

Fast change of exchange units for various HELICOIL® types, dimensions and lengths

Saves time

Brushless motor for clean room applications

Compact and transportable tool

The exchange unit and the BitBox are determined by HELICOIL® type and size.
Type P-PSG 256/ 714/ 1626

The installation tool has a reversible compressed air motor and a size-related exchange unit.
The HELICOIL® installation depth is adjusted by changing compensation discs.
The tool is recommended for medium and large-scale production.
Type P-PSG 256SF/ 714SF

The installation tool has a reversible compressed air motor and a size-related exchange unit.
The HELICOIL® installation depth is adjusted by changing compensation discs.
The tool is recommended for medium and large-scale production.
HELICOIL® E-PSG Process Controlled

The E-PSG Process Controlled electrical installation tool is used to install HELICOIL® Classic and HELICOIL® Plus thread inserts in a monitored process. During the entire installation process, sensors on the nosepiece monitor the correct positioning of the tool to the component. This ensures the accurate installation of the HELICOIL® thread insert. Moreover, the rotation angle- and torque-controlled installation guarantees the precise insertion depth for the HELICOIL®.

Benefit from a documented, accurate installation and thus reduce your production time.

HELICOIL® manual tools

For HELICOIL® Classic and HELICOIL® Plus thread inserts The manual tools are available with and without pitch control.

Type H-PSG

Thread mandrel, pitch-controlled and with depth stop.
Typ H-M

Fly-over tool with depth stop for M 18 to M 36 thread inserts.

HELICOIL® tang break-off tools

For quick and easy tang break-off on HELICOIL® Classic and HELICOIL® Plus thread inserts.

Tang break-off mandrel

Standard HELICOIL® tang break-off tool for tang removal without loss of performance. Easy-to-use, economical and fitting for HELICOIL® Plus and HELICOIL® Classic thread inserts with lengths between 1 d and 2 d.
Type TB-M

TB-M mechanical HELICOIL® tang break-off tool for tang removal without loss of performance. Easy-to-use, economical and fitting for HELICOIL® Plus and HELICOIL® Classic ranging from 1 d to 2 d.
Type TB-P

TB-P pneumatic HELICOIL® tang break-off tool for tang removal without loss of performance. Easy-to-use, economical and fitting for HELICOIL® Plus and HELICOIL® Classic thread inserts with lengths between 1 d and 2 d.

HELICOIL® extraction tool

For the manual and mechanical extraction of HELICOIL® thread inserts

Extraction tool

Manual disassembly can be carried out using a tap wrench or ratchet; mechanical disassembly with a cordless screwdriver.
Other dimensions on request.

HELICOIL® Accessories

Parallel-arm stand, type S
Advantages

Rationalisation

Fast and reliable positioning, particularly for smaller dimensions

Easy handling, fatigue-free work

Technical data

Working radius: 130 mm – 450 mm

Working height: 50 mm – 450 mm

Weight without tool: 8 kg

Torque absorption: max. 15 Nm
HELICOIL® Depth Gauge
Your benefits at a glance
Precise measurement and detection of installed HELICOIL® thread inserts
Easy handling
Compact design
Detailed documentation incl. certificate

Automation

HELICOIL® Automatic installation tools

Cost-effective installation of HELICOIL® thread inserts is just as important as their high quality standard. Our range includes modules for integration into automatic processes and complete systems.

Do you have specific requirements? If so, please contact us!

Contact us