Cap Pressing Force

height-10 and thk-2.2, material-crc

Can you explain what is diffrence between hight and thickness in a cap & full form of crc?

Dear sir,

this cap is like cap of the cocacola bottle.

in this height me the total length which i want to press in the bore.

And this cap is not compltely solid, it is open from one side, so it has thickness 2.2 mm.

And sorry for the misspell crc - this is crs-colled rolled stell.

Details- cap od-30.25 +0.1 and height-10 and thk-2.2, material-crc

bore dia-30+0.03 material-aluminum casting.

this cap is like cap of the cocacola bottle.

It is not clear how you want to cap the bore. If it is to be caped like cocacola bottle, then OD is required instead of bore. But if you want insert the cap OD inside the bore, then its a shrink fit. For shrink fit, heat the Al casting in an oil bath or induction heater (do not use flame), cool the cap (preferably by liquid nitrogen or dry ice) and just push the cap inside the bore. Much effort is not required.

Dear sir,

It is a mass production, and the procedure suggested by you is not sufficient for production, it takes more time.

I am designing a spm for that operation. this is a cylinder block and at a time 4 caps will be pressed. so i want to know that how much force to apply for pressing.

Regards

It's so simple for you but equally difficult for others to tell you the exact figure. Experiment in a hydraulic press. Gradually increase the force until the cap starts moving inside the bore & gets fitted. Keep required force 1.5 times higher to take care of different tolerances during mass production.

Dear sir,

Thanks your comment, but i do not have the sample.

If samples are available i will also check them practically on force checking machine.

If do you want complete data then please mail me your email address

my email address- <email removed>

Regards

CR4 Admin - email address removed

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I'd be concerned about '4 at once' going in evenly. Given usual tolerances you may have canting issues if the rig is not extremely rigid.

And GA K Fry for decoding/linking.

Looks like the interference can run from .22mm to .35mm. That is a great deal of interference. With a solid plug, the hole would be broached by the plug. I gather these are freeze plugs, which are usually made of heavy sheet metal, often cup shaped, and usually tapered, so they can be started. These are usually pressed in with an arbor that applies force to the center but not the edges.

I think you really need to measure the required force with a couple tests (or call the manufacturer of the plugs).

The cupped plug recommendations referred is not having any interference. It clearly shows 0.002' clearance. Even with interference, it's a simple job, can be carried out by a semiskilled worker my hammering with a medium weight hammer. Hundreds of plugs can be fixed in few hours.

It clearly shows 0.002' clearance.
In the link I provided, the "cupped plug" is at the bottom of the page. The plug has a minor diameter and a major diameter. The minor diameter is smaller than the hole (.003 smaller) so that the plug can be easily started. The major diameter is larger than the hole (so that an interference fit is obtained).

Incidentally, Welch plugs (expansion plugs) are also interference fit when installed. The plug, being dome shaped, fits into the hole easily, having a slight clearance. Once pressed (or hammered) it becomes flat, expanding the outer diameter to an interference fit. (Otherwise even the slightest pressure would cause the plug to fall out.)