Stepped shear bolts

Das Kaltstauchverfahren ist eines der neuen Verfahren für die Druckbearbeitung mit weniger oder gar keiner Zerspanung
Metall. Es handelt sich um eine Verarbeitungsmethode, die die plastische Verformung von Metall unter der Einwirkung von
äußere Kräfte, und mit Hilfe von Formen wird das Metallvolumen umverteilt und in die Form gebracht
die gewünschten Teile oder Rohlinge. Das Kaltstauchverfahren ist am besten geeignet für die Herstellung von Standard
Verbindungselemente wie Bolzen, Schrauben, Muttern, Nieten, Stifte usw.

Stepped Scherbolzen are specialized fasteners designed to provide controlled shear failure under specific load conditions, often used in structural or mechanical applications where safety and predictable failure points are critical. Here’s a detailed description:

Key Features of Stepped Shear Bolts:

1. Stepped Shaft Design

   • The bolt has a reduced-diameter section (shear groove) along its shank, creating a deliberate weak point.

   • This step ensures the bolt shears at a predetermined load, protecting other components from damage.

2. Material & Strength

   • Typischerweise hergestellt aus hochfester Stahl (e.g., Grade 5, Grade 8, or alloy steel) to ensure consistent shear performance.

   • Heat-treated for precise shear strength.

3. Kopf-Typen

   • Available in various heads (hex, socket, round) depending on application needs.

   • Some designs include a breakaway head that snaps off after proper installation torque.

4. Gewindetyp

   • Mai-Funktion full or partial threading, with the shear step located in the unthreaded portion to avoid thread distortion during shearing.

5. Shear Load Control

   • The stepped section is engineered to fail at a specific shear force, acting as a mechanical fuse.

   • Verwendet in safety-critical systems (e.g., aircraft, machinery, structural joints) to prevent overload.

Anwendungen:

• Structural Engineering: Shear-critical connections in steel frameworks.

• Aerospace: Shear pins in flight control systems.

• Automobilindustrie: Suspension or drivetrain components.

• Industrielle Maschinen: Overload protection in couplings or gearboxes.

Vorteile:

• Predictable Failure: Prevents catastrophic damage by shearing at a set load.

• Easy Replacement: Broken bolts can be quickly replaced post-failure.

• Korrosionsbeständigkeit: Often coated (e.g., zinc, cadmium) for durability.

Example Use Case:

In a wind turbine, stepped shear bolts may secure the blade hub. If excessive force occurs (e.g., storm winds), the bolts shear, protecting the rotor assembly from severe damage.