I would just buy the inserts - see link below:- http://www.shur-lok.com/product_dls/Sandwich_Structure.pdf
thank you a lot Lochnagar for that reference..so kind of you... but that apart,can i be routed to an explicit reference detailing the processes employed in manufacturing inserts for honey comb panel sandwiches?
I would suggest you send Shur-lok an email - and ask to what American, European or International Standard they make these inserts to. If they do conform to a particular standard - it should be possible to get that particular standard - and that would I suspect detail the manufacturing processes as well as the dimensional tolerances and material properties, strength, hardness, impact, fatigue, etc. I imagine they are hot forged - and the threads are rolled (to give improve fatigue life). Hope this helps.
Dear Lochnagar, thank you again for that guide.The problem is that Shur-lok doesnt reply to such queries.Same goes for other top-notch insert manufacturers.Any way out from this dilemma? i intend to manufacture some inserts for my honeycomb panel sandwich project with the available facilities without compromising the functional features inserts provide for fastening assemblies to honeycomb structures. regards,
When you design anything - you should always begin with a good product functional design specification. When I refer to the product functional design specification - I mean for example - the rowing boat, the refuse bin, the glider, etc, etc. As you move through the design process you will decide what materials you need and why you need them - in order to achieve the requirements detailed in this product functional design specification. So for example you may decide the material that you are going to use needs to achieve certain impact properties - because of the very low ambient temperature you have specified in your product functional design specification. Additionally, for example - you will decide that the material has to achieve certain minimum strength requirements from calculations - again in order to satisfy the product functional design specification - which will specify the type and magnitude of the loads the product has to take. When you come to the detailed drawings and specification process - it will be essential that you detail these requirements that you have determined in the design process - so you will be asking for material certification - and also that the minimum values you have computed in the design process - are certified by the manufacturer. So when these materials come into your premises - you can check that what you asked for on the drawings - is what you got delivered. So - these insert manufacturers will certainly be making these inserts to some specification - which could possibly be their own internal specification - if not to a particular international standard. So if you make your own inserts - make sure by appropriate calculation that they are going to meet your overall product functional design specification. As with anything in the composites sector - quality throughout the whole process is critical.
The escalated importance of weight saving to obtain reduction of fuel consumption combined with manufacturing of complex shaped parts increases the need for composite honeycomb and sandwich constructions in aircraft manufacturing. Although they are light and stiff, honeycomb sandwich structures need local reinforcement in load-bearing areas or in fixation spots like inserts. Naturally, open sandwich edges need reinforcement and protection as well to prevent from impact damages and moisture ingress.
