Plastic Flow Binding Technology.
Innovations by KSK.
KEIHIN SEIMITSU KOGYO CO. LTD. (KSK)KSK

PLASTIC FLOW BINDING

KSK’S PLASTIC FLOW BINDING TECHNOLOGY

A

luminum diecast parts are indispensable as structural parts
that provide both lightweight and complex functions, but it
is necessary to join them together with parts made of steel
to attain wearability and strength. The most commonly used type ofbinding technology up until now has been bolt binding. This method
requires holes to be drilled in both parts, and an assembly process tojoin them together with screws which, in turn, increases size, weight
and the number of parts, and also leads to a rise in production costs.
In comparison, KSK’s Plastic Flow Binding technology is a dream
to come true: simple process, high precision, strong binding, lightweight, and with excellent productivity. This has been acknowledgedby the Japanese Society for Technology of Plasticity, which awarded
KSK with its Medal for Innovative Technology in 2015.

NEW METHOD FOR JOINING PARTS ...
Plastic Flow Binding is a new method of joining parts of different
materials together by first machining grooves in the hard material.
Applying pressure to the softer parts with a punch allows the softparts to ‘flow’ into the grooves. This happens at room temperature,
meaning it is a relatively simple cold-machining process which offersa high-strength and high-precision method of connecting parts.
The technology sounds simple but because aluminum diecast parts
lack ductility, i.e. the capacity for plastic deformation, there has
until now been no such method for these materials. Plastic Flow
Binding raises the elongation at break of aluminum diecast material(EN AC-46100/ADC12) from 1% to 18%. In tests of aluminum diecast
and steel joints, a binding efficiency (breaking load/binding load) of
10%-23% and a leak tightness of >8 MPa has been confirmed*.

1

Steel part

2Aluminum diecast part

3

Plastic ﬂow

10%–23%>8 MPa

Binding efficiency

Leak tightness

APPLYING PRESSURE
Punch
Constraint ring
1

2

Aluminum diecasting material
EN AC-46100
3

Steel part

PRESS DIE STRUCTURE: The constraint ring prevents the widening of the aluminum diecast material. The compressive stress field inside thematerial leads to pressure strain and a plastic deformation of appr. 18% thus becomes possible.
* In order to prevent electrochemical corrosion, the steel-based parts are coated (with a ferrosoferric oxide film).

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PLASTIC FLOW BINDING

KSK

In the case of the part described below, Plastic Flow Binding replaced the former bolt joining of parts and simplified the process:drilling is eliminated and assembly takes place on a standard press machine.

… WITH LARGE EFFECTS ON COST AND WEIGHT
KSK developed the technology for parts used in automobile engines.
The first such part required a parallelity of 5/100-mm of a spline tothe outer surface of the aluminum diecast actuator housing. Thislevel of precision cannot be achieved by integrally casting in the steel
holder part. While bolt binding was the method of choice before, theapplication of KSK’s Plastic Flow Binding technology has drasticallyreduced costs and resulted in lighter weight of the actual part. Plastic
Flow Binding is currently undergoing additional development, andtechnology to bind other materials together is also being developed.
Patent protection has been acquired in Japan; international patents
are pending.

34%

18%

Cost reduction

Weight reduction

0.83 kgACTUATOR HOUSING
Previous design: parts
joined with three bolts

0.68 kgACTUATOR HOUSING
Current design:developed by KSK

Serial production started in February 2013 and has continued sincewith volumes of 20,000 pcs./month.

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Contact person in Germany:
Dr. Roman Ditzer
Phone+49.40.3861 8956

Emailditzer@interlogue.deWebrdinterlogue.com/de/ksk

Contact person in Japan:
Mr. Yukinao Takeya
Phone+81.45.401 4721

Emailyukinao-takeya@ksk-inc.co.jp

Webksk-inc.co.jp

KEIHIN SEIMITSU KOGYO CO. LTD. (KSK)
2-12-4 Irie Kanagawa-ku
Yokohama-shi
Kanagawa Prefecture 221-0014
JapanCopyright © KSK 2015
V-2015.1
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