Design Guidelines

Wall thickness/distances from edge

As the radial expansion of the KOENIG Expander® sleeve occurs, the base material in which it will be anchored plastically deforms. The resultant strength, as well as the hydraulic pressure and temperature service conditions depending on the Expander type and characteristics of the base material, require minimum wall thickness, or distance from edge.

Distance to external wall	Distance to exterior wall	Wall thicknesse between bores
The guideline values for minimum wall thickness and distance from edge (Wmin.) express these influencing factors. At these minimum values, only slight deformation on the exterior profile of the base material of less than 20 µm is likely. This does not affect the function of the KOENIG Expander®. Below the guideline values (Wmin.) the possibility of overloading the base material exists, which can adversely influence the function of the KOENIG Expander®. In such cases tests must be conducted.

Guideline values W_min. for wall thickness and distance from edge

For KOENIG Expander® diameters	d1 ≥ 4 mm: Wmin. = fmin. ⋅ d1
	d1 < 4 mm: Wmin. = fmin. ⋅ d1 + 0.5 mm

Base material	Description	1	2	3	4	5	6	7
		ETG 100	C15Pb	GG-25	GGG-50	AICuMg2	AIMgSiPb	G-AISi7Mg
	Avg. tensile strength [N/mm²]	1000	560	250	500	480	340	300
	Min. elongation A5 [%]	6	6	-	7	8	8	4
	Avg. ultimate strength Rp 0,2 [N/mm²]	865	300	-	320	380	300	250
KOENIG Expander® series		Factor fmin.
MB 600		0.6	0.8	1.0	0.8	0.8	1.0	1.0
MB 700		0.6	0.8	1.0	0.8	0.8	1.0	1.0
MB 850		0.5	0.6	1.0	0.6	0.6	1.0	1.0
SK		0.5	0.6	1.0	0.6	0.6	1.0	1.0
HK 55		0.4	0.5	0.8	0.5	0.5	0.8	0.8
LP 900		0.3	0.3	0.5	0.3	0.4	0.5	0.5
LK 600		0.3	0.3	0.6	0.5	0.4	0.5	0.5
LK 950		0.3	0.3	0.6	0.5	0.4	0.5	0.5

Roundness tolerance

To assure reliable functioning of the KOENIG Expander® with regard to pressure performance and to assure leak tight sealing, a roundness tolerance of t = 0.05 mm must be held.

By using a double lipped twist drill, the called out hole and roundness tolerances are reached. Better tolerances, particularly for larger diameter holes, can be held by using a triple lipped twist drill

Conicity of the bore

Within the effective sealing area of the KOENIG Expander®, the bore must be according to the data sheets. The bore lead in can be beveled up to a depth of 0.25 x d₁ (LK: 0.15 x d₁) because this area has no significant effect on the sealing function.

MB series	SK series	HK series	LP series	LK series

Required Installation Lengths

dN	MB series			SK series		HK series		LP series		LK series		Threaded Plugs DIN 908
	d1	l3 min	l4 min*	d1	l4 max	d1	l4 max	d1	l2 min	d1	l4 max	d1	l4 max
2.0	3.0	3.4	5.0	.	.	.	.					.	.
3.0	4.0	3.8	5.5	.	.	3.0	7.0	3.25	5.80			.	.
4.0	5.0	5.3	7.0	4.0	6.5	4.0	8.0	4.40	7.00	4.0	4.0	.	.
5.0	6.0	6.3	8.5	5.0	7.5	5.0	9.5	5.40	8.00	5.0	4.8	M 8x1	11.5
6.0	7.0	7.3	9.5	6.0	8.0	6.0	10.0	6.40	8.50	6.0	5.3	M 8x1	11.5
7.0	8.0	8.3	11.0	7.0	9.0	7.0	11.0	7.40	8.50	7.0	5.8	M 10x1	12.0
8.0	9.0	9.8	12.5	8.0	10.5	8.0	11.5	8.45	9.50	8.0	6.8	M 10x1	12.0
9.0	10.0	10.8	13.5	9.0	11.0	9.0	13.0	9.60	10.00	9.0	6.8	M 12x1.5	16.0
10.0	12.0	12.8	16.0	10.0	12.5	10.0	13.5	10.65	11.00	10.0	6.8	M 12x1.5	16.0
12.0	14.0	14.5	18.0	.	.	.	.	12.75	12.00	12.0	7.8	M 14x1.5	16.5
14.0	16.0	16.5	20.0	.	.	.	.			14.0	8.7	M 16x1.5	16.5
16.0	18.0	18.5	22.5	.	.	.	.			16.0	11.5	M 18x1.5	17.5
18.0	20.0	21.5	25.5	.	.					.	.	M 20x1.5	19.5
20.0	22.0	24.5	28.5	.	.					.	.	M 22x1.5	19.5

dN = given nominal bore/system bore size
*Installation lengths MB series
The required installation length (I4) min. for MB plugs is for base materials with hardness greater than HB=90. For softer materials, deeper installation is required.