Pressing plugs into Aluminum
Pressing plugs into Aluminum
(OP)
We press an anodized Aluminum 1.314" dia x .44" Long plug with a 15 degree chamfer cut .06" deep into an anodized Aluminum block where the tolerance between parts causes an interference fit of .001" to .003".
Plug also has a sealant groove of .02 to .06 wide and .01 deep for loctite.
Does anyone have information on chamfer design to provide optimal pressing conditions.
We wish plug to go in with minimal force, straight and allow air seal. Block air pressure when energized is 90psi.
Plug also has a sealant groove of .02 to .06 wide and .01 deep for loctite.
Does anyone have information on chamfer design to provide optimal pressing conditions.
We wish plug to go in with minimal force, straight and allow air seal. Block air pressure when energized is 90psi.





RE: Pressing plugs into Aluminum
With this appoach your 15 degree chamfer should be adequate. A 0.003 interference fit performed with a thermal shrink in this manner should resist 90 psi (122lb F) many times over.
RE: Pressing plugs into Aluminum
Thanks for the response, unfortunately we cannot heat the block but we could cool the plug.
Question is truly with regards to what is the optimal chamfer and the minimum interference fit for this pressing operation, where parts cannot be heated.
RE: Pressing plugs into Aluminum