In high-torque industrial applications, selecting the correct bit type is critical for ensuring performance, longevity, and operational efficiency. This case study outlines a real-world issue experienced by a customer using T60 bits, the diagnostic process undertaken, and the ultimate solution that led to improved performance and cost savings.

A customer had been using T60 bits successfully for several months. However, after approximately three months, the bits began breaking multiple times per day, leading to increased downtime and operational inefficiencies.

To determine the root cause of the failures, a comprehensive review was conducted, focusing on machine torque data and physical examination of the bits and fasteners.

Key findings included:

• The torque data indicated that the customer was applying an unusually high amount of torque for a standard T60 bit.
• Closer inspection of the fasteners revealed that they were actually 60IP (TorxPlus) fasteners rather than standard T60 fasteners.

This misalignment between bit type and fastener design was causing excessive stress on the T60 bits, leading to premature failures.

• Design: T60 bits, which use the Torx system, have a standard six-lobed star shape, while 60IP bits, which follow the TorxPlus system, have slightly rounded lobes, allowing for better engagement with fasteners.
• Torque Capacity: TorxPlus (60IP) bits provide a greater surface area for torque transfer, reducing stress on the bit and improving durability.
• Fastener Compatibility: Standard T60 bits can fit into TorxPlus fasteners but do not provide optimal grip, leading to premature wear and breakage.
• Application: TorxPlus (60IP) is designed for high-torque applications, offering improved longevity and resistance to cam-out compared to traditional Torx designs.
• Abbreviations: "T" represents Torx fasteners and bits, while "IP" represents TorxPlus fasteners and bits.

To address the issue, the customer was provided with trial samples of 60IP bits. These bits are specifically designed to accommodate the TorxPlus fastener design, offering improved engagement and durability under high torque applications.

The implementation of 60IP bits resulted in immediate improvements:

• The new bits remained in service for 4-5 weeks without any breakages.
• The customer experienced reduced downtime and increased operational efficiency.
• Based on the success of the 60IP bits, the customer decided to transition fully to this solution and placed an order for custom, longer 60IP bits tailored to their specific needs.

Selecting the correct bit type is crucial for optimizing performance in high-torque applications. The transition from T60 (Torx) to 60IP (TorxPlus) bits allowed for improved tool longevity, reduced operational disruptions, and enhanced fastener engagement. This case study underscores the importance of matching fastener and bit designs to ensure long-term efficiency and cost savings in industrial settings.