Global Mechanical Design Standards GMD1

Table of Contents
9. Standard Components and Specifications ...........................................................................2
9.1. Pivot Shaft Criteria __________________________________________________________________ 2
9.1.1. Non-Rotating Shaft ............................................................................................................................................... 2
9.1.2. Shaft Requirements when used with Non-Lube Bearings ................................................................................ 2
9.1.3. Rotating Shaft ....................................................................................................................................................... 3
9.1.4. Stub Shaft Pivots .................................................................................................................................................. 4
9.2. Bearings ___________________________________________________________________________ 5
9.2.1. Types of Bearings ................................................................................................................................................ 5
9.2.2. Selection Criteria .................................................................................................................................................. 5
9.2.3. Solid Bearing ........................................................................................................................................................ 6
9.2.4. Split Bearing ......................................................................................................................................................... 7
9.2.5. Bearing Length / Pivot Shaft Diameter Ratio Determination ............................................................................ 8
9.3. Fasteners __________________________________________________________________________ 9
9.3.1. Screws and Dowels .............................................................................................................................................. 9
9.3.2. Set Screws .......................................................................................................................................................... 10
9.3.3. Dowel Pins .......................................................................................................................................................... 11
9.3.4. Threaded Inserts................................................................................................................................................. 11
9.3.5. Roll Pins (Not Preferred) .................................................................................................................................... 12
9.3.6. Self-locking Nuts ................................................................................................................................................ 12
9.4. Counterbored Holes ________________________________________________________________ 13
9.5. Shot Pins _________________________________________________________________________ 14
9.6. Springs ___________________________________________________________________________ 14
9.7. Cam Followers and Rollers __________________________________________________________ 15

Standard Components and Specifications

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9. Standard Components and Specifications

9.1. Pivot Shaft Criteria

9.1.1. Non-Rotating Shaft

A non-rotating shaft is the most common design for moving a mass about a central pivot. It consists
of a clevis type assembly with dual bearings, thrust washers, and a mass. The mass is located about
the centerline of the detail.

The shaft diameter is determined by the width of the clevis assembly on a single clevis set-up as well
as the load.

See the following pages for bearing configurations.

NOTES:
• Manufactured pivot pins/shafts must be ground to finish specified by bushing / bearing
manufacturer.
• Surfaces that contact thrust bearings must be finished per requirements of bearing
manufacturer.
• Usage of self-lubricating Rulon composite bearings is preferred for pivoting and linear
applications.

9.1.2. Shaft Requirements when used with Non-Lube Bearings

• Hardness - Rc50 min.
• Finish - 0.2 - 0.4 µ m - RMS.
• Provide smooth, generous lead-in radii.
• Consult bearing manufacturer’s specification for proper housing bores and lead-in chamfers.
• Coat shaft, thrust bearings, and bearing I.D. with white lithium grease before assembly.
• Use with thrust bearings made of 660 Bronze.
• Seal all exposed bearings.

Refer to the Plant Specific Components List for approved bearings.

If a lube type bearing is required, the GM representative must approve before use.

Standard Components and Specifications

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9.1.3. Rotating Shaft

A rotating shaft must be used when the driver of the rotating mass is offset to that mass. The
rotating shaft connects the driving member to the driven member. The length of the shaft is
determined by the overall size of the driven mass. The diameter of the shaft must be calculated for
torsional and shear loads. Considerations must be taken for removal of stock for keyways, taps, etc.

When the driver of a rotating mass is off-set to that mass, a rotating shaft must be used to connect
the driver and driven members. The length of the shaft is determined by the overall size of the driven
mass. The diameter of the shaft must be calculated for torsional and shear loads. Considerations
must be taken for removal of stock for keyways, taps, etc.

Driving Member

Pre-Lubricated Bearing

Driven Member

Shaft Detail – Not Preferred:

• Do not mill key slot thru to avoid bearing damage.
• Requires the GM representative’s approval
• Example non-preferred Shaft Detail

Standard Components and Specifications

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9.1.4. Stub Shaft Pivots

For any stub shaft pivot unit application, the GM representative shall work with the supplier to
complete the Commercial Component Application Buy-off Form.

Shown below is a NAAMS stub shaft pivot assembly. These units are durable, easy to service, and
versatile in usage. They can be used in any attitude (horizontal or vertical) with adequate precision
and long life.

Refer to NAAMS specifications for load ratings. There are four different load-rated kits available that
include all components except those noted below.

Standard Components and Specifications

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9.2. Bearings

9.2.1. Types of Bearings

There are many types of bearings available for use; however, not all of them are suitable to the
environment of a body shop.

Self-lubricating composite bearings are preferred for most pivoting and linear applications to avoid
lubrication maintenance. Care must be taken that the application does not exceed the bearing load
capabilities specified by the supplier. Do not use this type bearing for shafts larger than 60mm
diameter.

Approved plastic bearings may be used in place of a composite bearing if appropriate steps are
taken to protect it from contamination. As with composite bearings, limit plastic bearing use to shafts
less than 60mm diameter.

For larger shafts, use approved bronze bearings or roller ball bearings, sized for the application, and
provide for the appropriate lubrication and protection from contamination.

Refer to the Plant Specific Components List for approved bearings.

9.2.2. Selection Criteria

Proper selection of bearings is critical in tools. Standard bearings are available that satisfy
requirements ranging from hi-speed, hi load to low speed, low load. In addition to speed and load,
other conditions must be considered.

Bearings are selected based on the following conditions:

• Partial to full rotation
• Multiple transfer speeds
• Loads induced
• Temperatures bearing will be subjected to
• Lubrication required

During the selection process, incorporate a practical yet conservative safety allowance to account for
changes within the tool not anticipated such as:
• Shock loads due to sudden stops or crashes
• Increased production rates
• Weld flash accumulation
• Dirt

For bronze bearings use double elliptical oil grooves if used as a bearing, and zigzag grooves if used
for slides and wear strips.

The design supplier source shall provide lubrication components / equipment for all applications that
are not pre-lubricated. All applications of rolling element-type (ball and roller) linear bearings, as
typically specified in linear slide applications, shall be ordered with lubrication ports in the bearing
raceway.

Standard Components and Specifications

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The design supplier shall follow the “Basic Lubrication Standard LS1 for Industrial Equipment and
Machine Tools”, (GM-1720). The LS1 standard can be located on the “GM SupplyPower” website.
The ratio length to inside diameter should not be less than 0.5 or greater than 2.0 in a double bearing
design. When only one bearing is used, the ratio should be greater than 1.0 but less than 3.0.

Double Bearing Example: Single Bearing Example:

Bearing Length = 25 mm Bearing Length = 60 mm
Bearing I.D. = 50 mm Bearing I.D. = 50 mm
L/D = .5 L/D = 1.2

BEARING BEARING
I.D. I.D.

BEARING LENGTH BEARING LENGTH

9.2.3. Solid Bearing

A solid bearing design is preferred.

A pivot design using a thru-shaft in a body shop is susceptible to corrosion and rust. As a result,
removal for maintenance becomes a consideration.

There are limitations to the length of bearings available dependent on type, diameter, etc. Refer to
Manufacturer’s specifications for limits.

Refer to the examples below for guidelines.

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9.2.4. Split Bearing

If a solid bearing cannot be used, add provisions for grease as shown.

Fill cavity between bearings at assembly to eliminate effects of contamination.

Use split bearings on large gates or dumps for ease of installation and/or replacement. Use requires
GM representative’s approval.

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9.2.5. Bearing Length / Pivot Shaft Diameter Ratio Determination

Use the ratio of length of bearing (L) to diameter of pivot shaft (D) for examples shown below (L/D).

Example of a Single Clevis:

Example of a Spread Single Clevis:

“W” Maximum equals 12 times “D”

Example of a Spread Double Clevis:

Either of the thrust bearing to clevis arrangements is acceptable when “W” max equals 32 times “D”

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9.3. Fasteners

9.3.1. Screws and Dowels

Screw and dowel sizes shall be designated in proportion to the size of the items being assembled.
The stress to which the joint is being subjected shall be considered. To avoid damage to the tool, pull
dowels shall be specified. Suggested screw and dowel sizes for specific applications are as follows:

Less than 8mm Not preferred except in special applications

8mm - 10mm Use for locator block and clamp finger attachment based on available space
10mm For general assembly conditions
Minimum for attaching units to a base. Also used to attach any large details within
12mm – 16mm
a unit assembly
For large units to a base or for overhead structure attachment or assembly. Also
20mm - 24mm
consider for attaching large overhanging units
24mm Leveling screws

When the slope of a surface in contact with a screw exceeds 1:20 with respect to a plane normal to
the screw axis a “Spot face” is required. For structural shapes such as channels, I- Beams, etc., a
spherical washer may be used.

Screw hole depths shall be deep enough to ensure full thread engagement (1.5 x thread diameter).
For soft materials use threaded insert (preferred) or 2.0 x thread diameter.

Use H6 for all dowel hole call-outs.

Wrench access must be considered in the design. Avoid forcing the disassembly of adjacent or
related components.

Hardened flat washers are to be used in these conditions:

• Under fastener head when used in a slotted hole
• Between fastener head and soft material such as copper, aluminum, etc.

All fasteners are to be metric coarse thread unless otherwise specified. Any deviation from coarse
thread must be noted on drawing. Fine threads may be required for situations where high vibration is
present or fine adjustment is required. Metric fasteners must be identified by an approved blue
coating.

Do not use lock washers under fastener head. To assure proper torque is maintained, use only
fasteners with the approved “torque-patch” feature.

Standard Components and Specifications

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9.3.2. Set Screws

Specify: Torque patch set screws (plastic patch)

Type # 1 - Cup point Type # 2 - Flat point Type # 3 - Cone point

General usage against Used against Special usage – requires
soft details; will bite into hardened details with drill spot at point contact
surface of contacted flat contact area. area.
detail.

For special applications, other set screws may be used, as required. For screws over 25mm, see
suitable catalog (may be special ordered).

Preferred size Common Available Lengths – Types #1, #2, #3

screw - threads 3 4 5 6 8 10 12 16 20 25 30 35 40 45 50
M3 x 0.5 1 1
1 1 1 1 1 1 1 1
M4 x 0.7 2 2 2 2 2 2 2
3 3 3 3 3 3 3
M5 x 0.8 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2
3 3 3 3 3 3
M6 x 1 1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
M8 x 1.25 1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
M10 x 1.5 1 1 1 1 1 1 1 1
2 2 2 2 2
3 3 3 3 3 3 3 3

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9.3.3. Dowel Pins

Use pull dowels.
TAP "L"

DIA.

Nominal Dowel Diameter

“L” 6 8 10 12 16 20
12 X X
20 X X X
25 X X X X
30 X X X X X
40 X X X X X
45 X X X X
50 X X X X X X
60 X X X X X X
70 X X X X X
80 X X X X X
90 X X
Tap Size M4 x 7 M5 x 8 M6 x 1.0 M6 x 1.0 M8 x 1.25 M10 x 1.5

9.3.4. Threaded Inserts

Avoid using tapped holes in soft nonferrous materials (aluminum, copper, brass and plastics).

It is preferred to use clearance holes with nuts and bolts.

When it becomes necessary to tap into a piece of nonferrous material a screw lock type insert must
be used.

Recommended sizes are M6, M8, M10 and M12.

For additional sizes and call outs, refer to the specific manufacturers specifications manual.

Refer to the program approved Plant Specific Component List (PSCL).

Threaded inserts are to be identified as a sub-detail on the detail drawing and treated accordingly on
the Bill of Material (BOM).

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9.3.5. Roll Pins (Not Preferred)

The use of roll pins in body shop tooling requires prior approval by the GM representative and should
only be considered as a last resort.

Roll pins (spring pins) are sometimes used as a simple way of locking two pieces of material together
that do not need the precision or close tolerance of a dowel.

Examples of this are as an anti-rotate, manual hand lever in small spring loaded parts or as a guide
in a non-precision slot.

The most commonly used sizes are: 1.5mm, 3mm, 6mm, 10mm, and 12mm.

A 1.5mm pin is to be used only when a minimum diameter is required. Refer to the Plant Specific
Components List for approved manufacturer.

9.3.6. Self-locking Nuts

To eliminate the loosening of lock nuts due to vibration in threaded, adjustable design conditions,
such as proximity switch targets, limit switch trippers, adjustable detail jackscrews, etc., specify the
use of a commercial self-locking nut.

Select either of the following locknuts based on design requirements:

• Full height: heavy-duty hex - unplated steel
• Thin height: heavy-duty hex - unplated steel

Use of a torque-patch is not required with locking type nuts.

Typical Clearance Typical Threaded

Hole Configuration Hole Configuration

Standard Components and Specifications

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9.4. Counterbored Holes

Use the following criteria for determining stock sizes when it is necessary to counterbore holes for screw
head clearance.

Do not use lock washers for any applications. Testing has proven that lock washer usage degrades the
torque tension integrity of the bolted joint.

Identify the attribute for the hole so the correct note appears in the hole chart.

Standard C’bore Depths:

Screw Cap C’bore Cap C'bore Min. Dim
Size DIA Height Depth “A”
M6 11 6 7 2.5
M8 15 8 9 4.0
M10 18 10 11 4.5
M12 20 12 13 6.0
M16 26 16 17 8.0
M20 33 20 21 10.0

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9.5. Shot Pins

For any shot pin application, the GM representative shall work with suppliers to complete the Commercial
Component Application Buy-off Form (download from Body-in-White (BIW) Forms Library).

Shot pins are used as lockouts for:

• Dumps / pivots
• Lifters
• Pallet stops
• Escapements
• Precision locating devices

Shot pins are also used to hold location for indexing mechanisms.

External Flow Controls must be ordered on the Bill of Material for all shot pin applications. This will
increase the MCBF for these components.

Minimum engagement of the pin is to be 1 times diameter.

Double acting shot pin assemblies are available commercially. Spring-extended or retract-type cylinders
are NOT to be used. When a custom shot pin package is needed, ensure that it includes the proper limit
switches and flow controls.

The GM representative’s approval is required for use. The diagram below shows an example of a typical
shot pin assembly.

9.6. Springs
For any spring application, the GM representative shall work with suppliers to complete the Commercial
Component Application Buy-off Form.

Springs are not to be considered for body shop tool designs without prior approval from the GM
representative. If approval is granted, refer to the spring supplier’s catalog for all engineering data
pertaining to spring rate, solid height, etc.

Operator safety, tool longevity, maintainability, and operating environment must be a consideration in
design.

Standard Components and Specifications

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9.7. Cam Followers and Rollers

For all applications with cam followers and rollers in welding cells, covers shall be added to prevent weld
slag from seizing the bearing similar to those shown in the following pictures.

This is an example of unprotected

rollers.

This is an example of excessive

weld slag which could seize the
roller.

This is an example of covers

installed to keep the weld slag
away from the bearing surface.

Standard Components and Specifications

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