1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2013 SAE International All rights reserved. No part of this pub
3、lication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970
4、(outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS4060AEROSPACESTANDARDAS4060Issued 1995-09 Reaffirmed 2013-01 Tube Fitting Swaged J
5、oint, Roller Expander Manual Process, Requirements for RATIONALEAS4060 has been reaffirmed to comply with the SAE five-year review policy. SAE AS4060 Page 2 of 32 2.1.1 (Continued): AS1710 AS1716 AS1730 AS1732 AS1733 AS1737 Coupling, Fuel, Flexible, Variable Cavity, Threaded Type With Ferrules Ferru
6、le, Coupling, Flexible, Variable Cavity, Threaded, Ferrule Tube Ends Coupling, Fuel, Rigid, Threaded Type Body, Coupling, Rigid, Fixed Cavity, Threaded, Ferrule Tube Ends, Type I Body, Coupling, Rigid, Fixed Cavity, Threaded, Ferrule Tube Ends, Type II Ferrule, Coupling, Rigid, Fixed Cavity, Threade
7、d Ferrule Tube Ends 2.1.2 U.S. Government Publications: Available from DODSSP, Subscription Services Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094. QQ-A-225/6 WVV-T-700F WVV-T-700/6F QQ-P-35 MIL-A-8625 MIL-C-13924 MIL-H-6088 MIL-T-5695 MIL-T-8808 MIL-T-9047 MS33533 Aluminum Allo
8、y Bar, Rod, and Wire; Rolled, Drawn, or Cold Finished, 2024 Tube Aluminum Alloy, Drawn, Seamless, 5052 General Specification For Tube Aluminum Alloy, Drawn, Seamless, 6061 General Specification For Passivation Treatments For Corrosion-Resistant Steel Anodic Coatings for Aluminum Heat Treatment of Al
9、uminum Alloys Coating, Oxide, Black, For Ferrous Metals Heat Treatment of Aluminum Alloys Tubing, Steel, Corrosion-Resistant (304), Cold Drawn, Annealed Tubing Steel Corrosion Resistant Aircraft Hydraulic Quality (321) Titanium and Titanium Alloys Bars (Rolled or Forged) and Reforging Stock, Aircraf
10、t Quality Tolerances - Seamless Corrosion-Resistant Steel Tubing Round 2.1.3 ASTM Publication: Available from ASTM, 1916 Race Street, Philadelphia, PA 19103-1187. ASTM A269 Seamless and Welded Austenitic Stainless Steel Tubing for General Service, Standard Specification For 2.1.4 ANSI Publications:
11、Available from American National Standards Institute, 11 West 42nd Street, New York, NY 10036-8002. ANSI/ASME B46.1 Surface Texture (Surface Roughness, Waviness, and Lay) ANSI Y14.5M-1982 Dimensioning And Tolerancing ANSI H35.2 Dimensional Tolerances for Aluminum Mill Products 2.2 Related Publicatio
12、ns: The following publication is provided for information purposes only and is not a required part of this document. ARP4986 Installation Standard for Couplings SAE AS4060 Page 3 of 32 3. REQUIREMENTS: 3.1 Material: The selected material for tubing covered in this document are 5052-0, 6061-T 4, 6061
13、-T6, 304, 321 CRES and Ti-50A. The selected material for ferrules covered in this document are 2024-T851, 17-4PH or 15-5PH CRES and Ti-6AL-4V. Each of these materials will swage differently due mainly to the variance in hardness. In the case of swaging 5052-0, 6061-T 4, or 6061-T6 tubing into the 20
14、24-T851 ferrules, the harder the tube material, the more swage tubing is required and the more deformation of the lands will occur. The deformation of the land will cause the land corners to be rounded as shown in Figure 1. Mlen swaging 304 or 321 CRES tubing into 17-4PH CRES ferrules, or Ti-50 tubi
15、ng into Ti-6AL-4Vferrules, a higher torque value is required for harder tube but there is not much deformation of the lands of the ferrules. Other tube materials may be used as long as they are softer than the ferrule, and new torque values must be developed for each case. 3.2 Swage Fittings: The in
16、formation in this document pertains to those swage fittings that conform to specifications listed in 2.1.1. Different fittings with the same groove configurations may be swaged using the information provided in Tables 1 and 2, except that modified tooling may be required. A typical ferrule cross sec
17、tion is shown in Figure 2. Note that the land corners have a maximum radius of 0.002 in. The actual number and depth of the grooves vary depending on the size. See the applicable parts standards for detail information. 3.2.1 Swage Fitting Preparation: The swage fittings shall be visually inspected f
18、or damage and shall be free of chips, burrs or lubricant that may be trapped in the annular grooves on the inside diameter of the fittings. 3.3 Tubing: The tubing covered in this document conform to the specifications listed under Section 2. The particular alloy, hardness, coating, and wall thicknes
19、s will all affect swaging results. These factors must be taken into account when selecting tooling and torque values (see 4.2, Table 1 and Table 2.) 3.3.1 Wall Thickness: The ferrules and bodies are designed to be used with a range of tube wall thicknesses and still produce an acceptable swage joint
20、. There is no definite maximum wall thickness (refer to ANSI H35.2 for Aluminum and MS33533 for stainless steel), but if the wall remains in the limits as shown on Table 3, the strength of the swage joint should be greater than the tube, the coupling strength, or both. Within these limits, the major
21、 effect of the wall thickness on swaging is that the greater the wall thickness, the greater the swage torque required. If the wall thickness is too thin, which is less than the limits specified in Table 3, excessive thinning of the tube walls occurs during swaging. SAE AS4060 Page 4 of 32 5052-0 AL
22、UMINUM ALLOY TUBING 2024-T851 ALUMINUM ALLOY FERRULE l MINIMALLY BREAK THE LAND CORNERS 2 USUALLY OBTAIN COMPLETE FILL FOR ALL GROOVES ESPECIALLY IN THE CENTER GROOVES TUBE EXTRUSION 3 FIRST GROOVE APPROACHING AND/OR REACHING COMPLETE F“fll 4 INCREASE IN SWAGE TORQUE AFTER REACHING OPTIUM JOINT WILL
23、 NOT BREAK THE LAND CORNERS BUT WILL EXHIBIT A DEFINITE TUBE EXTRUSION 6061-T6 ALUMINUM ALLOY TUBING 2024-T851 ALUMINUM ALLOY FERRULE TUBE EXTRUSION 1 ONE END OF THE LAND CORNER IS ROUNDER THAN THE OTHER END 2 USUALLY OBTAIN COMPLETE FILL FOR ALL GROOVES ESPECIALLY IN THE CENTER GROOVES 3 FIRST AND
24、LAST GROOVES APPROACHING AND/OR REACHING COMPLEiE FILL 4 SIMILAR TO 5052-0 TUBING, AN INCREASE IN SWAGE TORQUE AFTER OPTIMUM JOINT WILL LENGTHEN THE TUBE EXTRUSION FIGURE 1- Cross Section Comparison FACE FIGURE 2- Ferrule Cross Section SAE AS4060 Page 5 of 32 6061-14 606114 6061-T6 6061-T6 50520 AL
25、5052-0AL ALAiy ALAiy ALAiy ALAiy 304 or Size (Tube Size) (Tube Wall) AlyTube AlyTube Tube Tube Tube Tube 321 Titanium Code Inch Inch Nonanoclized Anodized Nonanodized Anodized Nonanodized Anodized CRES Ti-50A 04 .250 .028 2 4 3 5 5 7 5 05 .312 .026 3 5 4 6 6 8 10 06 .375 .028 4 6 5 7 7 9 16 08 .500
26、.028 8 9 9 10 10 12 28 40 10 .625 .028 13 14 14 16 17 20 47 55 12 .750 .028 17 21 21 23 25 28 59 75 16 1.000 .028 30 34 36 40 46 50 100 120 ;! 20 1.250 .028 56 60 62 70 75 95 160 180 OJ r 24 1.500 .028 100 110 108 120 120 145 220 250 m . 28 1.750 .028 140 155 150 165 180 200 300 340 32 2.000 .028 20
27、0 220 220 245 265 300 400 460 (f) 36 2.250 .028 265 290 295 330 355 390 550 :E Q) (0 40 2.500 .028 310 340 345 380 415 455 655 -(I) 44 2.750 .035 385 425 425 475 515 565 ci 48 3.000 .035 465 510 515 565 620 700 -., .a c 56 3.500 .035 630 700 700 775 840 925 (I) - - -. 64 4.000 .035 - - 895 985 1080
28、1180 - -cr 64 4.000 .049 840 925 -. 5 _. 72 4.500 .035 1000 1100 1200 1250 1320 1450 80 5.000 .035 1200 1375 80 5.000 .049 -1400 1500 1750 1800 88 5.500 .049 1450 1585 1600 1750 2000 2200 96 6.000 .049 1750 1850 2000 2150 2300 2500 NOTE: Ferrule materials: 2024-T851 is used with aluminum tubing 17-4
29、PH or 15-5PH CRES is used with 321 CAES tubing Ti-6AL-4V is used with titanium tubing SAE AS4060 Page 6 of 32 3.3.1 (Continued): TABLE 2- Typical Linear Growth Per Joint Tube Material 5052-0 6061-T4 6001-T6 Size Codes 04 to 16 .015 .012 .010 Size Codes 20 to 64 .020 .015 .015 Size Codes 72 to 96 .03
30、0 .020 .030 TABLE 3 - Recommended wall Thickness for Different Tube Sizes Tube Size Code 04 to 06 08 to 12 16 to 32 36 to 56 64 to 96 Wall Thickness (Inch) .020 to .049 .016 to .065 .020 to .065 .022 to .084 .035 to .093 Given the groove depth on different sizes of AS ferrules, if using the minimum
31、wall thickness shown in Table 3 and assuming the grooves are completely filled, approximately 0.010 in of wall is left after swaging. If the wall thickness is less than the limit, the consequences not only weaken the swaged joints but also weaken the back end section of the ferrule as shown in Figur
32、e 3. The suggested reduction of wall thickness is to be not more than 36% of the original wall thickness as shown in Figure 4. 3.3.2 Surface Coatings: Surface coating or treatments may affect swaging and must be taken into account. Common treatments of aluminum include anodizing and chemical convers
33、ion coatings. Chemical finishes will not affect swaging. Anodizing hardens the surface of the tube, and requires greater torque values (see 4.2.1) for the same groove fill. 3.3.3 Tube Preparation: To obtain a proper swage joint, the tubing and tube ends need to be prepared prior to swaging. 3.3.3.1
34、Tube Bend Radius: Tube bends are recommended not to begin less than 1.50 in from the tube end for all sizes as shown in Figure 5. This is based on a minimum bend radius of twice the tube diameter; smaller bend radii may interfere with the expander tool unless the bend begins farther from the tube en
35、d. The other reason is to prevent having a bent or curved tube end placed in the straight ferrule as illustrated in Figure 6. There are certain sizes where the bend may start closer to the tube and where a smaller radius may be used. Vvtlere the bend radius is greater than 90, you may encounter inte
36、rference with the die block, holder, or expander. It is best to contact the tooling manufacturer for more complete information. SAE AS4060 Page 7 of 32 WALL THICKNESS 20 PERCENT WALL lHICKNESS -REDUCTION GROOVE DEPTH ,. .010 GROOVE DEPTH (.010) X 100% WALL THCKNESS (.020) - 50% FIGURE 3- Maximum Acc
37、eptable wall Reduction WALL THICKNESS 28 t PERCENT WALL THICKNESS ., REDUCTION GROOVE OEPTrl - .010 GROOVE DEPTH (.01 O) X lOO% WALL THICKNESS (.028) 36 FIGURE 4- Suggested Maximum wall Reduction SAE AS4060 Page 8 of 32 STRAIGHT l1.50 RECOMMENDED R2.00 FIGURE 5- Bent Tube with 1.5 Inch Straight on t
38、he Swage End .50 STRAIGHT R2.00 FIGURE 6- Bent Tube with Only 0.51nch Straight on the Swage End SAE AS4060 Page 9 of 32 3.3.3.2 Tube Ends: The tube end is to be sharp cornered and free of burrs. The face of the tube is to be square with the OD to an angular tolerance of 020. These items are importan
39、t to insure proper seating of the tube end against the ferrule tube stop and accurate alignment. This will be most critical for rigid joints. Refer to Figure 7 and Table 4 for the effect of the tubing angular tolerance on the different sizes of tube when placed in the ferrule. 3.3.3.3 Cleanliness: T
40、he tube shall be clean and free of all foreign matter that could be embedded in the tube wall during swaging. Tube bending lubricants, grease or oils may cause a slight discoloration but are not detrimental to the performance of the swage joint. 3.4 Tooling: The basic tooling required for either man
41、ual or power swage includes a die block, a die block holder, a torque wrench (for manual swage only), and an expander. 3.4.1 Die Block: Die blocks are designed to fit over the fitting with a close tolerance. This is to prevent excessive fitting growth during swaging. The die block shown in Figure 8
42、(dimensions are in Table 5) is round and made in two halves which are hinged together for ease of handling and to prevent mixing with the other half of the die block. Other external die block designs may be used as long as there is no mismatch on the internal diameter for the two halves and the I D
43、conforms to the applicable fitting. The hardness of the die block has to be greater than the hardness of the fitting to prevent deformation when swaging. The recommended hardness for the die block is 44 HRC or harder. 3.4.2 Die Block Holder: The holder that is shown in Figure 9 (dimensions are in Ta
44、ble 6) accepts the die block and is tightened to prevent movement or separation of the die block halves. Other designs and configurations may be used as long as they will restrain the die blocks during the swaging operation. 3.4.3 Torque Wrench: A calibrated torque wrench with an accuracy of 4% or b
45、etter shall be used for manual swaging. The torque limiting type usually prove to be more convenient when performing repeated swages, since it eliminates the need to watch the indicator during swaging. Other instrumentation may be used to control torque. 3.4.4 Expander: The expander consists of a ta
46、pered mandrel, tapered rollers, and roller cage as shown in Figure 10. The mandrel is self-feeding, so that it is only necessary to initiate expansion by means of a small axis load while rotating the mandrel clockwise. The number of rollers varies from three on the smaller sizes up to seven on the l
47、arger sizes. In addition to the expander design requirements shown in Figure 10 and Table 7, the expander has to meet the minimum expansion requirement specified in Table 8. It is to assure the minimum swaged result and that the expander is not bottomed up when using the torque value listed in Table
48、 1 with minimum wall thickness for the specific expander and tube wall thickness. SAE AS4060 Page 10 of 32 f TUBE DIAMETER 0“20MAX THE RESULT OF THIS ASSEMBLY AFTER SWAGING WILL HAVE A COMBINATION OF TUBE EXTRUSION IN ONE END AND NOT ENOUGH FILLING IN THE FIRST GROOVE ON THE OTHER END OF THE FERRULE
49、. THE EFFECT WILL BE CLEARLY DETECTED AS TUBE SIZE INCREASES. FIGURE 7- Affect of Angular Tolerance on Tubing TABLE 4- Gap Between Tube Face and Tube stop with Angular Tolerance of 020 Tube Gap First Groove Diameter X Width Inch Inch Inch .250 .0014 .045 .500 .0029 .035 1.000 .0058 t 1.500 .0087 I 2.000 .0116 i I 3.000 .017 4 1 4.000 .0233 5.000 .0291 6.000 .0349 .045 .035 SAE AS4060 Page 11 of 32 LINKAGE PR
