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 reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this publication ma
3、y 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 (outside US
4、A) 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/AS5440AAEROSPACESTANDARDAS5440 REV. A Issued 1998-04 Revised 2011-01Superseding AS5440 (R) Hydr
5、aulic Systems, Military Aircraft, Design and Installation, Requirements For RATIONALEAS5440 has been updated to Revision A for the following reasons: a. Minor technical changes have been made b. The references called up in the document have been updated c. Editorial changes have been made to improve
6、 the readability of the document TABLE OF CONTENTS 1. SCOPE 41.1 Classification . 41.1.1 Types 41.1.2 Classes . 42. REFERENCES 42.1 Applicable Documents 42.1.1 SAE Publications . 42.1.2 US Government Publications 72.1.3 NAS Publications 92.2 Definitions . 92.2.1 Utility System 92.2.2 Flight Control
7、System 102.2.3 Combined Flight Control Utility System 103. REQUIREMENTS . 103.1 Materials 103.2 Design . 103.3 Hydraulic Fluid 103.4 Hydraulic Seals . 113.4.1 Gland Design 113.4.2 O-ring and Seal Assemblies . 113.4.3 Backup rings . 113.5 Functional Simulator . 113.6 General System Design 123.6.1 Flu
8、id Temperature Limitations 123.6.2 Fire Hazards 123.6.3 Surge Pressure . 123.6.4 Strength . 163.6.5 Reservoir Pressurization . 16Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AS5440A Page 2 of
9、443.6.6 Fluid Velocity Limitations 163.6.7 Subsystem Isolation 163.6.8 Ground Service Provisions . 163.6.9 Removal of Entrapped Air . 173.6.10 Power Pumps 183.6.11 Pump Supply Shutoff Valves 183.6.12 Special Tools . 183.6.13 System Pressure Indication 193.6.14 Fluid Sampling Valves 193.6.15 Automati
10、c Diagnostic Monitor System 193.7 Utility System Design 193.7.1 Wheel Brake Systems . 203.8 Flight Control System Design . 203.8.1 System Isolation 203.8.2 Hydraulic Power Failures 203.8.3 System Separation 213.8.4 Subsystems Pressure . 213.8.5 Flight Control Power Sources . 213.8.6 System Temperatu
11、re 213.9 Emergency System Design for Utility System 213.9.1 Emergency System Types 213.9.2 Emergency Line Venting . 223.10 Components 223.10.1 Standard Components 223.10.2 Fixed Orifices 223.10.3 Actuators Essential to Safe Operation of the Aircraft . 223.11 Component Design and Installation 223.11.
12、1 Design Practice and Installation 223.11.2 Accumulators 233.11.3 Actuating Cylinders . 233.11.4 Manual Bleed Valves 233.11.5 Brake Valves . 233.11.6 Check Valves 233.11.7 Directional Control Valves . 233.11.8 Pressure Regulating Valves 243.11.9 Filters 243.11.10 Fittings . 253.11.11 Flow Dividers .
13、 263.11.12 Flow Regulators 263.11.13 Protective Devices 263.11.14 Snubbers . 263.11.15 Manually Operated Pumps . 263.11.16 Flexible Connections . 273.11.17 Lock Valves . 273.11.18 Motors . 283.11.19 Power Pump Variable Delivery . 283.11.20 Power Pump Fixed Displacement . 283.11.21 Relief Valves, Sys
14、tem and Thermal Expansion 283.11.22 Reservoirs . 283.11.23 Restrictor Valves . 303.11.24 Self-Sealing Couplings 303.11.25 Shuttle Valves . 313.11.26 Pressure Switches 313.11.27 Swivel Joints . 313.11.28 Tubing . 313.11.29 Design of System Installations 343.12 Workmanship 35Copyright SAE Internationa
15、l Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AS5440A Page 3 of 444. QUALITY ASSURANCE PROVISIONS 354.1 Responsibility for Inspection . 354.1.1 Responsibility for Compliance . 354.2 Inspection 354.2.1 Vibration Prior to
16、 First Flight . 354.2.2 Ground and Flight Tests . 364.3 Cleaning of Parts and Systems . 364.3.1 System Contamination Level forPproduction Aircraft . 364.4 Hydraulic System Information . 364.4.1 Hydraulic System Analysis and Design Study 364.4.2 Developmental and Preproduction Study . 364.4.3 Hydraul
17、ic System Production Study 364.4.4 Hydraulic System Design 374.4.5 Hydraulic System Nonstandard Component Cross-Sectional Assembly Drawings . 374.4.6 Functional Simulator Design and Test Program . 374.4.7 Vibration Test Plan 374.4.8 Consideration of Data Requirements 375. PREPARATION FOR DELIVERY .
18、386. NOTES 386.1 Intended Use . 386.2 MIL-H-5440 . 386.3 Qualified Products Lists 396.4 Document Change Identification . 39APPENDICIESAPPENDIX A CERTIFICATION/DATA REPORT TECHNICAL CONTENT REQUIREMENTS . 40APPENDIX B TEST REPORT TECHNICAL CONTENT REQUIREMENTS . 44TABLESTABLE 1 SYSTEM PEAK PRESSURE 1
19、2TABLE 2 HYDRAULIC PRESSURE 13TABLE 3 HYDRAULIC LINE SUPPORT SPACING, U.S. CUSTOMARY . 32TABLE 4 HYDRAULIC LINE SUPPORT SPACING, METRIC . 33TABLE 5 DATA REQUIREMENTS 38Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without lice
20、nse from IHS-,-,-SAE AS5440A Page 4 of 441. SCOPE This specification covers the design and installation requirements for Types I and II military aircraft hydraulic systems. 1.1 Classification Military aircraft hydraulic systems shall be of the following types and classes, as specified: 1.1.1 Types T
21、ype I Maximum fluid operating temperature +160 F (+71 C). Type II Maximum fluid operating temperature +275 F (+135 C). 1.1.2 Classes The class of operating pressure shall consist of the following: a. Class 1500. 1500 psi (10 342 kPa) nominal operating pressure b. Class 3000. 3000 psi (20 684 kPa) no
22、minal operating pressure c. Class 4000. 4000 psi (27 579 kPa) nominal operating pressure d. Class 5000. 5000 psi (34 473 kPa) nominal operating pressure e. Class 8000. 8000 psi (55 158 kPa) nominal operating pressure For variable pressure level systems, such as 5000 psi and 3000 psi, the highest pre
23、ssure shall determine the pressure class. The pressure class shall be annotated with a “V” to indicate variable pressures (example: class 5000V) 2. REFERENCES The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The
24、 applicable issue of the other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable law
25、s and regulations unless a specific exemption has been obtained. 2.1 Applicable Documents 2.1.1 SAE Publications Publications are available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.
26、ARP584 Coiled Tubing, Corrosion Resistant Steel, Hydraulic Applications, Aerospace ARP598 Aerospace Microscopic Sizing and Counting of Particulate Contamination for Fluid Power Systems AS603 Impulse Testing of Hydraulic Hose, Tubing, and Fitting Assemblies AS604 Hose Assembly, Polytetrafluoroethylen
27、e, Metallic Reinforced, 3000 psi, 400 F, Heavyweight, Hydraulic AS614 Hose Assembly, Polytetrafluoroethylene, Metallic Reinforced, 4000 psi, 400 F, Heavy Duty, Hydraulic and PneumaticCopyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitt
28、ed without license from IHS-,-,-SAE AS5440A Page 5 of 44ARP994 Recommended Practice for the Design of Tubing Installations for Aerospace Fluid Power SystemsARP1192 Procedure for Calibration and Verification of a Liquidborne Particle Counter: An Absolute Standard AS1290 Graphic Symbols for Aircraft H
29、ydraulic and Pneumatic Systems AS1300 Port - Ring Locked Fluid Connection Type, Standard Dimensions For AS1339 Hose Assembly, Polytetrafluoroethylene, Metallic Reinforced, 3000 psi, 400 F, Lightweight, Hydraulic and Pneumatic ARP1383 Impulse Testing of Aerospace Hydraulic Actuators, Valves, Pressure
30、 Containers, and Similar Fluid System Components AS1975 Hose Assembly, Polytetrafluoroethylene, Para-Aramid Reinforced, 3000/4000 psi, 275 F, Standard Duty, Hydraulic, Aircraft Systems AMS3216 Fluorocarbon (FKM) Rubber, High-Temperature- Fluid Resistant Low Compression Set 70-80 AMS3218 Fluorocarbon
31、 (FKM) Rubber, High-Temperature- Fluid Resistant Low Compression Set 85-95 AIR4057 Secondary Filters For Fluid System Reliability AS4059 Aerospace Fluid Power-Cleanliness Classification For Hydraulic Fluids AMS4081 Aluminum Alloy Tubing, Hydraulic, Seamless, Drawn, Round, 1.0Mg - 0.60Si - 0.28Cu - 0
32、.20Cr (6061-T4), Solution Heat Treated and Naturally Aged AMS4083 Aluminum Alloy Tubing, Hydraulic, Seamless, Drawn, Round, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-T6), Solution and Precipitation Heat Treated ARP4146 Coil Tubing, Titanium Alloy, Hydraulic Applications, Aerospace AS4201 Port-Ring Lock
33、ed Fluid Connection Type 8000 psi - Design Standard AS4251 Coupling Assemblies, Non-Locking Probe Style, Self-Aligning, Self-Sealing, Disconnects AS4330 Tubing, Flared, Standard Dimensions For, Design Standard ARP4378 Aerospace - Accumulator, Hydraulic, Welded Bellows, Factory Precharged ARP4386 Ter
34、minology and Definitions for Aerospace Fluid Power, Actuation and Control Technologies AS4395 Fitting End, Flared, Tube Connection, Design Standard AS4396 Fitting End - Bulkhead Flared Tube Connection, Design Standard ARP4553 Aerospace, Hydraulic, Accumulator, Self Displacing AS4716 Gland Design, O-
35、Ring and Other Elastomeric Seals ARP4835 Valves, Aircraft, Hydraulic, Thermal Expansion Relief AMS4945 Titanium Alloy Tubing, Seamless, Hydraulic, 3Al - 2.5V, Controlled Contractile Strain Ratio Cold Worked, Stress Relieved ARP4946 Aerospace - Valves, Check, Hydraulic, Aircraft and Missile Copyright
36、 SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AS5440A Page 6 of 44AS5202 Bosses, Fluid Connection-Internal Straight Thread AMS5561 Steel Tubing, Welded and Drawn, 9.0Mn-20Cr-6.5Ni-.28N High Pressure Hyd
37、raulic AS5586 Aerospace General Requirements for Hydraulic System Reservoirs AS5781 Retainers (Backup Rings), Hydraulic and Pneumatic, Polytetrafluoroethylene Resin, Single Turn, Scarf-Cut, for Use in AS4716 Glands AS5782 Retainers (Backup Rings), Hydraulic and Pneumatic, Polytetrafluoroethylene Res
38、in, Solid, Un-Cut, For Use in AS4716 Glands AIR5829 Air in Aircraft Hydraulic Systems AS5891 Achieving Cleanliness Standards for Aircraft Hydraulic Systems During Manufacture AS5994 Pump Units, Hydraulic, Electric Motor Driven, Variable Delivery AMS-T-6845 Tubing, Steel, Corrosion Resistant (530400)
39、, Aerospace Vehicle Hydraulic System, 1/8 Hard Condition AMS7259 Rings, Sealing, Fluorocarbon (FKM) Rubber, High-Temperature- Fluid Resistant Low Compression Set 85-95 AMS7276 Rings, Sealing, Fluorocarbon (FKM) Rubber, High-Temperature- Fluid Resistant Low Compression Set 70-80 AS7997 Motors, Aircra
40、ft Hydraulic, Constant Displacement, General Specification For AS8775 Hydraulic System Components, Aircraft and Missiles, General Specification for AS19692 Pumps, Hydraulic, Variable Flow, General Specification For AS33583 Tubing End - Double Flare, Standard Dimensions For AS33584 Tubing End - Stand
41、ard Dimensions for Flared AS33611 Tube Bend Radii AS50881 Wiring, Aerospace Vehicle AMS-P-83461 Packings, Preformed, Petroleum Hydraulic Fluid Resistant, Improved Performance at 275 F (135 C)AMS-P-83461/1 Packing, Preformed, Petroleum Hydraulic Fluid Resistant, Improved Performance at 275 F (135 C)
42、Sizes and Tolerances AMS-P-83461/2 Packing, Preformed, Petroleum Hydraulic Fluid Resistant Improved Performance at 275 F (135 C) For Use In Boss Fittings, Sizes and Tolerances AMS-R-83485 Rubber Fluorocarbon Elastomer Improved Performance at Low Temperatures AS85421 Fittings, Tube, Fluid Systems, Se
43、parable, Beam Seal, 3000/4000 psi, General Specification For AS85720 Fittings, Tube, Fluid Systems, Separable, High Pressure Dynamic Beam Seal, 5000/8000 psi, General Specification For AS94900 Aerospace - Flight Control Systems-Design, Installation and Test of Piloted Aircraft, General Specification
44、 For Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AS5440A Page 7 of 442.1.2 US Government Publications Available from the Document Automation and Production Service (DAPS), Building 4D, 700 Ro
45、bbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-9495, https:/assist.daps.dla.mil/quicksearch/.2.1.2.1 Active Specifications MIL-PRF-5503 Actuators: Aeronautical Linear Utility, Hydraulic, General Specification For MIL-DTL-5508 Fuses, Aircraft Automatic Quantity-Measuring, Hydraulic MIL-J-551
46、3 Joints, Hydraulic, Swivel MIL-B-8584 Brake Systems, Wheel, Aircraft Design Of MIL-F-8815 Filter and Filter Elements, Fluid Pressure, Hydraulic Line, 15 Micron Absolute and 5 Micron Absolute, Type II Systems, General Specification For MIL-DTL-9395 Switches Pressure (Absolute, Gage and Differential)
47、, General Specification For MIL-DTL-25427 Coupling Assembly, Hydraulic, Self Sealing, Quick Disconnect, General Specification For MIL-DTL-25579 Hose Assembly, Tetrafluoroethylene, High Temperature, Medium Pressure, General Specification For MIL-DTL-27267 Hose, Polytetrafluoroethylene, 450 Degrees F, Medium Pressure MIL-DTL-27272 Fittings, Polytetrafluoroethylene Hose, High Temperature, Medium Pressure, General Re
