1、ASD STANDARD NORME ASD ASD NORM prEN 3298 Edition P 2 October 2006 PUBLISHED BY THE AEROSPACE AND DEFENCE INDUSTRIES ASSOCIATION OF EUROPE - STANDARDIZATIONGulledelle 94 - B-1200 Brussels - Tel. + 32 2 775 8126 - Fax. + 32 2 763 3565 - www.asd-stan.orgICS: Supersedes edition P 1 of June 1993 and wil
2、l supersede EN 3298:1998 Descriptors: ENGLISH VERSION Aerospace series Inserts, thin wall, self-locking Installation and removal procedure Srie arospatiale Douilles filetes, paroi mince, freinage interne Procdure dinstallation et dextraction Luft- und Raumfahrt Gewindeeinstze, dnnwandig, selbstsiche
3、rnd Ein- und Ausbauverfahren This “Aerospace Series“ Prestandard has been drawn up under the responsibility of ASD-STAN (The AeroSpace and Defence Industries Association of Europe - Standardization). It is published for the needs of the European Aerospace Industry. It has been technically approved b
4、y the experts of the concerned Domain following member comments. Subsequent to the publication of this Prestandard, the technical content shall not be changed to an extent that interchangeability is affected, physically or functionally, without re-identification of the standard. After examination an
5、d review by users and formal agreement of ASD-STAN, it will be submitted as a draft European Standard (prEN) to CEN (European Committee for Standardization) for formal vote and transformation to full European Standard (EN). The CEN national members have then to implement the EN at national level by
6、giving the EN the status of a national standard and by withdrawing any national standards conflicting with the EN. Edition approved for publication 31 October 2006 Comments should be sent within six months after the date of publication to ASD-STAN Mechanical Domain Copyright 2006 by ASD-STAN prEN 32
7、98:20062 Contents Page Foreword2 1 Scope 3 2 Normative references 3 3 Hole serration profile (short inserts)4 4 Installation of inserts.5 5 Minimum criteria for the installation and removal tools and their methods of application.5 6 Assembly tools and gauges .5 6.1 General5 6.2 Installation drive to
8、ol.5 6.3 Swage tools6 7 Installation procedure .7 7.1 Insertion7 7.2 Insert alignment prior to swaging8 7.3 Swaging 9 7.4 After swage inspection 10 7.5 Inspection for minimum locking torque .11 8 Insert removal and replacement 12 Annex A (informative) Recommended tooling 14 Foreword This standard wa
9、s reviewed by the Domain Technical Coordinator of ASD-STANs Mechanical Domain. After inquiries and votes carried out in accordance with the rules of ASD-STAN defined in ASD-STANs General Process Manual, this standard has received approval for Publication. prEN 3298:20063 1 Scope This standard specif
10、ies the conditions of installation and removal (hole serration profile, tools, swaging procedure) of self-locking thin wall inserts defined by EN standards, for aerospace applications. 2 Normative references The following referenced documents are indispensable for the application of this document. F
11、or dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 3236, Aerospace series Inserts, thin wall, self-locking, short, in heat resisting nickel base alloy NI-P100HT (Inconel 718), silver plated
12、 internal thread. EN 3237, Aerospace series Inserts, thin wall, self-locking, long, in heat resisting nickel base alloy NI-P100HT (Inconel 718), silver plated internal thread. EN 3676, Aerospace series Inserts, thin wall, self-locking Design standard. prEN 3298:20064 3 Hole serration profile (short
13、inserts) Figure 1 and Table 1 provide details of the insert part number and associated bolt thread in relation to the serration profile in the counterbore of the installation hole. AA AD AB AE1 AC Key 1 Corners may vary from a sharp corner to a radius within the profile tolerance Figure 1 Table 1 Di
14、mensions (mm) Bolt thread diameter Short inserts No of serrations AA AB AC AD AE MJ5 0,80 MJ6 1,00 MJ7 1,00 MJ8 1,00 MJ10 1,25 EN3236-050 EN3236-060 EN3236-070 EN3236-080 EN3236-100 18 24 27 28 33 0,41 0,28 0,25 0,27 0,27 7,46 8,55 9,51 10,50 12,48 7,25 8,30 9,30 10,25 12,25 0,13 0,10 0,10 0,10 0,10
15、 114,5 82,0 83,0 83,3 84,3 For recommended serration profile gauge numbers, see Annex A, Table A.1. prEN 3298:20065 4 Installation of inserts Pre-installation requirements Prior to installation, check that the tapped hole, counterbore and serrations (if applicable) are free from burrs and foreign pa
16、rticles, grease, oil, etc. This will particularly apply to removal of the burrs produced by the cutting of the serrations. The required insert shall be inspected to ensure that it is clean and free from protective grease etc. Inserts installed in steel, heat resisting alloy or titanium alloy compone
17、nts may be lightly smeared externally with clean engine oil (i.e., any of the recognised oils used for the engine lubrication system. If in any doubt, consult the Controlling Quality Engineer) to facilitate assembly into the tapped and serrated counterbored hole. Inserts installed in aluminium or ma
18、gnesium components must be lightly smeared externally with a suitable jointing compound to prevent electrolytic corrosion. A minimum of 10 minutes air drying time shall be allowed before installation of insert. 5 Minimum criteria for the installation and removal tools and their methods of applicatio
19、n The tools and their methods of application described in this standard are not mandatory and show only the basic principles to be observed to achieve the satisfactory installation and subsequent swaging or removal of the inserts. The minimum dimensional requirements provided shall be achieved and o
20、n no account shall the design of the tools or their methods of application be such that damage may occur to the threads or the locking zone of the insert or the component into which it is being installed. Always ensure the appropriate tool/insert size combinations have been chosen for either the ins
21、ertion or swaging of the insert to enable correct installation of the insert. See 6.2 and 6.3. During the swaging operation, the component into which the inserts are installed shall be adequately supported to ensure no flexing or distortion at the insert assembly face occurs. This particularly appli
22、es to drum shaped components which are prone to flexing. 6 Assembly tools and gauges 6.1 General The tools and methods shown in this section for the installation, swaging and removal of thin wall inserts are mandatory (see clause 4) for standard installations. When installing inserts in counterbores
23、 or other applications, e.g., curved surfaces, where standard tooling is unsuitable, alternative tools are permissible but all the dimensions in the tables must be adhered to. 6.2 Installation drive tool Figure 2 shows an example of the installation drive tool configuration and Table 2 gives the rel
24、evant tool dimensions to ensure the correct tool size is used for screwing the insert into the tapped hole. The driving feature shall be hexagonal, the insert driving feature shall be tri-lobed but other tool features may vary depending upon the manufacturer prEN 3298:20066 D EBA 0,55 0,50 C Figure
25、2 Table 2 Dimensions in millimetres A B C D E Short insert Long insert 0,3 0,2 + 0,050 0,15 0,05 EN3236-050 EN3237-050 7,3 2,50 4,435 1,05 6,95 EN3236-060 EN3237-060 8,5 2,70 5,325 1,30 7,95 EN3236-070 EN3237-070 10,5 3,10 6,325 1,55 8,95 EN3236-080 EN3237-080 12,5 3,50 7,175 1,75 9,95 EN3236-100 EN
26、3237-100 16,0 4,20 9,015 2,25 11,95 For recommended drive tools, see Annex A, Table A.2. 6.3 Swage tools Table 3 gives the tool dimensions related to insert diameter code to ensure the correct tool size is used for swaging the insert into the component. Figure 3 shows an example of the swage tool co
27、nfiguration. The swage tool has a protective nylon washer, see Figure 3, which acts as a stop during the swaging operation and helps to protect the surface of the component from damage. This must be replaced when dimension “Fmax.“ is exceeded. The use of incorrect tools will cause damage to the inse
28、rt and surrounding material and may also cause the flange(s) of the component to be distorted. prEN 3298:20067 F GH1 2 32,5 1,5 Key 1 Shape optional 2 Rad. J 3 Nylon stop washer (Replaceable) Figure 3 Table 3 Dimensions in millimetres F G H Rad. J Short insert Long insert + 0,1 0 0,015 0,015 0,25 EN
29、3236-050 EN3237-050 2,255 5,975 3,775 0,65 EN3236-060 EN3237-060 2,455 6,995 4,575 0,80 EN3236-070 EN3237-070 2,655 8,005 5,575 1,00 EN3236-080 EN3237-080 3,055 9,025 6,275 1,00 EN3236-100 EN3237-100 3,755 11,085 7,775 1,15 For recommended swage tool numbers, see Annex A, Table A.3 and Table A.4. 7
30、Installation procedure 7.1 Insertion Screw the insert into tapped hole in a clockwise direction using the appropriate drive tool selected from Table 2 (Figure 2) until the insert is 0,40 mm to 0,65 mm (for manual installation) or 0,50 mm to 0,65 mm (for power tool installation) below surface of pare
31、nt metal as shown in Figure 4. Check that the insert is flush with or just below the bottom of the chamfer. Due to the configuration of the inserts, they may be “crimped” externally into an elliptical shape by the manufacturer to achieve the self-locking effect on the internal thread. This may make
32、the insert a tight fit into the tapped hole and it may be necessary to apply additional torque. This shall be only up to a maximum of prEN 3298:20068 0,5 Nm using hand pressure only. If the insertion force is high it has been found to be beneficial to run a tap into the tapped hole that is at the up
33、per end of the tolerance range (e.g., a GH 5 tap as designated in the USA). 2 1 23 4Key 1 Insert installation depth before swaging for manual tools: 0,400,65mm for power tools: 0,500,65mm (see clause 6 for after swage inspection) 2 Serrations in counterbore of hole Key 2 Serrations in counterbore of
34、 hole 3 Serrations on insert 4 Line up serrations between Insert and counterboredhole to provide “best fit” Figure 4 Figure 5 7.2 Insert alignment prior to swaging Before swaging the insert ensure the mating component is well supported, especially in the area the inserts are installed Where a serrat
35、ed counterbore is used, i.e. with the short inserts EN 3236 series in titanium, nickel and steel alloys, it is essential that the insert serrations line up to provide “best fit” with the counterbore serrations whilst maintaining the 0,40 mm to 0,65 mm installation depth below the surface of the pare
36、nt metal (see Figures 4 and 5). Where possible use 10 1 magnification plus illumination as an aid for fitting and inspection. In some installations, the quality of the serrations may be better defined on one side of the counterbored hole than the other. In these cases, the insert serrations shall be
37、 aligned with the better-defined serrations on the hole to obtain the “best fit”. prEN 3298:20069 7.3 Swaging To swage and lock insert in place apply sufficient force to the appropriate swage tool selected from Table 3 (Figure 3) using one of the following methods. First preference for swaging of in
38、serts shall be power tooling (a list of approved power swaging tools is shown in Annex A), but where this is not practical manual swaging may be used, i.e. hammer or mechanical press. The insert is correctly swaged and locked when the gauging criteria shown in 7.4 and Figure 6 is achieved. During th
39、e swaging operation care must be exercised to ensure no unwarranted force is used, which could cause damage to the component into which the insert is being installed. If difficulty is experienced with the removal of the swage tool after swaging, its release may be assisted by a very gentle rocking a
40、ction, care being taken not to cause cracking to the insert or damage to the parent component. Removal may be particularly difficult when inserts have been swaged into a non pre-broached hole, i.e. those assembled into light alloy components Key 1 When using manual swaging, inserts should be effecti
41、vely installed when the replaceable washer face touches the parent component surface; this is not applicable with power tooling. In both instances the correct swaging shall be confirmed by inspection using correct after swaging gauge, see 7.4. 2 Replaceable washer Figure 6 Swaging of insert Figure 7
42、 After swage dimensions B A 1 2 prEN 3298:200610 7.4 After swage inspection After the insert has been swaged, the swaged insert shall conform to the dimensional requirements of Figure 7 and Table 4. Inserts installed using a power tool will exhibit tooling steps caused by the split swaging jaws. The
43、 dimensional requirements “A” and “B” shall be inspected using one of the after swage checking gauges specified in Table 4 and shown in Figure 8, inserts installed using the power tooling will need to be inspected using the power tool after swage gauge (this gauge can also be used to inspect inserts
44、 installed by manual methods). When inserts are installed into non-standard counterbored holes, special checking gauges shall be required to check correct installation. No Go GoFigure 8 After swage checking gauge Table 4 After swage checking dimensions and gauge part numbers Dimensions in millimetre
45、s Short inserts Long inserts A min. B depth min. EN3236-050 EN3237-050 5,860 2,08 EN3236-060 EN3237-060 6,875 2,28 EN3236-070 EN3237-070 7,890 2,48 EN3236-080 EN3237-080 8,905 2,88 EN3236-100 EN3237-100 10,965 3,58 For recommended after swage checking gauge numbers, see Annex A, Tables A.5 and A.6.
46、After swaging, inspect the insert and surrounding metal for damage. Flaking or damage to the silver coating is permitted in the counterbore of the insert only, however, any loose flakes of silver shall be carefully removed and shall not be permitted to contact the surfaces of the parent component. T
47、he insert thread shall be checked for damage, which may have occurred during swaging, by using the correct sized thread mandrel or bolt (see Table 1 for bolt thread diameter). This shall be screwed into the insert by hand only until resistance is felt from the integral locking element and then remov
48、ed. If difficulties are experienced with starting the threaded mandrel or bolt into the insert, on no account shall the internal thread be cleaned out with a threaded tap. The insert shall be removed (see clause 8) and a new insert fitted (see clause 7). If, after swaging and inspecting, it is neces
49、sary to remove the insert, this shall be carried out in accordance with clause 8. prEN 3298:2006 11 7.5 Inspection for minimum locking torque The minimum self locking torque for the installed insert shall conform to Table 5 and shall be checked using the torque test mandrel as specified in Figure 9 and Table 5; alternatively a standard aero engine bolt manufactured from INCO 718 material, selected such that its pitch diameter is within the lower part of the tolerance band (see Table 6) may be used. The t
