1、STD-AECflA PREN 39Lb-ENGL 11999 IBg 1012311 0046494 O58 AECMA STANDARD prEN 3926 NORME AECMA Edition P 1 AECMA NORM September 1999 PUBLISHED BY THE EUROPEAN ASSOCIATION OF AEROSPACE INDUSTRIES (AECMA) Gulledelle 94 - 8-1200 BRUXELLES - Tel. (+32) 2 775 8110 - Fax. (+32) 2 775 81 11 ICs: 49.030.99 Ed
2、ition approved for publication Descriptors: aircraft industry, joining adaptor C8 Chairman Comments should be sent within six months after the date of publication to ENGLISH VERSION Aerospace series Insert, thin wall Salvage procedure for components Srie arospatiale Douilles filetes, a paroi mince P
3、rocdure pour rcupration Luft- und Raumfahrt Gewindeeinstze, dnnwandig Verfahren fr Nacharbeit von Bauteilen This “Aerospace Series“ Prestandard has been drawn up under the responsibility of AECMA (The European Association of Aerospace Industries). It is published on green paper for the needs of AECM
4、A-Members. It has been technically approved by the experfs of the concerned Technical Committee following comment by the Member countries. Subsequent to the publication of this Prestandard, the technical content shall not be changed to an extent that interchangeability is affected, physically or fun
5、ctionally, without re-identification of the standard. Affer examination and signature of the AECMA Standard Checking Centre (NPS) and formal agreement of the Official Services of the Member countries it will be submitted as a draft European Standard to CEN (European Committee for Standardization) fo
6、r formal vote. 1999-09-30 AECMA Guiledelie 94 8-1200 BRUXELLES Mr Feltham aecma 1999 STD*AECMA PREN 37Lb-ENGL I979 LOL23LL OOLb495 T74 Page 3 prEN 391 6: 1999 I Scope 1 .I thin wall inserts. within assemblies. This specification covers the accepted methods for the reclamation of installation holes f
7、or standard 1.2 hole, or to rectify any out of position of the hole within the specified parameters of use. To enable rectification when defects or damage occur to the standard insert tapped installation 1.3 replacement oversize thinwall insert. To control there machining of the existing insert hole
8、 and the installation requirements of the 2 Normative references IS0 965-1 IS0 general purpose metric screw threads - Tolerances - Part 1 : Principles and basic data IS0 5855-2 Aerospace - MJ threads - Part 2: Limit dimensions for bolts and nuts EN 3913 Aerospace series - Insert, thin wall, self-loc
9、king, short, in heat resisting nickel base alloy NI-PH2601 (NI-PIOOHT, Inconel 718), silver plated on internal thread, for salvage of components 1) EN 3914 Aerospace series - Insert, thin wall, self-locking, long, in heat resisting nickel base alloy NI-PH2601 (NI-PIOOHT, Inconel 718), silver plated
10、on internal thread, for salvage of components 1) EN3915 Aerospace series - Insert, thin wall, self-locking, Mj threads, in heat resisting nickel base alloy NI-PH2601 (NI-PI OOHT, Inconel 71 8), for salvage of components - Classification: 1 275 MPa (at ambient temperature) / 550 “C - Technical specif
11、ication 1) 3 Conditions of use 3.1 Engineering Drawings. After reclamation, assemblies shall conform to the dimensional requirements of their respective 3.2 Table 1 shows the values for the maximum out of position as applied to the theoretical centreline of the original hole. In practice this is a c
12、ylinder of diameter x,xx applied down the theoretical centreline of the original hole. If the actual position of the hole centreline falls outside the perimeter of this cylinder the hole cannot be reclaimed. 3.3 been used in the original design. (See EN 3676, Table 6). Salvage using oversize inserts
13、 is only possible if the Boss thickness for component salvage has 1) Published as AECMA Prestandard at the date of publication of this standard. Prcvious page is blank 3.4 The reclamation facility shall at this stage investigate the component Engineering Drawings to check that the operations detaile
14、d and controlled by sections 4 and 5 will not cause a further non conformance of the component. Standard insert internal thread size I 3.4.1 Table 2 demonstrates that 2 types of oversize insert can be used ie long or short. Before commencing reclamation the original Engineering Drawings shall be che
15、cked to establish which type of standard insert has been used e: long or short. The replacement oversize insert and accompanying dimensions from this specification shall correspond with it, je: short for short, long for long. I Maximum out of position of the original hole (regardless of feature size
16、) 3.4.2 conformance occurring to the oversize insert hole cannot be rectified using this method. Only 1 reclamation is possible using the oversize insert method for any one hole. Further non M J 5x0,8-4 H6H M JGxI -4H5H 3.5 Performance 0 0,5 0 0,5 It should be noted that the salvage inserts conformi
17、ng with EN 391 5 give I O reuses at 550 OC. MJ8xl-4H5H MJI01,25-4H5H Table 1 0 0,5 0 0,5 Dimensions in mm 4 Re-machining of an existing insert hole 4. i aligned cutter (see Figure 1). The existing threaded portion of the insert hole shall be completely removed by using a correctly 4.2 The cutter use
18、d shall enable the modified minor diameter B listed within Table 3 to be produced. 4.3 The old counterbore and serrations will be removed when the new counterbore is machined. 4.4 new oversize insert hole is machined in its correct position, see paragraph 3.2 and Table I. In the case of the original
19、 insert hole being out of position, the manufacture shall ensure that the STD-AECMA PREN 39Lb-ENGL 1999 a$I LOL231L 00Lb497 67 m Page 5 prEN 3916: 1999 Example Figure I 5. Insert and tapped hole particulars 5.1 and insert lengths. Table 2 provides details of the oversize insert part numbers in relat
20、ion to the bolt thread diameter Table 2 Dimensions in rnm STDaAECMA PREN 391b-ENGL 1999 a LO123Ll 00Lb496 7T3 m Page 6 prEN 3916: 1999 Thread Minor B Hoe Length Associated bolt code a thread A max. min. diameter code 050 M J5xO18-4h6h MJ9xl,0-4H5H 82 8,1 L S L S L S L S L S 060 MJ61,0-4hGh MJ101,0-4
21、H5H 9,24 9,11 070 MJ7x1,0-4h6h MJIIx1,0-4H5H 10,29 10,16 080 MJ81,0-4h6h MJ121,0-4H5H 11,29 11,16 1 O0 MJl01,25-4h6h MJ141,0-4H5H 13,32 13,17 5.2 thinwall inserts. Table 3 and Figure 2 provide the necessary information for tapped holes to receive oversize C max. min. 9,l 9,o 10,13 10,O 11,13 11,0 12
22、,13 12,O 14,15 14,O The counterbore depth DI applies when oversize inserts are to be installed into light alloy components and prebroaching is not required. Counterbore depth D2 (refer to Table 4 and Figure 3) applies when oversize inserts are to be installed into hard materials, ie steels, nickel a
23、nd titanium alloys, and the counterbore will need to be prebroached. Hoe diameter code 050 Table 3 DI D2 Chamfer G H M +0,13 +0,13 max. min. rt 0,25 L 2,59 14,8 17,951 10,03 S 2,97 9,25 12,4 Length code a 080 1 O0 L 3,OO 218 24,95 S 3,38 14,40 17,6 L 3,51 15,06 26,5 29,65 S 3,89 17,80 21,O 13,OO I 0
24、70 w 12,04 1- Length code L for long inserts (EN 3914 series), Code S for short inserts (EN 3913 series). Modified Minor diameter See paragraph 5.2. STD.AECMA PREN 3316-ENGL 1939 81111 L0123LL 00Lb439 b3T II Page 7 prEN 3916: 1999 Major diameter of 14 0 0,15 120“ 2 ; A Nlillll lG IH 4 MJlOx1,O 4H5H
25、MOD MINOR DIA 9,11 TO 9,2& SEE PARA 5.3 W_A#PLE TiKEAO DIAMETER A MODIRED MINOR DIA THREAO CALL OUT:- FOR ALL OttiER PARTICULARS AND TITANIUM REFER ?O PARENT DRAWING 2,OO HIN AFTER FINA WACHINIMG, SEE PARA 3.3. THREAD PITCH DIA Figure 2 5.3 Table 4 and Figures 3 and 4 give the additional information
26、 required to produce the serrations in the counterbore for steel, nickel and titanium alloys. Serrations are required in the counterbore when oversize inserts are to be used in harder materials. These serrations are produced using a special broaching tool. Thread pitch 0 M to be broached in counterb
27、ore using a wobble broach with the cutting tool offset by 1“ to the broaching tool body a See paragraph 5.2. Figure 3 Hole serration profile (short inserts) Table 1 Figures I and 2 provide details of the insert part number and associated bolt thread in relation to the serration profile in the counte
28、rbore of the installation hole. Page 8 STDeAECMA PREN 391b-ENGL 1999 W 1012311 001b500 LB1 prEN 391 6: 1999 AE“ Table 4 Dimensions in mm I l i L Number of max. I min. max. serrations J R2 Short Dimensions Associated bolt thread 1 inserts I AA I AB I AC I AD MJ5x0,8 MJ6xl MJ7xl MJ8xl MJ101,25 EN 3913
29、-050 0,41 9,55 9,34 0,13 EN 3913-060 0,28 10,54 10,29 EN 3913-070 0,25 11,56 11,32 0,lO EN 3913-080 12,552 12,29 0,27 EN 3913-100 14,58 14,36 Senation form at mir position my vw dw fo bro.ch wear. 114,5 2,59 2,33 82,O 3 2,74 83,O 3 2,74 83,3 3 2,74 84,O 3,51 3,25 I I 27 28 0,25 32 33 40 Figure 4 6 I
30、nstallation of oversize inserts 6.1 6.1.4 the oversize insert, are free from burrs and any foreign particles, grease, oil, etc. P re instal lation requirements Prior to installation check that the tapped hole, counterbore and serrations (if applicable) to receive 6.1.2 Oversize inserts to be install
31、ed in aluminium or magnesium components shall be lightly smeared externally with a suitable universal jointing compound to prevent electrolytic corrosion. Care shall be taken to ensure the internal thread of the insert is not contaminated with any compound used. The relevant drying period shall be o
32、bserved before installation of the oversize insert, when applying these requirements. 7 Minimum criteria for the installation and removal tools and their methods of application 7.1 The tooling and their methods of application described in this specification only show the basic principles to be obser
33、ved to achieve the satisfactory assembly and subsequent swaging or removal of the oversize thinwall inserts, and are not mandatory. STDDAECMA PREN 39Lb-ENGL 1999 11111 1012311 0016501 018 Page 9 prEN 3916: 1999 7.2 The minimum dimensional requirements provided shall be achieved, and on no account sh
34、all the design of the tools or their methods of application, be such that damage may occur to the threads or the locking element of the oversize thinwall insert, or the component into which they are being inserted. 7.3 Always ensure the appropriate tool/insert size combinations have been chosen for
35、either the insertion or swaging of the oversize insert to ensure the inserts correct assembly. (See 8.2 and 8.3 respectively ). 7.4 During the swaging operation the component into which the oversize inserts are installed shall be adequately supported to ensure no flexing or distortion occurs at the
36、insert assembly face. This particularly applies to components which are prone to flexing. 8 Assembly drive tool and swage tool 8.1 inserts are only examples and are not mandatory. The tools and methods shown in this section for the installation, swaging and removal of thin wall 8.2 dimensions to ens
37、ure the correct tool size is used for screwing the oversize insert into the tapped hole. The driving feature will be tri-lobed but other tool features may vary depending on manufacturer. Figure 4 shows an example of the drive tool configuration and Table 5 gives the relevant tool I x (INT) Figure 4
38、Table 5 Dimensions in mm I I I I I I l Short insert Long insert X Y N P part number part number k 0,4 f 0,4 f 0,125 0,15 EN 3913-050 EN 3914-050 7,3 4,435 I ,O5 I EN 3913-060 I EN 3914-060 I 8,5 I 2,7 I 5,325 I 1,30 I I EN 3913-070 1 EN 3914-070 I 10,5 I 3,lO I 6,325 I 1,55 I EN 3913-080 EN 3914-080
39、 123 3,50 7,175 1,75 EN 391 3-1 O0 EN 391 4-1 O0 16,O 9,015 2,25 Page 10 STD-AECMA PREN 371b-ENGL 1797 LOL2311 0036502 T54 prEN 391 6: 1999 Short incerf Long insert part number pait number 8.3 dimensions to ensure the correct tool size is used for swaging the oversize insert into the parent componen
40、t. Figure 5 shows an example of the swage tool configuration and Table 6 gives the relevant tool OQ R OQ Rad S -r 0,015 rt 0,175 f 0,25 8.3.1 The swage tool has a protective nylon washer, see Figure 5, which acts as a stop during the swaging operation and helps protect the surface of the component f
41、rom damage, this must be replaced when dimensions R Max is exceeded. EN 3913-070 EN 3913-080 EN 3913-100 8.3.2 also cause the flange(c) of the components to be distorted. The use of incorrect tools may cause damage to the oversize insert and parent material and may EN 3914-070 10,085 2,145 10,22 0,7
42、5 EN 3914-080 10,895 2,245 11,27 0,75 EN 3914-100 13,015 2,295 13,25 I ,o0 R (i NTERSECTION 1 SHAPE OPTION REPLAE E ABLE NY LON 5 TO? Figure 5 I EN 3913-050 I EN 3914-050 I 7,915 I 1,895 I 8,02 I 0,65 1 I EN 3913-060 I EN 3914-060 I 8,965 1 2,045 I 9,065 I 0,75 I 9 Assembly procedure 9.1 Insertion S
43、crew the oversize insert into the tapped hole in a clockwise direction using the appropriate drive tool selected from Table 5 until the insert is 0,4 to 0,65 mm below the surface of the parent metal, see Figure 6. 1 DRIVE TOOL 0,65mm 0,45rnrn Figure 6 9.2 Swaging 9.2.1 the area the inserts are to be
44、 installed. Before swaging the oversize insert ensure the mating component is well supported, especially in 9.2.2 Care shall be taken to ensure that when a serrated counterbore is used, ie with short oversize inserts (EN 3913 series) in titanium, nickel and steel alloys, the external serrations on t
45、he insert line up with the serrations in the counterbore (see Figure 7), whilst maintaining the 0,4 to 0,65 mm installation depth below the surface of the parent metal (see Figure 6). 9.2.3 To swage and lock insert in place, apply sufficient force to the appropriate swage tool selected from Table 6
46、by either mechanical or manual means until the nylon stop washer of the tool contacts the surface of the component. The insert should now be correctly swaged and locked (see Figure 8). STD-AECMA PREN 3916-ENGL $999 111 1012311 001b504 827 .I Page 12 prEN 3916: 1999 9.2.4 could cause damage to the co
47、mponent. During the swaging operation care shall be taken to ensure unwarranted force is not used which SERR4TIDNS IN HATING HOLE -7 Figure 7 IONS ON 1 I rswAGE *OoL -SWAGED ARA Figure 8 9.3 Gauging and inspection 9.3.1 After the oversize insert has been swaged and the nylon stop washer has contacte
48、d the work surface, the swaged insert shall conform to the dimensional requirements of Figure 9 and Table 7. These requirements shall be checked using an appropriate swage checking gauge. 9.3.2 After swaging, inspect the oversize insert and surrounding metal for damage. Any flaking or damage to the
49、silver coating is permissible only within the counterbore. However, any loose flakes of silver shall be carefully removed and shall not be permitted to contact the parent component, surfaces. 9.3.3 The oversize insert thread shall now be checked for damage which may have occurred during swaging by using the correctly sized thread mandrel or bolt. This shall be screwed into the insert by hand only until resistance is felt by the integral locking element and then removed. If difficulties are experienced with starting the threaded mandrel or bolt in
