1、ASD STANDARD NORME ASD ASD NORM prEN 4619 Edition P 1 June 2008 PUBLISHED BY THE AEROSPACE AND DEFENCE INDUSTRIES ASSOCIATION OF EUROPE - STANDARDIZATIONAvenue de Tervuren, 270 - B-1150 Brussels - Tel. + 32 2 775 8126 - Fax. + 32 2 763 3565 - www.asd-stan.orgICS: Descriptors: ENGLISH VERSION Aerospa
2、ce series Inserts, MJ threads, self-locking, with self-broaching keys Installation and removal procedure Srie arospatiale Douilles filetes, filetage MJ, freinage interne, clavettes auto-brochantes Procdure dinstallation et dextraction Luft- und Raumfahrt Gewindeeinstze, MJ-Gewinden, selbstsichernd,
3、mit selbstrumenden Stiften 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
4、 technically approved by 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 standar
5、d. After examination and 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 E
6、N at national level by giving the EN the status of a national standard and by withdrawing any national standards conflicting with the EN. Edition approved for publication 30 June 2008 Comments should be sent within six months after the date of publication to ASD-STAN Mechanical Domain Copyright 2008
7、 by ASD-STAN prEN 4619:20082 Contents Page Foreword2 1 Scope 3 2 Normative references3 3 Insert information 3 4 Inspection requirements before installation.5 5 Installation tools 5 6 Checks of insert position and keys broaching.8 7 Inspection of minimum self-locking torque8 8 Insert replacement.9 Fo
8、reword This standard was 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 4619:20083 1 Sco
9、pe This standard specifies the installation and removal procedure (hole profile, tools) of self-locking, self-broaching key, MJ thread inserts defined by EN standards, for aerospace applications. 2 Normative references The following referenced documents are indispensable for the application of this
10、document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. ISO 5855-1, Aerospace MJ threads Part 1: General requirements. ISO 5855-2, Aerospace MJ threads Part 2: Limit dimensions for bolts
11、 and nuts. EN 4620, Aerospace series Inserts, self-locking, with self-broaching keys Design standard. 1)EN 4622, Aerospace series Inserts, MJ threads, self-locking, with self-broaching keys, in heat resisting steel FE-PA2601 (A286), MoS2coated. 1)EN 4623, Aerospace series Inserts, MJ threads, self-l
12、ocking, with self-broaching keys, in heat resisting nickel base alloy NI-PH2601 (Inconel 718), silver plated. 1)EN 4624, Aerospace series Inserts, MJ threads, self-locking, with self-broaching keys, in heat resisting nickel base alloy Ni-P100HT (Inconel 718), silver plating. 1)3 Insert information T
13、ables 1 to 3 provide the cross reference between the insert codification, the related bolt thread and the tapped hole diameter. 1) Published as ASD Prestandard at the date of publication of this standard. prEN 4619:20084 Table 1 Normal size insert Insert reference Bolt thread diameter a, bTapped hol
14、e diameter bTapped hole reference EN 4622-050-0 EN 4624-050-0 EN 4623-050-0 MJ50,8 MJ91-4H5H EN 4620-050-0 EN 4622-060-0 EN 4624-060-0 EN 4623-060-0 MJ61 MJ101-4H5H EN 4620-060-0 EN 4622-070-0 EN 4624-070-0 EN 4623-070-0 MJ71 MJ111-4H5H EN 4620-070-0 EN 4622-080-0 EN 4624-080-0 EN 4623-080-0 MJ81 MJ
15、121-4H5H EN 4620-080-0 EN 4622-100-0 EN 4624-100-0 EN 4623-100-0 MJ101,25 MJ141-4H5H EN 4620-100-0 aAccording to ISO 5855-2. bAccording to ISO 5855-1. Table 2 First repair size insert Insert reference Bolt thread diameter a, b Tapped hole diameter bTapped hole reference EN 4622-050-1 EN 4624-050-1 E
16、N 4623-050-1 MJ50,8 MJ101-4H5H EN 4620-050-1 EN 4622-060-1 EN 4624-060-1 EN 4623-060-1 MJ61 MJ111-4H5H EN 4620-060-1 EN 4622-070-1 EN 4624-070-1 EN 4623-070-1 MJ71 MJ121-4H5H EN 4620-070-1 EN 4622-080-1 EN 4624-080-1 EN 4623-080-1 MJ81 MJS131-4H5H EN 4620-080-1 EN 4622-100-1 EN 4624-100-1 EN 4623-10
17、0-1 MJ101,25 MJ151-4H5H EN 4620-100-1 aAccording to ISO 5855-2. bAccording to ISO 5855-1except MJS131 (see Table 4). prEN 4619:20085 Table 3 Second repair size insert Insert reference Bolt thread diameter a, bTapped hole diameter bTapped hole reference EN 4622-050-2 EN 4624-050-2 EN 4623-050-2 MJ50,
18、8 MJ111-4H5H EN 4620-050-2 EN 4622-060-2 EN 4624-060-2 EN 4623-060-2 MJ61 MJ121-4H5H EN 4620-060-2 EN 4622-070-2 EN 4624-070-2 EN 4623-070-2 MJ71 MJS131-4H5H EN 4620-070-2 EN 4622-080-2 EN 4624-080-2 EN 4623-080-2 MJ81 MJ141-4H5H EN 4620-080-2 EN 4622-100-2 EN 4624-100-2 EN 4623-100-2 MJ101,25 MJ161
19、-4H5H EN 4620-100-2 aAccording to ISO 5855-2. bAccording to ISO 5855-1 except MJS131 (see Table 4). Table 4 Dimensions in millimetres Major diameter Pitch diameter Minor diameter Thread Designation max. max. min. max. min. MJS131-4H5H 13,244 12,450 12,350 12,216 12,026 4 Inspection requirements befo
20、re installation Prior to installation check the installation hole to receive the insert are free from burrs and any foreign objects, grease, oil, etc. Inspect insert to be installed and ensure that it is clean and free from protective grease, etc. 5 Installation tools 5.1 General In order to facilit
21、ate the correct assembly of the inserts use the appropriate tools. It is necessary to use one tool by insert reference. 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 a
22、nd subsequent broaching and the satisfactory removal of the inserts. prEN 4619:20086 The maximum dimensional requirements provided shall be achieved and on 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
23、 insert or the component into which it is being installed. 5.2 Hand installation 5.2.1 Installation tool Figure 1 illustrates a combined tool used for hand screwing and hand broaching and its overall dimensions. Figure 1a and Table 5 give the overall dimensions. F2Key 1 Screwing nose 2 Broaching nos
24、e for keys setting Figure 1a Figure 1b Figure 1c Table 5 Dimensions in millimetres Insert external thread H L MJ91 14,3 MJ101 15,9 MJ111 14,3 MJ121 17,5 MJS131 17,5 MJ141 19,0 MJ151 20,6 MJ161 71 20,6 prEN 4619:2008 7 5.2.2 Procedure a) Lubricate the outer thread of the insert with the lubricant ref
25、erenced on the assembly drawing. Inserts installed in aluminium or magnesium alloy components shall be lightly smeared externally with a suitable compound to prevent galvanic corrosion if required on the assembly drawing. b) Fit into place and screw the insert by two turns into the component. c) Fit
26、 into place the screwing nose of the tool onto the keys, then screw the assembly into the threaded hole until the screwing nose mates the component surface as shown in Figure 1a. d) Adjust the insert position within the X limits given in Figure 3. e) Turn the tool on the broaching nose side as showe
27、d in Figure 1b. f) Apply a sufficient load in the direction indicated Figure 1c to broach the keys by stamping or by pressing on the tool. The keys are fitted in the proper position corresponding to Y dimension given in Figure 3. g) Remove the tool from the insert. h) Remove excess sealing compound
28、or lubricant if any. 5.3 Air pressure installation 5.3.1 Installation tool Figure 2 illustrates a tool for screwing, broaching and unscrewing assembled on an air pressure gun. The overall dimensions are given in Figure 2. Dimensions in millimetres 24360 2954 7613Key 1 Threaded mandrel 2 Interchangea
29、ble installation nose corresponding to the insert reference 3 Gun 4 600 kPa (6 bars) air pressure inlet Figure 2 prEN 4619:20088 5.3.2 Procedure The air pressure gun shall be previously adjusted in order to obtain the satisfactory installation of insert and of the keys as given in Figure 3. a) Lubri
30、cate the outer thread of the insert with the lubricant referenced on the assembly drawing. Inserts installed in aluminium or magnesium alloy components shall be lightly smeared externally with a suitable compound to prevent galvanic corrosion if required on the assembly drawing. b) Screw the insert
31、on to the threaded mandrel until it is fully seated against the installation nose. c) Using the tool, screw the insert into the tapped hole until positioned: The screwing/broaching tool comes into contact with the surface of the component, when operating the air gun. The insert comes in position as
32、shown in Figure 3 below the surface of the casing. d) Use the air gun in the percussion mode to broach the keys. e) Unscrewing is automatic to extract the tool from the crimped insert. f) Remove excess sealing compound or lubricant if any. 6 Checks of insert position and keys broaching These checks
33、shall be carried out with an inspection gauge common to all insert dimensions. Check dimensions X and Y which shall be in accordance with Figure 3. After broaching of keys, the component surface shall not show any distortion or cracks. Dimensions in millimetres 12X =0,130,75Y =0,250,75Key 1 Installa
34、tion depth of the keys 2 Installation depth of the insert Figure 3 7 Inspection of minimum self-locking torque The minimum self-locking torque for the installed insert shall conform to Table 6 and shall be checked using a low third pitch diameter passivated stainless steel test bolt (see Table 6). B
35、olts shall not be lubricated. The test bolts shall be periodically checked for wear and damage, any bolt falling outside the tolerances in Table 6 shall not be used for this check. The sample size/frequency for this check shall be at the responsibility of the installer. prEN 4619:2008 9 Table 6 Part
36、 number Test bolt pitch diameter Self-lockingtorque mm mm Nm Associated bolt thread Normal size insert First repair size insert Second repairsize insert max. min. min. MJ50,8 EN 4622-050-0 EN 4624-050-0 EN 4623-050-0 EN 4622-050-1EN 4624-050-1EN 4623-050-1 EN 4622-050-2EN 4624-050-2EN 4623-050-2 4,4
37、40 4,420 0,5 MJ61 EN 4622-060-0 EN 4624-060-0 EN 4623-060-0 EN 4622-060-1EN 4624-060-1EN 4623-060-1 EN 4622-060-2EN 4624-060-2EN 4623-060-2 5,303 5,279 0,7 MJ71 EN 4622-070-0 EN 4624-070-0 EN 4623-070-0 EN 4622-070-1EN 4624-070-1EN 4623-070-1 EN 4622-070-2EN 4624-070-2EN 4623-070-2 6,303 6,279 1,1 M
38、J81 EN 4622-080-0 EN 4624-080-0 EN 4623-080-0 EN 4622-080-1EN 4624-080-1EN 4623-080-1 EN 4622-080-2EN 4624-080-2EN 4623-080-2 7,303 7,279 1,4 MJ101,25 EN 4622-100-0 EN 4624-100-0 EN 4623-100-0 EN 4622-100-1EN 4624-100-1EN 4623-100-1 EN 4622-100-2EN 4624-100-2EN 4623-100-2 9,138 9,113 2,4 8 Insert re
39、placement 8.1 Insert removal When repairing, the self-broaching key inserts can be removed as follows: a) Drill using a diameter A drill to depth B as shown in Figure 4 and Table 7 or pilot spot facing cutter. Material may also be ground or milled away locally in the key area as shown in Figure 4, s
40、o that keys can be removed. or Key 1 Drill 2 Mill or grinder Figure 4 prEN 4619:200810 b) Deflect the keys inward to clear the tapped hole as shown in Figure 5. Figure 5 c) Unscrew the insert with the extraction tool as shown in Figure 6. Figure 6 d) After machining, remove the part fragments of the
41、 insert using the appropriate tool. Table 7 Dimensions in millimetres Tapped hole A B reference diameter max. max. EN 4620-050-0 MJ91 7,8 3,0 EN 4620-050-1 EN 4620-060-0 MJ101 8,8 3,1 EN 4620-050-2 EN 4620-060-1 EN 4620-070-0 MJ111 9,8 3,4 EN 4620-060-2 EN 4620-070-1 EN 4620-080-0 MJ121 10,8 3,6 EN
42、4620-070-2 EN 4620-080-1 MJS131 11,8 EN 4620-080-2 EN 4620-100-0 MJ141 12,8 4,0 EN 4620-100-1 MJ151 13,8 4,2 EN 4620-100-2 MJ161 14,8 4,5 prEN 4619:2008 11 8.2 Repair 8.2.1 General rules After removal of the insert, check for cleanliness of tapped hole and check tapped hole dimensions using a thread
43、ed plug gauge. If correct and damage free, it is possible to install a new insert of same part number. Otherwise install a repair size insert (first or second repair as applicable) if the design makes it possible (see EN 4620) following 8.2.2. When installing a new insert, the keys shall not be alig
44、ned with the housing of the previous insert keys. The dimensions specified in Figure 3 must be met. 8.2.2 First and second repair size installation First and second repair size part numbers and their installation and removal methods are given: Tables 2 and 3 respectively for first and second repair size part numbers selection; Figure 3 for the under-flushing of the insert and of the keys; See Clause 8 for the replacement of the insert.
