1、BRITISH STANDARD AEROSPACE SERIES BS EN 4015:2004 Inserts, thickwall, self-locking Installation and removal procedure The European Standard EN 4015:2004 has the status of a British Standard ICS 49.030.30 BS EN 4015:2004 This British Standard was published under the authority of the Standards Policy
2、and Strategy Committee on 16 December 2004 BSI 16 December 2004 ISBN 0 580 45114 3 National foreword This British Standard is the official English language version of EN 4015:2004. It supersedes BS EN 4015:2003 which is withdrawn. The UK participation in its preparation was entrusted to Technical Co
3、mmittee ACE/12, Aerospace fasteners and fastening systems, which has the responsibility to: A list of organizations represented on this committee can be obtained on request to its secretary. Cross-references The British Standards which implement international or European publications referred to in
4、this document may be found in the BSI Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Search” facility of the BSI Electronic Catalogue or of British Standards Online. This publication does not purport to include all the necessary provisions of a
5、contract. Users are responsible for its correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. aid enquirers to understand the text; present to the responsible international/European committee any enquiries on the interpretation, or proposa
6、ls for change, and keep the UK interests informed; monitor related international and European developments and promulgate them in the UK. Summary of pages This document comprises a front cover, an inside front cover, the EN title page, pages 2 to 14, an inside back cover and a back cover. The BSI co
7、pyright notice displayed in this document indicates when the document was last issued. Amendments issued since publication Amd. No. Date Comments EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 4015 November 2004 ICS 49.030.30 Supersedes EN 4015:2003 English version Aerospace series - Inserts,
8、thickwall, self-locking - Installation and removal procedure Srie arospatiale - Douilles filetes, paroi renforce, freinage interne - Procdure dinstallation et dextraction Luft- und Raumfahrt - Gewindeeinstze, dickwandig, Selbstsichernd - Ein- und Ausbauverfahren This European Standard was approved b
9、y CEN on 11 September 2003. CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national st
10、andards may be obtained on application to the Central Secretariat or to any CEN member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified
11、to the Central Secretariat has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands,
12、 Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG Management Centre: rue de Stassart, 36 B-1050 Brussels 2004 CEN All rights of exploitation in any form an
13、d by any means reserved worldwide for CEN national Members. Ref. No. EN 4015:2004: E EN 4015:2004 (E) 2 Contents Page Foreword3 1 Scope 4 2 Normative references 4 3 Insert information 4 4 Broaching .5 5 Hole serration profile.7 6 Inspection requirements before installation.8 7 Installation tools 8 8
14、 Checks of insert position and crimping 11 9 Inspection of minimum self-locking torque12 10 Insert removal 13 11 Repair14 EN 4015:2004 (E) 3 Foreword This document (EN 4015:2004) has been prepared by the European Association of Aerospace Manufacturers - Standardization (AECMA-STAN). After enquiries
15、and votes carried out in accordance with the rules of this Association, this Standard has received the approval of the National Associations and the Official Services of the member countries of AECMA, prior to its presentation to CEN. This European Standard shall be given the status of a national st
16、andard, either by publication of an identical text or by endorsement, at the latest by May 2005, and conflicting national standards shall be withdrawn at the latest by May 2005. This document supersedes EN 4015:2003. According to the CEN/CENELEC Internal Regulations, the national standards organizat
17、ions of the following countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Sloven
18、ia, Spain, Sweden, Switzerland and United Kingdom. EN 4015:2004 (E) 4 1 Scope This standard specifies the conditions of installation and removal procedure (hole serration profile, tools, swaging) of self-locking thickwall inserts defined by EN standards, for aerospace applications. 2 Normative refer
19、ences The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 3831, Aerospace series Inserts, thickwal
20、l, self-locking, MJ threads, in heat resisting steel FE-PM3801 (17-4PH), MoS 2coated EN 4014, Aerospace series Inserts, thickwall, self-locking Design standard3 Insert information Tables 1 and 2 provide the cross reference between the insert codification, the related bolt thread and the tapped hole
21、diameter. Table 1 Normal size insert Insert reference Bolt thread diameter Tapped hole diameter Tapped hole reference EN3831-050-0 MJ50,8 MJ81 EN4014-050-0 EN3831-060-0 MJ61 MJ91 EN4014-060-0 EN3831-070-0 MJ71 MJ101 EN4014-070-0 EN3831-080-0 MJ81 MJ111 EN4014-080-0 EN3831-100-0 MJ101,25 MJS131 EN401
22、4-100-0 Table 2 First repair size insert Insert reference Bolt thread diameter Tapped hole diameter Tapped hole reference EN3831-050-1 MJ50,8 MJ91 EN4014-050-1 EN3831-060-1 MJ61 MJ101 EN4014-060-1 EN3831-070-1 MJ71 MJ111 EN4014-070-1 EN3831-080-1 MJ81 MJ121 EN4014-080-1 EN3831-100-1 MJ101,25 MJ141 E
23、N4014-100-1 EN 4015:2004 (E) 5 4 Broaching 4.1 In materials with R m 900 MPa Figure 1 illustrates an example of hand broaching tool which may be used in materials with a strength of R m 900 MPa. Table 3 gives dimensions of the broach. Dimensions in millimetres Key 1 J, number of teeth 2 mandrel 3 nu
24、t backed off 4 turn clockwise to remove cutter. 5 stop 6 pin up 7 mandrel stops here 8 pin down 9 body 10 cutter up 11 pilot 12 broaching complete 13 tap drill hole 14 load 15 cutter up 16 view enlarged cutter up Figure 1 EN 4015:2004 (E) 6 Table 3 Dimensions in millimetres A B C E F H L R 1Tapped h
25、ole reference Ref. + 0,06 + 0,02 0,03 Ref. Ref. + 0,1 0 J Number of teeth Ref. max. EN 4014-050-0S 8,53 4 9,37 18 6,8 4,1 24 82 0,15 EN 4014-060-0S EN 4014-050-1S 9,50 10,36 7,8 4,2 27 84 EN 4014-070-0S EN 4014-060-1S 10,49 5 11,28 20 8,8 4,6 28 85 EN 4014-080-0S EN 4014-070-1S 11,47 12,32 21 9,8 4,
26、7 32 87 EN 4014-080-1S 12,73 13,57 22 10,8 33 88 EN 4014-100-0S 13,46 6 14,30 23 11,8 5,1 37 EN 4014-100-1S 14,55 7 15,39 24 12,8 5,3 40 90 0,2 4.2 In materials with R m 900 MPa Figure 2 illustrates an example of a machine broaching tool which may be used in materials with a strength of R m 900 MPa.
27、 Table 3 gives dimensions of the broach. Dimensions in millimetres Key 1 J, number of teeth 2 wobbling drift holder 3 broach 4 tool Figure 2 EN 4015:2004 (E) 7 5 Hole serration profile Table 4 and Figures 3 and 4 provide details of the insert part number and associated bolt thread in relation to the
28、 serration profile in the counterbore of the installation hole. Table 4 Dimensions in millimetres K Tapped hole reference Tapped hole diameter Nominal diameter (Associated bolt) AB AC J Number of teeth max. min. EN 4014-050-0S MJ81 MJ5 8,42 8,02 24 2,6 2 EN 4014-060-0S MJ6 EN 4014-050-1S MJ91 MJ5 9,
29、39 8,99 27 2,7 2,1 EN 4014-070-0S MJ7 EN 4014-060-1S MJ101 MJ6 10,389,98 28 3 2,4 EN 4014-080-0S MJ8 EN 4014-070-1S MJ111 MJ7 11,3610,96 32 3,2 2,6 EN 4014-080-1S MJ121 MJ8 12,6212,22 33 EN 4014-100-0S MJS131 13,35 12,95 37 3,6 3 EN 4014-100-1S MJ141 MJ10 14,4514,05 40 3,8 3,2 Dimensions in millimet
30、res Key 1 major diameter of serration 2 pitch diameter 3 thread Figure 3 Figure 4 EN 4015:2004 (E) 8 6 Inspection requirements before installation Prior to installation check the installation hole, counterbore and serration (when applicable) to receive the insert are free from burrs and any foreign
31、objects, grease, oil, etc. Inspect insert to be installed and ensure that it is clean and free from protective grease, etc. Inserts installed in aluminium or magnesium alloy components shall be lightly smeared externally with a suitable compound to prevent electrolytic corrosion. 7 Installation tool
32、s 7.1 General 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 ac
33、hieved 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 insert or the component into which it is being installed. Always ensure the appropriate tool/insert size combinations have been chosen for ei
34、ther the insertion or swaging of the insert to enable correct installation of the insert. 7.2 Drive tools for installation In order to facilitate the correct assembly of the inserts use the appropriate tools. EN 4015:2004 (E) 9 7.2.1 Air crimping tool 7.2.1.1 Configuration Dimensions Figure 5 illust
35、rates a type of tool for screwing, crimping and unscrewing that may be fitted to an air gun. Dimensions are given in Tables 5 and 6. Dimensions in millimetres Key 1 self-locking nut 2 body 3 plastic ring retainer 4 pin 5 plastic ring 6 mandrel Figure 5 Table 5 Dimensions in millimetres B C D E H L M
36、 Insert reference A Thread + 0,05 0 0 0,05 0,5 + 0,05 0 0 0,1 EN3831-050-0 MJ50,8 6,9 8 6 76 2,25 EN3831-060-0 MJ61 7,9 9 15 23 7 77 2,35 EN3831-070-0 MJ71 8,9 10 16 24 8 79 2,65 EN3831-080-0 MJ81 9,9 11 17 25 9 83 2,85 EN3831-100-0 MJ101,25 11,9 13 18 26 11 84 3,25 20 EN 4015:2004 (E) 10 Table 6 Di
37、mensions in millimetres B C D E H L M Insert reference A Thread + 0,05 0 0 0,05 0,5 + 0,05 0 0 0,1 EN3831-050-1 MJ50,8 7,9 9 15 23 7 76 2,25 EN3831-060-1 MJ61 8,9 10 16 24 8 77 2,35 EN3831-070-1 MJ71 9,9 11 17 25 9 79 2,65 EN3831-080-1 MJ81 11,9 13 18 26 11 83 2,85 EN3831-100-1 MJ101,25 12,9 14 19 2
38、7 12 84 3,25 20 7.2.1.2 Procedure Screw the insert to be crimped on to the thread mandrel until it is fully seated against the plastic ring retainer, the upper part of the tool set in the high position. Using the tool, screw the insert into the tapped hole until positioned; the screwing/crimping too
39、l comes into contact with the surface, when operating the air gun. The insert comes automatically in the crimping position: (0,3 to 0,5) mm below the surface of the casing. Use the air gun in the percussion mode to bring the upper part of the tool against the plastic ring retainer and initiate crimp
40、ing of the insert. Unscrew the crimping tool to extract it from the crimped insert. 7.2.2 Hand crimping tooling 7.2.2.1 Configuration For hand crimping, use the screwing/crimping/unscrewing tool defined in 7.2.1 (Figure 5) fitted with a sleeve (see Figure 6). 7.2.2.2 Procedure Screw the insert to be
41、 crimped on to the threaded mandrel until fully seated against the plastic ring retainer, the upper part of the tool set up to the high position. Screw the insert/threaded mandrel assembly into the tapped hole until the plastic ring contacts the surface. The insert is automatically positioned in the
42、 crimping position: 0,3 mm to 0,5 mm below the surface. Fit the sleeve to the crimping tool. Apply sufficient force in the direction indicated, until the upper part of the tool bears against the plastic ring retainer and the insert is crimped. Unscrew the crimping tool to extract it from the crimped
43、 insert. Key 1 sleeve 2 load Figure 6 EN 4015:2004 (E) 11 8 Checks of insert position and crimping These checks shall be carried out with and inspection gauge specific to each insert dimension, which shall be introduced inside the crimped counterbore (see Figure 7). Dimensions are given in Tables 7
44、and 8. Visual inspection of the crimped zone shall not reveal any cracks. Check of insert position Check of crimping Dimensions in millimetres Key 1 flush 2 chamfer 0,545 3 clear 4 acceptable 5 not acceptable NOTE N and G markings on the inspection gauge means respectively “Not GO” and “GO” Figure 7
45、 Table 7 Normal size insert Dimensions in millimetres A B C D E F G H S T Insert reference 0 0,1 0 0,05 0,5 0 0,05 0 0,05 0 0,1 0 0,05 0,25 0,25 EN3831-050-0 3,9 6,8 10 1,35 5,5 7,95 2,6 5,9 6 4 EN3831-060-0 4,7 7,8 11 1,45 6,7 8,95 2,7 6,9 6,5 4,5 EN3831-070-0 5,7 8,8 12 1,75 8,5 9,95 3 7,9 7 5 EN3
46、831-080-0 6,4 9,8 13 1,95 10,2 10,9 3,2 8,9 7,5 5,5 EN3831-100-0 7,9 11,8 15 2,35 12 12,9 3,6 10,9 8,5 6 20 EN 4015:2004 (E) 12 Table 8 First repair size insert Dimensions in millimetres A B C D E F G H S T Insert reference 0 0,1 0 0,05 0,5 0 0,05 0 0,05 0 0,1 0 0,05 0,25 0,25 EN3831-050-1 3,9 7,8 1
47、1 1,35 5,5 8,95 2,6 7,95 6 4 EN3831-060-1 4,7 8,8 12 1,45 6,7 9,95 2,7 8,95 6,5 4,5 EN3831-070-1 5,7 9,8 13 1,75 8,5 10,9 3 9,95 7 5 EN3831-080-1 6,4 10,8 14 1,95 10,2 12,9 3,2 10,9 7,5 5,5 EN3831-100-1 7,9 12,8 17 2,35 12 13,9 3,6 12,9 8,5 6 20 9 Inspection of minimum self-locking torque The minimu
48、m self-locking torque for the installed insert shall conform to Table 9 and shall be checked using a standard bolt (titanium), selected such that its pitch diameter is within the lower part of the tolerance band (see Table 9). Bolts shall not be lubricated. The test bolts shall be periodically check
49、ed for wear and damage, any bolt falling outside the tolerances in Table 9 shall not be used for this check. The sample size/frequency for this check shall be at the responsibility of the supplier of the installed inserts and the purchaser. Table 9 Dimensions in millimetres Part number Test bolt pitch diameter aSelf-locking torque Nm Associated bolt thread Normal size
