1、VND.NAVISTAR 1059-ENGL L999 131 b7444b5 0004340 818 W TRUCK MATERIAL SPECIFICATION Title Aluminum Tubing For Engine AirFluid Systems WRITTEN/EDITED BY APPROVED BY Materials Engineering Materials Engineering NAVISTAR INTERNATIONAL TRANSPORTATION CORP. NUMBER TMS-1059 C April 1999 RE VISION DATE ISSUE
2、D PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purpot? to address all of the safety issues associated with its use. The user is responsible to consult appropriate safet
3、y and health practices and to determine the applicability of regulatory limits prior to use. Change Notice: Reformatted and Editorial Chanages. Figure 5 is modified Reference: File 650-8 1.0 APPLICATION This specification covers aluminum tubing used in engine air intake and charge air cooler systems
4、 (CAC), with formed, beaded, or straight ends. 2.0 SCOPE This specification covers construction, material, design requirements and guidelines, tolerances and KCC, workmanship standards, and Quality Control and Source Approval. 2.1 Existing drawings for product covered by this specification may refer
5、 to Engineering Drawing AM-74447 or to TMS-1058 for workmanship standards, such references on existing drawings are superseded by this specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards applies. specifications, standards, and regulations a
6、re referenced herein. The following Quality System Standard QS-9000 (IS0 9001) Navistar NSR Quality Standard Navistar Engr. Design Std. A-16 Navistar Manufacturing STD D- 13 CFR-Title 40, Section 205 CFR-Title 29, Section 1910 Navistar Specification C- 1 O Navistar Spec. TMS-9528 AN SUA W S A2.4 ANS
7、I H35.2 4.0 GENERAL REQUIREMENTS 4.1 Construction 4.1.1 Engineering design (RPO) is generally based upon single piece construction, rather than cut and weld construction. The welding process adds extra cost and introduces distortion, which reduces the consistency and accuracy of alignment at the tub
8、e ends. Unless otherwise specified on This document is restricted and may not be sent outside Navictar International Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are rewired to assuine ali patent liability. 01 999 by Navistar International Tranmortation
9、Corp. APRIL 1999 Page 1 of 12 COPYRIGHT International Truck and Engine Corporation (formerly NAVISTAR)Licensed by Information Handling ServicesNUMBER: TITLE: TMS-1059 Aluminum Tubing For Engine Air/Fluid Systems the engineering drawing or purchase order, the use of cut and weld construction shall re
10、quire engineering approval. RE VISION: C 4.1.2 In many cases tubing used in the air intake and/or charge air systems are parts of the truck system which are required to meet Federal Noise Regulations (CFR-Title 40, Section 205). All such applications shall be so indicated on the engineering drawing
11、or blueprint, and in these applications no deviations in construction and/or material shall be permitted without prior engineering approval. 4.2 Material Aluminum Tubing: Shall be seamless drawn, extruded, or welded tube at the option of the tubing fabricator. Tubing shall meet dimensional requireme
12、nts of ANSI H35.2 4.2.1 Material: Shall be 3003, or 6061, or 6063 aluminum as per Navistar Specification C-10. 4.2.2 Temper: The tubing fabricator is responsible to select a temper suitable for fabrication which will also meet all requirements of this specification. 4.3 Dimensional Tolerances: Unles
13、s otherwise specified, the dimensional tolerances shown in Figs. 1 thru 10 of this specification shall apply to fabricated tube and tube assemblies, and the standard dimensional tolerances shown in the title block of the Navistar Engineering drawing are not applicable. 4.3.1 Tubing Gauge or Wall Thi
14、ckness: Tubing thickness (gauge) shall be shown on the engineering drawing. Normal practice is to use 14 gage tube, nominally 0.083 inch thickness which is generally shown on the drawing as 0.078 inch. 4.4 Welding Weld symbols shown on engineering drawings and blue prints are in accordance with ANSU
15、AWS A2.4. Sizes of fillet/groove welds shown on the engineering drawing are minimum values. All welds on fabricated tube shall be neat and continuous with a minimum of flash and/or weld spatter. No weld spatter is permitted on flange sealing surfaces. Welded pipeshubing shall show no leakage when pr
16、essure-tested at 25 psi (min) pressure. 4.5 Workmanship 4.5.1 Unless otherwise specified, contour of the pipeskube is to be maintained to provide f 0.25 inch location of the end points with the layout. Intermediate points shall be located within f 0.25 inch. Bend radii to be within f 0.25 inch. See
17、Figures 2 and 3. 4.5.2 Wrinkles in or adjacent to bends shall not exceed 0.030 inch depth on pipeshbes up to 3.0 inch OD (inch) and shall not exceed 0.040 inch depth on larger OD pipedtubes. This document is restricted and may not be sent outside Navistar International Corporation or reproduced with
18、out permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. O 1999 by Navistar International Transportation Corp. APRIL 1999 Page 2 of 12 COPYRIGHT International Truck and Engine Corporation (formerly NAVISTAR)Licensed by Information Handling ServicesNUM
19、BER: TMS-1059 4.5.3 Reduction of the OD in bend areas shall conform to limits shown in chart #1 and Fig. 3. TITLE: REVISION: Aluminum Tubing For Engine Air/FLuid Systems C 4.5.4 There shall be no severe scratches or tool marks on the pipekube. All product supplied to the requirements of this specifi
20、cation shall be free of rust, stains, oil, dirt, metal chips, grease, etc . and shall be clean and dry to the touch. When specified on the engineering drawing the pipe shall meet cleanliness requirements and when so specified the ends of the pipe shall be capped to prevent contamination in shipment
21、and/or storage. 5.0 KCC - KEY CONTROL CHARACTERISTICS - GENERAL APPLICATION One KCC value (minimum) should be designated on each new drawing released by Engineering in accordance with provisions of Navistar Engineering Design Standard A- 16. Engineering should consult with the supplier to assure sel
22、ection of appropriate KCC values prior to release of the Engineering drawing/blue print. KCC values shall be incorporated in the Quality Control Plan for each part as features for which management by statistical process control is mandatory. 5.1 KCC Requirements Applicable To CAC Pipes Specific dime
23、nsions have been designated by Engineering as KCC features for all charge air cooler (CAC) pipes. Unless specific exception is noted on the engineering drawinghlue print and/or purchase order the following characteristics are designated as KCC features: WC 1. OD of the pipe within 1.5 inches of the
24、pipe ends. 2. Height of the sealing bead. 5.2 KCC Requirements Applicable to Air Cleaner Pipes Specific dimensions have been designated by Engineering as KCC features for air cleaner pipes. Unless specific exception is noted on the engineering drawing and/or purchase order the following characterist
25、ics are designated as KCC features: KCC) 1. OD of the pipe within 1.8 inches of the pipe ends. 2. Height of the sealing bead. 6.0 SOURCE APPROVAL AND OUALITY CONTROL 6.1 Supplier Requirements Suppliers must conform to the requirements of the Navistar NQR Quality Standard which includes conformance t
26、o the International QS-9000 (IS0 9001) Quality System Standard. A mutually acceptable Quality Control Plan as described therein is required for source approval to the requirements of this specification. This document is restricted and may not be sent outside Navistar International Corporation or rep
27、roduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. O1 999 by Navistar International Transportation Corp. APRIL 1999 Page 3 of 12 COPYRIGHT International Truck and Engine Corporation (formerly NAVISTAR)Licensed by Information Handling
28、 ServicesNUMBER: TITLE: TMS-1059 Aluminum Tubing For Engine Air/Fluid System 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing p
29、ractices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall noti Materials Engineering at Navistar Technology and Engineering Center and Navistar Purchasing and Supp
30、lier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. RE VISI
31、ON: C 6.3 Proccess Control The supplier shall either perform and report results of tests on specific lots of parts produced or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supp
32、lier and the plant metallurgist and/or the quality control manager of the using Navistar plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Loading, packing and identification shall be in accordance with Navistar Manufacturing Std. D
33、- 13. 8.0 DESIGNATION ON DRAWINGS The drawing must indicate material and workmanship as per TMS-1059. stampshotes are included in the U.G. library. An example is shown below: Standard drafting Note: This is an example of the types of notes available in the UG library. All of the notes may not be req
34、uired on each drawing. 1. Material and Workmanship: TMS-1059 2. Bead design per TMS-1059, Fig. 5 or Fig. 7 3. Optional Engagement Dimple per TMS-1059, Fig. 9 4. Cleanliness per TMS-9528, ends to be capped. 5. KCC Requirements as per TMS-1059 GENERAL INFORMATION (NOT A REQUIREMENT) Design Procedure f
35、or Engineering Reference A MORE EFFECTIVE AND EFFICIENT METHOD FOR THE DESIGN OF TUBULAR PRODUCTS USED IN ENGINE AIIUFLUID SYSTEMS HAS BEEN DEVELOPED. This method involves the simple use of a line drawing (center line) and XYZ coordinate table. An example of this method is shown in Figure 10. All ra
36、dii are specified to the center line of the pipe This document is restricted and may not be sent outside Navistar International Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 01999 by Navistar International Tran
37、sportation Corp. APRIL 1999 Page 4 of 12 COPYRIGHT International Truck and Engine Corporation (formerly NAVISTAR)Licensed by Information Handling ServicesNUMBER: TITLE: RE VISION: TMS-1059 Aluminum Tubing For Engine Air/Fluid Systems C and all dimensions are given from the centerline and intersectin
38、g points. Provision of coordinates is via the XYZ-Tubing program available within the UNIGRAPHIC GRIP Program system. Design Procedure for Engineering Reference (Continued) The use of this design method facilitates transfer of data from the engineering drawing to manufacturing operations because the
39、 data can be transferred directly into CNC controlled tube benders and/or coordinate measuring systems to permit manufacturinghnspection without the need for intermediate manufacturing drawings and/or checkinghesting templates fixtures. The elimination of these steps improves efficiency/economy of o
40、perations. The use of the XYZ coordinate system is essential to establish the appropriate interface between the UNIGRAPHICS design system and the “Bar and Tube Design Expert System“ which is planned to be installed on the Engineering “Network“. The use of the expert system will enable the designer t
41、o optimize his design with respect to product cost. In order to obtain maximum life for pipekubing systems and to minimize costs, procedures described herein should be followed. This is particularly important with regard to bend radii and bend locations relative to each other. “Press“ (compression)
42、bends generally have higher production rates and hence lower costs than “Mandrel“ bends and should be used whenever space permits their larger radii and lesser degree of bend. The supplier should be consulted for the preferred bend radius and availability of tooling before release of the drawing. Av
43、oid bends which are too close together and the use of “bends-within-bends.“ They are difficult to fabricate, require non-standard tooling, and add significantly to the cost of the product. In many cases, rotating the bends (as shown in Fig. 6) will achieve the same result while permitting the use of
44、 standard tooling and reducing the costs. Use Chart #1, if necessary, to maintain adequate distance between bends as shown in Fig. 8. All radii on each pipe/tube should be the same in order to minimize tool changes and Set-up time. The exception to this rule is the special case where bends smaller t
45、han those shown in Chart #1 are necessary at one or two points and space permits the use of larger bend radii (as shown in Chart #1) at other points. The tubing fabricator/supplier should be consulted for guidance in these cases. Pipes used in charge air coolers and air cleaner systems are often con
46、nected to elastomeric hose(s) or use elastomeric connectors to reduce vibration. Beading at the end of the tube is used to provide adequate sealing and pull-off resistance. To reduce the transmission of vibrations and stresses between the engine and the radiator/CAC, a minimum spacing or gap of 2.0
47、inches should be maintained between the pipe and turbo charger and also between the pipe and the CAChadiator. The length of the pipe and the lengths of the lose connectors must be carefully considered in order to maintain the gap spacing. Figures 5 and 7 indicate bead configurations used in current
48、design. Consideration for ease of assembly, anticipated peak pressures, and analysis of stack-up tolerances may aid in selection of the proper bead configuration. To assure proper clamping a minimum This document is restricted and may not be sent outside Navistar International Corporation or reprodu
49、ced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. O 1999 by Navistar Internationai Transportation Corp. APRIL 1999 Page 5 of 12 COPYRIGHT International Truck and Engine Corporation (formerly NAVISTAR)Licensed by Information Handling ServicesNUMBER: TITLE: RE VISION: TMS-1059 Aluminum Tubing For Engine Air/Fluid Systems C straight length portion of 30mm (1.2 inch) should be provided from the end of the tube or between beads. Alternate Construction As previously noted, single piece construction is the preferred design method (RPO
