擰緊基礎(chǔ)知識(shí)講解課件

1、擰緊基礎(chǔ)知識(shí)擰緊機(jī)資料之一POSITIVES正版的High power to weight ratio重量比率高Fast快速（速度快）No Reaction沒(méi)有反應(yīng)Non Technical Maintenance非技術(shù)維修Compact體積小Inexpensive價(jià)格適中NEGATIVES盜版的Little or No control半受控或不受控Noisy有噪音High Vibration高振動(dòng)外形、輪廓巨大的錘子NEGATIVES消極消極t Torque Readoutt Run down speedt Two Hand Operation (angle wrenches)POSITIV

2、ES積極積極tGood Repeatabilityt Inexpensivet Low Overshoot價(jià)格適宜沖勁低重復(fù)性能好運(yùn)行速度下降雙手操作自己讀力矩Once pre set torque is delivered to the joint, Clutch spring gets compressed triggering the mechanism to shut off air supply to the motor, providing excellent repeatability.一旦預(yù)先設(shè)定的扭矩傳遞到結(jié)合處，離合器彈簧壓縮，觸發(fā)空氣供應(yīng)切斷機(jī)制運(yùn)行 ，并能重復(fù)性工作，且

3、效果優(yōu)良。扭矩推桿汽車末端離合器彈簧離合器調(diào)節(jié)螺母螺絲起子POSITIVESAccurate Low NoiseCleanClosed - Loop FeedbackErgonomicLow Running CostCan be interfaced with PLCs and BCRsNEGATIVESHigh Initial InvestmentTorque ReactionTwo hand operation (angle tools)電動(dòng)擰緊機(jī)電動(dòng)擰緊機(jī)精確噪音低清潔閉環(huán)反饋工效性運(yùn)行成本低兼具燃料裝填控制系統(tǒng) 和BCRs初始投資高扭矩反應(yīng)兩手操作擰緊機(jī)控制柜擰緊機(jī)控制柜擰緊工具選擇擰

4、緊工具選擇嚴(yán)謹(jǐn)?shù)牟呗跃S修能力力源數(shù)據(jù)收集結(jié)合臨界預(yù)算緊固件通道扭矩水平循環(huán)率緊固件和驅(qū)動(dòng)類型人機(jī)工程學(xué)的應(yīng)用（反應(yīng)，工具重量，力臂位置，頻率）擰緊工具選擇綜述擰緊工具選擇綜述Reliable bolted joints are dependent on many factors:Fastener quality and typeConsistency of joint materialsAssembly tool usedAssembly method or strategyOperator InfluenceFrictional ScatterMaintenance of bolt clam

5、p loadTool and assembly method selection should occur early in the design process to be most effective螺栓連接的可靠性影響因素很多：緊固件質(zhì)量和類型聯(lián)合材料的一致性所用的集裝工具集裝方法或集裝策略操作人員的影響摩擦散射螺栓鉗負(fù)荷的維護(hù)工具和裝配方法的選擇應(yīng)在設(shè)計(jì)過(guò)程中及早進(jìn)行，這樣才最有效扭矩測(cè)量術(shù)語(yǔ)扭矩測(cè)量術(shù)語(yǔ)動(dòng)態(tài)扭矩- Peak Torque Measured During the Installation of a Fastener Using a Power Tool- The Pre

6、ferred and Most Accurate Measurement For Assembly Statistical process Control靜態(tài)扭矩- Torque Value That Exist Without Producing Rotation in a Fastener- Used Only as an Indication of a Minimum Torque峰頂扭矩測(cè)量應(yīng)用在用扭力工具進(jìn)行緊固件安裝中-這是統(tǒng)計(jì)過(guò)程控制最恰當(dāng)最精確的測(cè)量方法。轉(zhuǎn)矩存在的價(jià)值不產(chǎn)生旋轉(zhuǎn)的緊固件，僅作為最低轉(zhuǎn)矩的說(shuō)明當(dāng)緊固件按某一方向被旋緊安裝后再進(jìn)行扭矩測(cè)量重大測(cè)量誤差的產(chǎn)生取決于所

7、使用設(shè)備的審計(jì)轉(zhuǎn)矩扭矩測(cè)量扭矩測(cè)量“標(biāo)記法 Back-to-the-Mark” 準(zhǔn)確度: 高 方便性/速度: 低Mark then loosen Bolt. Tighten Back to Original Position標(biāo)記后檸松螺栓，再擰緊回初始位置。Truly Checks Dynamic Tightening Torque切切實(shí)實(shí)的檢查動(dòng)態(tài)擰緊扭矩Works Only in Tapped Holes這種方法僅僅用在各塞孔處Time Consuming耗費(fèi)時(shí)間扭矩測(cè)量扭矩測(cè)量“Off-torque” 準(zhǔn)確度: 低 方便性/速度: 中Measure Peak Loosening Torq

8、ue測(cè)量松動(dòng)扭矩的峰值Measurement of Off-Torque Does Not Relate Accurately to Tightening Torque Off-Torque緊固扭矩的測(cè)量方法缺乏準(zhǔn)確性不知道不知道扭矩測(cè)量扭矩測(cè)量帶響聲手動(dòng)扭矩扳手 準(zhǔn)確度: 低 方便性/速度: 高Apply Torque Until Wrench Clicks at Set Torque扳手點(diǎn)擊所設(shè)扭矩之前的扭矩為適合扭矩Not a Real Audit Method - Basically a Torque Re-Application Method不是一種真正的審查方法,基本上是一種扭矩再

9、應(yīng)用檢測(cè)Only Gives Assurance That Inspected Fastener Has Been Tightened只能用來(lái)檢測(cè)早先緊固件的緊固情況扭矩測(cè)量扭矩測(cè)量扭矩手動(dòng)扳手 準(zhǔn)確度: 低 方便性/速度: 中Apply Torque Until Operator Senses Movement操作人員能夠感應(yīng)到移動(dòng)之前的扭矩為適合扭矩Read Peak Torque on Tool Indicator從指示器上讀出峰值扭矩Subject to Operators Skill and Joint Conditions遵從操作技能和共同條件扭矩測(cè)量扭矩測(cè)量扭矩/角度 扳手帶外部

10、記錄儀器 準(zhǔn)確度: 較高 方便性/速度: 低Capable of Measuring Dynamic Torque能夠測(cè)量動(dòng)態(tài)扭矩Equipment Is Bulky and Difficult to Use設(shè)備龐大很難用扭矩測(cè)量扭矩測(cè)量扭矩/角度 力矩扳手帶有動(dòng)態(tài)扭矩監(jiān)測(cè)算法準(zhǔn)確度:高 方便性/速度: 高Truly Checks Dynamic Torque After the Fastener Has Been Rotated a Small Amount 緊固件已經(jīng)小幅度旋轉(zhuǎn)之后再切實(shí)檢查動(dòng)態(tài)扭矩動(dòng)態(tài)扭矩動(dòng)態(tài)扭矩Peak Static Torque靜態(tài)扭矩峰值A(chǔ)ngle, q qResi

11、dual Torque Measured Dynamically殘余扭矩的動(dòng)態(tài)測(cè)量Torque, T“Snug”Torque“事宜扭矩Capture Angle2 - 4角度工件連接基礎(chǔ)知識(shí)工件連接基礎(chǔ)知識(shí)Hard Joint - 30 or less - high torque rate 硬連接30或更小高轉(zhuǎn)矩率 軟連接720或更大-低扭矩率連接形式連接形式硬連接30 or less rotation between snug and final torque (27 between 10% and 100% torque) 介于適宜扭矩與最后扭矩30度或小于30度的旋轉(zhuǎn) 的公差)。軟連接7

12、20 rotation between snug and final torque (650 between 10% and 100% torque) 介于適宜扭矩與最后扭矩做720度的旋轉(zhuǎn) 的公差)。JOINT RATES AS DEFINED BY ISO 5393連接率的定義由國(guó)際標(biāo)準(zhǔn)化組織5393界定Joint rate highly effects the final clamp load achieved by a given torque連接率對(duì)最后給定的夾負(fù)載力矩有很大的影響力Clamp Load (torque)Angle (Time)Clamp Load夾負(fù)荷夾負(fù)荷Angl

13、e扭矩扭矩A1TLTHTCSNUG適宜適宜A0As連接形式連接形式 PREVAILING TORQUENotable Torque Before Fastener Begins to Seat緊固件在開(kāi)始設(shè)定位置前應(yīng)予以重視Can be Hard or Soft或是硬鏈接或只是軟連接Examples例如-Thread Forming線程的形成-Thread Cutting 螺紋切削-Self Locking 自鎖功能-Damaged Threads-Damaged 螺紋破損PrevailingTorque現(xiàn)行扭矩現(xiàn)行扭矩SNUGTLTHTC擰緊基礎(chǔ)知識(shí)擰緊基礎(chǔ)知識(shí)扭矩和轉(zhuǎn)角扭矩和轉(zhuǎn)角長(zhǎng)度長(zhǎng)度(

14、Feet, Meters) 腳、米力力(Newtons, Pounds)牛頓, 英鎊扭矩扭矩 = 力力 x 長(zhǎng)度長(zhǎng)度角度90135擰緊基礎(chǔ)擰緊基礎(chǔ)Tightening Threaded Fasteners is Basically an Energy Transfer Process 螺紋緊固件緊固過(guò)程可以說(shuō)是能量轉(zhuǎn)移的過(guò)程Area Under Torque-Angle Curve is Proportional to the Energy Required to Tighten the Fastener 扭矩角度曲線以下的區(qū)域與緊固件緊固所需的能量成正比。T = K d F T = Torq

15、ue扭矩 d = Nominal Diameter公眾認(rèn)可的直徑 F = Force力 K = Friction Factor 摩擦因素角度, q扭矩, TArea Energy扭矩消耗到哪里去了扭矩消耗到哪里去了?螺紋摩擦力夾緊力螺帽摩擦力扭矩螺帽摩擦力螺帽摩擦力 55%羅紋摩擦力羅紋摩擦力- 35%夾緊力夾緊力 - 10%擰緊曲線擰緊曲線扭矩上限扭矩下限合格窗口角度下限角度上限Snug Torque (Threshold)適宜扭矩(閾值）PrevailingTorque現(xiàn)行扭矩JointRateientTorqueGradddTq扭矩扭矩(夾緊力夾緊力)角度角度, q q目標(biāo)扭矩 螺栓屈服

16、點(diǎn)Plastic Range塑性范圍Elastic Range彈性范圍擰緊曲線擰緊曲線Rundown破舊Rundown: Before the bolt head/nut comes into full contact with bearing area在螺栓頭/螺母完全接觸軸承區(qū)域之前Plastic/Post-Yield塑性/ 標(biāo)桿-效益Plastic/Post-Yield: Permanent deformation of fastener or possible yielding of threads, joint or gasket緊固件的永久變形或只是線程、連接或墊圈的形成Elast

17、ic Clamping彈性?shī)A緊Elastic Clamping: Constant torque/angle slope where energy is transferred from tool to assembly恒量扭矩/斜率界定在能源問(wèn)題轉(zhuǎn)移到裝配工具過(guò)程時(shí)Snug適宜Snug: Fastener and joint mating surfaces are drawn into alignment 緊固件及連接點(diǎn)表層要對(duì)齊kdPT 扭矩控制擰緊過(guò)程扭矩控制擰緊過(guò)程扭矩上限扭矩下限Snug Torque (Threshold)適宜的扭矩(閾值)。扭矩扭矩(夾緊力夾緊力)角度角度, q

18、q目標(biāo)扭矩 The variation in clamp loads is controlled by friction scatter. Using a very accurate wrench will not help preload scatter. However, a very inaccurate wrench will have a detrimental impact on preload scatter.負(fù)荷作用下的變形源于摩擦。使用非常精確的扳手不能緩解再負(fù)荷式的散射，然而對(duì)負(fù)荷分散會(huì)產(chǎn)生不利影響。扭矩控制擰緊扭矩控制擰緊扭矩控制擰緊扭矩控制擰緊擰緊方法擰緊方法Appli

19、ed Torque Is Controlled Directly or Indirectly扭矩的應(yīng)用直接或間接受控Target Torque Is Usually 50% to 85% of Yield Torque目標(biāo)扭矩通常介于效益扭矩的50%-85%Used in Elastic Range of Fastener用于緊固件彈性范圍內(nèi)90% Of Applied Torque Is Used to Overcome Friction 90%的應(yīng)用扭矩是用來(lái)克服摩擦的Also known as: Torque, Straight Torque據(jù)目前所知：扭矩、直扭矩Preload Acc

20、uracy 25%再負(fù)荷精確度25%Step 1: Apply a Torque to Consolidate the JointComponents (Snug Torque) 第一步：運(yùn)用扭矩來(lái)鞏固部件的連接情況Step 2: Turn the Fastener Through a Pre-determined Angle第二步:通過(guò)預(yù)先設(shè)定的角度進(jìn)行緊固Originally Developed for Beyond Yield Tightening, Now Also Used in the Elastic Range最初的超出擰緊區(qū)域的發(fā)展屈服,現(xiàn)在也用在彈性范圍內(nèi)Requires A

21、pplication Testing to Establish Snug Torque and Angle Parameters 需要應(yīng)用試驗(yàn)建立適宜的轉(zhuǎn)矩和角參數(shù)Also known as: Turn of the Nut, Torque-Angle 目前所知:螺母的旋轉(zhuǎn)扭矩-角度Preload Accuracy 15%再負(fù)荷精確度15%角度控制角度控制角度控制kdPT 360pFpqLow Angle Limit角度下線High Angle Limit角度上限Snug Torque (Threshold)Torque(Clamp Load)Angle, q q角度控制角度控制Scatter

22、 in Preload is Caused Mainly by The Scatter in Friction During the Torque Tightening (Snug Torque) Portion of the Tightening Procedure預(yù)分散主要由于在緊縮過(guò)程中扭矩?cái)Q緊部分產(chǎn)生的分散摩擦造成的。During the Angle Tightening Portion There is no Scatter in Preload Due to Friction, Only the Scatter in Applied Angle Turned在角度緊縮部分，沒(méi)有因摩

23、擦而產(chǎn)生負(fù)荷的散射，只有應(yīng)用角度旋轉(zhuǎn)時(shí)的散射。kdTFp360ppFFq角度控制角度控制角度說(shuō)明:Snug torque has a tolerance which can increase the initial clamp load scatter.適宜扭矩已為能夠增加最初的預(yù)散射提供了空間。A low snug torque should be used whenever possible. When a high snug torque is used, the effect of constant preload v. angle is lost.較低的適宜扭矩應(yīng)該盡量加以利用。而當(dāng)

24、使用一個(gè)高的適宜扭矩時(shí),預(yù)設(shè)的角度常量的作用會(huì)被忽視。A low snug torque will also reduce the effects of torque scatter before the angle is counted. 角度計(jì)算之前，較低的適宜扭矩將會(huì)減少扭矩分散。When tightening in the plastic range of a fastener, variation in yield strength is also a factor.在緊固件塑性范圍內(nèi)緊縮時(shí)，變形也是產(chǎn)生角度的一個(gè)原因。屈服點(diǎn)控制屈服點(diǎn)控制Torque and Angle Are M

25、onitored During Tightening緊縮時(shí)扭矩和角度是相輔相成的。The Maximum Gradient is Stored & the Yield Point Identified When the Gradient Falls to a Fraction of the Maximum當(dāng)梯度下降達(dá)到最大值的一部分時(shí)，最大梯度值會(huì)被記錄，緊縮點(diǎn)也會(huì)被確定。Utilizes Maximum Load Potential of the Fastener利用緊固件的最大承載潛力Largely Uninfluenced by Friction在很大程度上不受摩擦的影響Allo

26、ws Torque Angle Inspection of Every Tightening允許對(duì)所有緊縮政策實(shí)施扭矩轉(zhuǎn)角的監(jiān)控Bolts Can Be Reused螺栓可以重復(fù)利用Also known as: Torque to Yield扭矩屈服點(diǎn) Preload Accuracy 8% 擰緊方法擰緊方法屈服點(diǎn)控制屈服點(diǎn)控制50% of Peak Gradient50%的峰值梯度扭矩梯度Bolt Yield Point螺栓屈服點(diǎn)Torque(Clamp Load)夾負(fù)荷Angle, q q屈服點(diǎn)控制屈服點(diǎn)控制Reduced Variation in Preload After Tighte

27、ning:緊縮之后減少預(yù)負(fù)荷中的變形Preload Scatter is More Dependent on Strength Variation Than Friction Variation 比起摩擦， 預(yù)分散更依賴于強(qiáng)度變化Bolt Strength is More Controllable Than Friction螺栓強(qiáng)度比起摩擦力可控性更強(qiáng)。 PRELOAD, N,預(yù)負(fù)荷預(yù)負(fù)荷NThread線程線程GradeSizeRange4,4006,2007,3005,6007,6008,80067,20010,00012,2009119,20012,40014,600121510,2001

28、4,20016,10011141813,00017,60020,50015202418,60026,20031,40025374423,80032,20037,80036516029,80041,60050,00052738838,00051,20060,000719911943,40060,70072,9009212815654,40074,90087,70012717320759,40083,300100,00014420524475,600102,000120,00020028033582,500115,000138,000228322383105,000141,000166,00031

29、045052099,200139,000167,000305430510127,000171,000201,000420595710GradeM6 x 1.0Minimum10,20014,20016,100111418Maximum13,00017,60020,500152024 EXPECTED TORQUE, Nm預(yù)期的扭矩預(yù)期的扭矩,海里海里Clamp Load Scatter夾負(fù)荷分散精密力矩扳手精密力矩扳手M10氣動(dòng)沖擊扳手氣動(dòng)沖擊扳手M14氣動(dòng)定扭氣動(dòng)定扭矩扳手矩扳手M12電動(dòng)扳手電動(dòng)扳手屈服點(diǎn)控制屈服點(diǎn)控制M8 8%15%25%30 - 40%工具和螺栓選擇工具和螺栓選擇屈服點(diǎn)

30、控制屈服點(diǎn)控制Joint May Not Be Critical Enough to Warrant its Cost 聯(lián)合不足以保證其成本Should Not Use When:不應(yīng)使用的時(shí)機(jī)可概括為以下方面：Bolt Yield Strength Joint Compressive Strength螺栓屈服強(qiáng)度大于聯(lián)合抗壓強(qiáng)度時(shí)Bolt Yields Somewhere Other Than Threads螺栓產(chǎn)量某個(gè)主題Head Shears螺栓頭掉了Nut Strips螺母無(wú)螺痕Applications Where Frequent Disassembly is Required應(yīng)用于

31、頻繁解體所必需的場(chǎng)所Joints With Unpredictable Stiffness Qualities連接質(zhì)量等的不可預(yù)知If Yield is the Most Accurate, Why Not Always Use it?如果產(chǎn)量是最準(zhǔn)確的, 為什么不常用呢?擰緊錯(cuò)誤擰緊錯(cuò)誤FOUR MAJOR ERRORS DURING BOLT TIGHTENING :螺栓緊固中的四大錯(cuò)： Human errors 人的操作錯(cuò)誤 Tightening method errors 緊固方法不當(dāng) Improper tool errors 工具不適宜 Joint parts errors 連接部位

32、錯(cuò)誤Forgot to tighten忘記擰緊Improper tools used使用了不恰當(dāng)?shù)墓ぞ遅rong specifications規(guī)格錯(cuò)誤Wrong tightening procedure緊固方法錯(cuò)誤Wrong selection of tools工具的選取不當(dāng)Inaccuracy 不精確Mechanical failure 機(jī)械故障Out of parts tolerance超出了部件的承受力Bad material材料不好Insufficient lubrication潤(rùn)滑不充分CLASSIFICATION & CAUSE FOR LOOSENING OF BOLTS

33、螺栓松動(dòng)分類及原因螺栓松動(dòng)分類及原因CHARACTERISTICS DIAGRAM OF DEFECTIVE JOINT缺陷連接特征圖缺陷連接特征圖擰緊錯(cuò)誤Tightening faults can be caused by the joint, the tool or the operator擰緊錯(cuò)誤可由連接、工具或操作人員引起These faults typically show up as major deviations from normal這些缺點(diǎn)通常顯示為相對(duì)正常的偏離The detection of tightening faults is best done by uncov

34、ering deviations from normal angle緊固故障的檢測(cè)最好不要覆蓋正常角度的偏離Modern DC controllers have the capability to monitor or control angle to flag these process errors現(xiàn)代的直流控制器能夠監(jiān)視和控制的角度，平復(fù)進(jìn)程中遇到的各種錯(cuò)誤裝配過(guò)程中裝配過(guò)程中擰緊錯(cuò)誤由下列方法判斷由下列方法判斷:錯(cuò)誤種類錯(cuò)誤種類 扭矩控制扭矩控制 扭矩控制帶扭矩控制帶 角度監(jiān)視角度監(jiān)視 屈服點(diǎn)控制帶屈服點(diǎn)控制帶 扭矩和角度監(jiān)視扭矩和角度監(jiān)視 Bolt too Soft(Low or h

35、igh friction conditions)摩擦過(guò)大或過(guò)小NOYESYESBolt too Soft(Normal Friction)摩擦適中NOUsually NOYESBolt too Hard螺栓過(guò)硬NONOYESThread Fault(Friction High)摩擦過(guò)大NOYESYESCoating/ Lube Fault (Friction extremely Low)摩擦微乎其微NOYESYES擰緊錯(cuò)誤Angle, q qTorque, TBlind Hole Too Short孔的深度欠缺ExpectedEffect on Torque/Angle End of Cycl

36、e Data:TorqueAngleTightening CyclesTorque High LimitTorque Low LimitAngle High LimitAngle Low Limit擰緊錯(cuò)誤擰緊錯(cuò)誤Angle, q qTorque, TIncomplete Operation(tool shut off early)沒(méi)有完全操作ExpectedEffect on Torque/Angle End of Cycle Data:TorqueAngleTightening CyclesTorque High LimitTorque Low LimitAngle High LimitA

37、ngle Low Limit擰緊錯(cuò)誤擰緊錯(cuò)誤Angle, q qTorque, TMisaligned Parts忽略了角度Effect on Torque/Angle End of Cycle Data:TorqueAngleTightening CyclesTorque High LimitTorque Low LimitAngle High LimitAngle Low LimitExpected擰緊錯(cuò)誤擰緊錯(cuò)誤Angle, q qTorque, TCrossed Threads孔直徑過(guò)大Effect on Torque/Angle End of Cycle Data:TorqueAng

38、leTightening CyclesTorque High LimitTorque Low LimitAngle High LimitAngle Low LimitExpectedAngle, q qTorque, TJoint Component Fails零部件連接錯(cuò)誤擰緊錯(cuò)誤擰緊錯(cuò)誤Effect on Torque/Angle End of Cycle Data:TorqueAngleTightening CyclesTorque High LimitTorque Low LimitAngle High LimitAngle Low LimitExpectedAngle, q qTorque, TStripped Threads多方面的滑扣擰緊錯(cuò)誤擰緊錯(cuò)誤Effect on Torque/Angle End of Cycle Data:TorqueAngleTightening CyclesTorque High L