Fastener-Torque-and-Fastening-(緊固件扭矩問題)解析課件

1、ABC about Fastener, Torque and Fastening on-site Issues 緊固件,扭矩和現(xiàn)場問題基礎(chǔ)1第1頁，共33頁。Fastener IntroductionEvery year we hear about issues related to the design or assembly of fastened joints. These issues bring us much trouble in on-site assembly, product liability, vehicle durability, even redesign. Fast

2、ener attention peaks when a catastrophic bolted joint failure occurs. This presentation is designed to raise the awareness of the need for proper joint design and validation.每年我們都可以聽說與緊固連接件的設(shè)計(jì)和安裝相關(guān)的問題。這些問題給我們的零件安裝，產(chǎn)品可靠性，整車耐久性帶來了許多麻煩，甚至導(dǎo)致重新設(shè)計(jì)。當(dāng)一個(gè)災(zāi)難性的螺栓連接失效發(fā)生時(shí)，緊固件就受到高度關(guān)注。這個(gè)報(bào)告主要用來提高工程師的意識，以進(jìn)行正確的連接設(shè)計(jì)和驗(yàn)證

3、。2第2頁，共33頁。Fastener IntroductionAdvantages of Proper Joint Design正確連接件設(shè)計(jì)的好處 Customer Satisfaction 客戶滿意 Mass Reduction 重量減少 Improve Reliability 可靠性提高 Reduce Costs (direct and indirect) 成本減少（直接和間接） Government Regulation Compliance 符合政府法規(guī) Complexity Reduction 復(fù)雜程度減低 Eliminate the need for “fixes” 減除了“安

4、裝”的需要3第3頁，共33頁。Fastener IntroductionWhy we need fasteners?為什么我們需要緊固件? Joint different materials together 將不同的材料連接起來Act as a heavy spring to keep components from slipping relative to one another 類似一個(gè)大彈簧，連接零部件以避免相互滑動(dòng)Act as a pivot/sheer point for the attachment of brackets, tethers, belts 在支架，繩，帶連接中，類

5、似一個(gè)支點(diǎn)/轉(zhuǎn)向點(diǎn) Connect hydraulic and other fluid lines to their respective components 將液壓的和其他液體管線連接到他們各自的零部件上Allow for disassembly 允許拆卸4第4頁，共33頁。Fastener IntroductionWhat must a fastener do？緊固件必須做些什么？Survive Assembly 起到連接的效果Provide clamp load (or other joint performance criteria) to resist any type of jo

6、int failure 提供拉緊力（或者其他連接性能標(biāo)準(zhǔn)）來防止任何性質(zhì)的連接失效Incorporate specific corrosion protection and lubrication characteristics 具備具體的腐蝕保護(hù)和潤滑特性5第5頁，共33頁。Fastener CategoriesAccording to different usage, shape and material, Fastener can be divided into following categories briefly：根據(jù)使用，外形和材料的不同，緊固件可以被大致分為以下幾種類型： Bo

7、lts and Screws Bolts Machine Thread Screws Tapping Screws6第6頁，共33頁。Fastener Introduction Nuts Free Spinning Nuts Lock Nuts Pierce Nuts Push-In Nuts U Shaped Nuts Weld Nuts7第7頁，共33頁。Fastener Introduction Push Pins Retainers Clips8第8頁，共33頁。Fastener Introduction Straps Studs Application Specific Fasten

8、ers9第9頁，共33頁。The head of bolt is marked with two numbers that indicate material properties used to define basic mechanical properties.螺栓的頭部標(biāo)示了兩個(gè)數(shù)字來表示定義基本機(jī)械特性的材料特性。 XX.YMaterial Minimum Ultimate Tensile Strength (UTS) = XX * 100 Mpa材料最小極限抗拉強(qiáng)度 (UTS) XX * 100 兆帕Material Yield Strength (YS) = UTS * .Y M

9、pa材料屈服強(qiáng)度 (YS) (UTS) * .Y 兆帕Material proof Strength (PS) = YS * .9 Mpa材料保證載荷 (PS) YS * .9 兆帕Material Shear Strength (SS) = .62 * UTS Mpa (unthreaded Body) = .47 * UTS Mpa (Threads)材料剪切強(qiáng)度 (SS) .62 * UTS 兆帕 (無螺紋段螺栓) .47 * UTS 兆帕 (帶螺紋段螺栓)Stress Markings10第10頁，共33頁。The bolt proof load,yield strength and

10、minimum ultimate tensile strength in (KN) are derived by multiplying the corresponding stress (Mpa) values by the subject bolt stress area (mm2). 螺栓的保證載荷，屈服拉力和最小極限抗拉強(qiáng)度（千牛）是通過將相應(yīng)的應(yīng)力值（兆帕） 乘以螺栓的承載面積。Thread Root Area 螺紋齒根面積 (Ar) Stress Area 同等受力面積 (As) Bolt Minimum Ultimate Tensile Strength (UTS) = XX *

11、 100 * As KNBolt Yield Strength (YS) = UTS * .Y * As KNBolt proof Strength (PS) = YS * .9 * As KNBolt Shear Strength (SS) = .62 * UTS * As KN (unthreaded Body) = .47 * UTS * Ar KN (Threads) Stress Markings11第11頁，共33頁。The only nut property we will concerned with is proof load. Proof load of a nut is

12、computed by multiplying the class marking stamped on the nut by 100, then multiplying by thread tensile stress area.我們需要考慮到的唯一的螺母特性是保證載荷。螺母的保證載荷通過將印在螺母上的等級乘以100，然后再乘以螺母的同等受力面積得到的。Stress Area 同等受力面積 (As)Nut proof Strength = Class * 100 * As KN螺母保證載荷 Class * 100 * As千牛Stress Markings12第12頁，共33頁。The Dy

13、namics of AssemblyThe most important job of the fastened joint is to survive final assembly and live through the life expectancy of the product and beyond. When properly designed, a fastened joint should retain the component without loosening. 緊固件連接的最重要的工作（要求）是通過最后安裝以及達(dá)到并且超過產(chǎn)品的期望使用壽命。如果產(chǎn)品設(shè)計(jì)正確，那么一個(gè)緊固

14、件應(yīng)該安裝保持在零部件上，而沒有松脫的現(xiàn)象出現(xiàn)。 In thread joint fastener,our target is clamp load, not torque. Torque (sometimes torque+angle) is our control method to get proper clamp load. 在螺紋連接緊固件中,我們的目標(biāo)是預(yù)載拉緊力，而不是扭矩。扭矩（有時(shí)候是扭矩旋轉(zhuǎn)角度）是我們用來獲得合適的預(yù)載拉緊力的控制方法。13第13頁，共33頁。There are five different kinds of torque. 現(xiàn)在主要有五種種類不同的扭矩。

15、1. Dynamic Torque: which is the peak value of torque measured as a fastener is being installed. A hand or power tool can apply dynamic torque, dynamic torque cant be checked after the fasteners are installed. 動(dòng)態(tài)扭矩：當(dāng)緊固件在被固定的過程中測量得到的最大峰值。扭力扳手和動(dòng)力工具都可以施加動(dòng)態(tài)扭矩，動(dòng)態(tài)扭矩不能在緊固件被緊固完之后測量。 Static Torque: which is t

16、he torque required to just begin further tightening of a fastener after it is initially installed. 靜態(tài)扭矩：在一個(gè)緊固件被固定好之后，需要將其在緊固方向上繼續(xù)旋轉(zhuǎn)的瞬間所需要的扭矩。 Audit Torque: which is same as static torque 檢測扭矩：與靜態(tài)扭矩相同。Five Torque Categories14第14頁，共33頁。 Breakaway Torque: The torque required to start an at rest fastene

17、r in the reverse tightening direction. 松脫扭矩：在一個(gè)緊固件被固定好之后，在緊固相反的方向上旋松該緊固件所需要的扭矩。 Prevailing Torque: A resistance to turn a fastener in the on or off direction, due to thread interference either intentional or unintentional. 鎖緊扭矩：由于有意或無意的螺紋干涉，在緊固或松脫方向轉(zhuǎn)動(dòng)一個(gè)緊固件所需克服的抵制扭矩。 Five Torque Categories15第15頁，共33頁

18、。Properties of Dynamic and Static Torque GM take manual or powerful tools to target to the dynamic torque spec and dynamic torque is the only ultimately standard for joint fastening. 通用系統(tǒng)將動(dòng)態(tài)扭矩標(biāo)準(zhǔn)作為設(shè)定手工或者動(dòng)力工具目標(biāo)，動(dòng)態(tài)扭矩是控制連接緊固件的最終標(biāo)準(zhǔn)。The static value is the manufacturing audit specification. And the static

19、 specification is only used to monitor the joint performance.靜態(tài)扭矩值是生產(chǎn)用的檢測標(biāo)準(zhǔn)，靜態(tài)扭矩標(biāo)準(zhǔn)只用來監(jiān)測連接件的連接狀態(tài)。The manufacturing engineer develops the static torque through plant trials. In addition, the static torque specifications are established to provide the plants with a means to inspect and verify the torqu

20、e of fasteners.制造工程師在工廠試制階段開發(fā)出靜態(tài)扭矩。靜態(tài)扭矩標(biāo)準(zhǔn)的建立用來給車間提供一個(gè)監(jiān)控和檢測緊固件扭矩的方法。16第16頁，共33頁。Why do we choose dynamic torque as fastening standard? Reason 1: Dynamic torque best represents the torque developed during joint design activity from torque tension, drive strip and torque angle testing. Reason 2: Dynami

21、c torque depends upon the dynamic coefficient of friction for its value. This coefficient of friction tends to be more consistent and less variable than the static coefficient of friction. Reason 3: Dynamic torque also facilitates accurate torque measurement during the tightening of joints employing

22、 adhesive thread locking mechanisms. Reason 4: The measurement of static torque by definition results in an extra operation, hence dynamic torque usage was promoted to cost effectively achieve 100% torque monitoring strategies.Properties of Dynamic and Static Torque 17第17頁，共33頁。Clamp Load is what ke

23、eps the joint together through durability.預(yù)載拉緊力保證了被連接件緊固在一起，達(dá)到耐久性要求。When a joint is secured by controlling accurate dynamic torque, the correct clamp load or other quality indicator should be guaranteed, and thus to prevent the loose and crush in the future driving process. Utilizing dynamic torque

24、can guarantee ultimate static clamp load, and this is the result of Reason 1 and Reason 2.當(dāng)一個(gè)固定連接件采用合適的動(dòng)態(tài)扭矩值進(jìn)行緊固的時(shí)候，他們都應(yīng)該保證正確的預(yù)載拉緊力和其他的和質(zhì)量相關(guān)的指標(biāo)，這樣就防止了這些緊固件在汽車運(yùn)行中的松脫和壓潰。使用動(dòng)態(tài)扭矩可以更好的保證產(chǎn)生較為穩(wěn)定的預(yù)載拉緊力，這是前面原因1和原因2產(chǎn)生的結(jié)果。Properties of Dynamic and Static Torque 18第18頁，共33頁。There are several methods that can be

25、 used to determine what dynamic torque is required for a particular joint. 對于一個(gè)連接件有幾種方法可以用來決定需要多大的動(dòng)態(tài)扭矩。Setback from failure 失效模式?jīng)Q定扭矩法Setback from yield 屈服模式?jīng)Q定扭矩法-3 Sigma yield torque 屈服-3 Sigma決定扭矩法Clamp Load Targeting 預(yù)載拉緊力決定扭矩法Properties of Dynamic and Static Torque 19第19頁，共33頁。When torque is appl

26、ied to a joint, about 90 of torque is utilized to conquest the friction caused in bearing surface and threads. Only 10 of torque is utilized to generate clamp load of the bolt. So the friction is very important to consequent proper clamp load.當(dāng)扭矩作用到一個(gè)連接件的時(shí)候，90的扭矩用來克服在接觸表面和螺紋表面產(chǎn)生的摩擦力。只有10的扭矩用來產(chǎn)生螺栓的拉緊

27、力。所以摩擦力對于最后能生成合適的拉緊力非常重要。Why Friction is so Important20第20頁，共33頁。In order to meet the target joint clamp load, with some degree of consistency, it is important to realize where the friction is and how to control it. There are ways of controlling friction through the use of washers, proper finishes a

28、nd improved bearing surfaces.In GMNA, some finish material supplier and finish processing supplier has been certificated, and GM only use their products and process, so that they can control the finish quality very well.為了達(dá)到預(yù)期的預(yù)載夾緊力，以滿足某種程度的堅(jiān)固性要求，認(rèn)識到哪里產(chǎn)生摩擦力和如何控制它是很重要的。通過使用墊圈，合適的表面處理和改良的接觸平面可以用來控制摩擦的

29、效果。在北美通用，一些表面處理原材料供應(yīng)商和表面處理加工供應(yīng)商得到了通用的認(rèn)證，通用只采用他們提供的原材料和加工工藝，所以他們可以很好的控制表面處理的質(zhì)量。Why Friction is so Important21第21頁，共33頁。Four Zones of Fastener Tightening Curve緊固件擰緊曲線的四個(gè)區(qū)域。Torque Angle Curve22第22頁，共33頁。After parts are seated, fastener rotation is proportional to clamping force在緊固件落位后，緊固件的旋轉(zhuǎn)和預(yù)緊拉力基本成正比。

30、Torque Angle Curve23第23頁，共33頁。Torque Tension CurveFrom the following chart, for free-spinning fastener, after seated the tension(ClampForce) is also proportional to Input Torque.從下圖可以看出，對于一般非自鎖緊固件，在落位后，拉應(yīng)力（預(yù)緊拉力）和輸入扭矩基本成正比。24第24頁，共33頁。Released Dynamic Torque and Static TorqueWhatever GMNA project or

31、GMDAT and S-car project, the dynamic torque which PATAC released in GPDS is torque value set for manufacturing, these value should not be changed if not necessary. The static torque PATAC get and release in GPDS is only used for audit reference of static torque value by shop.無論是北美項(xiàng)目還是韓國大宇項(xiàng)目，小車項(xiàng)目泛亞在G

32、PDS中發(fā)布的動(dòng)態(tài)扭矩都是生產(chǎn)操作扭矩的設(shè)定值，如果沒有必要這些值不應(yīng)該被改變。 而泛亞得到并在GPDS中發(fā)布的靜態(tài)扭矩值只是車間檢測用靜態(tài)扭矩的參考值。Because of different fastening tools used in global GM systems, same dynamic torque will cause different static torque values. At this time we should modify these static torque values.由于通用全球系統(tǒng)使用的緊固工具的不同，相同的動(dòng)態(tài)扭矩會產(chǎn)生不同的靜態(tài)扭矩值。這

33、時(shí)就需要修正這些靜態(tài)扭矩。25第25頁，共33頁。Several torque description styles幾種扭矩的表示形式1. D55+/- 5NM = Dynamically checked torque to 55 Newton Meters, plus or minus five. 動(dòng)態(tài)檢驗(yàn)扭矩為55+/-5牛米（也就是5060牛米）。2. S55+/- 5NM = Statically checked torque to 55 Newton Meters, plus or minus five. 靜態(tài)檢驗(yàn)扭矩為55+/-5牛米（也就是5060牛米)。 In GMNA in

34、or after 2009 MY vehicle the static torque value will be represented like S50-60 NM, and we will follow this modification.3. D 2.0NM FDSNS = Dynamically checked torque to 2.0 Newton Meters, Fully Driven Seated Not Stripped ( not restricted tolerance ) . 動(dòng)態(tài)檢驗(yàn)扭矩為2.0牛米,完全安裝到位不產(chǎn)生滑牙（以此為標(biāo)準(zhǔn)，不限制扭矩公差）。Severa

35、l Description Styles about Torque26第26頁，共33頁。4. D35+115+/-10= Dynamically checked torque to 35 Newton Meters, and then drive 115 plus or minus 10 . 動(dòng)態(tài)檢驗(yàn)扭矩為35牛米,然后再繼續(xù)旋緊115+/-10 。5. * TORQ: CLAMP LOAD 60 10 KN= no direct torque value, followed by a description,which is its requirement . or TORQ: DRAW

36、IN .6 TO .8 MM 有些扭矩并不直接表明，而以*表示，但后面的說明表示緊固件的扭矩要求為拉緊力達(dá)到60 +/- 10 牛米（或者有些是旋入0.6到0.8mm)。Since there are torque deviations when on-site power tools output torque, dynamic torque specification should contain tolerance; And because static torque are scatter when they are inspected, in order to cover this

37、scatter situation, static torque also need tolerance. 由于現(xiàn)場使用的動(dòng)力工具存在著扭矩輸出的偏差,所以動(dòng)態(tài)扭矩在制定標(biāo)準(zhǔn)時(shí)需要有公差要求; 而靜態(tài)扭矩由于在檢測時(shí)存在一定的離散,為了包容這些離散的狀態(tài),所以也需要有公差值。Several Description Styles about Torque27第27頁，共33頁。Some on-site issues and reasons/methods about fasteners.一些關(guān)于緊固件的在線問題以及原因和解決方法。 Static torque readings are outsi

38、de the static torque limit. Reason: Static torque is not reasonable or dynamic torque set in the operation tools is not correct or static torque is not reasonable Methods: The operator check dynamic readings firstly, if the dynamic readings are within the dynamic specification, ME would check the st

39、atic specification accordingly and decide whether it should be modified or not. If the dynamic readings are outside the dynamic torque specification, the tool would be adjusted to bring it back into the correct dynamic torque readings. The static torque would be stay the same and then updated after

40、the product begins production. 靜態(tài)扭矩讀取值超出了靜態(tài)扭矩值范圍。 原因：靜態(tài)扭矩不合理或者設(shè)定在工具上的動(dòng)態(tài)扭矩不準(zhǔn)確。 方法：操作者首先檢查動(dòng)態(tài)扭矩的讀取值，如果動(dòng)態(tài)扭矩讀取值在動(dòng)態(tài)扭矩標(biāo)準(zhǔn)內(nèi)，ME將因此檢測靜態(tài)扭矩值，決定其是否需要被修改。假如動(dòng)態(tài)扭矩讀取值在動(dòng)態(tài)扭矩標(biāo)準(zhǔn)范圍之外，那么需要調(diào)整工具以使其回復(fù)到正確的動(dòng)態(tài)扭矩讀取值之內(nèi)。靜態(tài)扭矩將保持不變?nèi)缓笤谏a(chǎn)重新進(jìn)行后來決定是否需要更新。On-site Issues and Reasons/Methods about Fasteners28第28頁，共33頁。Bolt/Screw thread stri

41、p or break in processing. Reason: The worker not operate properly; the tools not suitable; the dynamic torque is too large;original design is not robust enough. Methods: The operator adjust operation method; select the suitable tools to process, or adjust the corresponding torque;change the original

42、 design. 螺釘在緊固時(shí)滑牙或斷裂。 原因：現(xiàn)場工人操作不當(dāng)；選取工具不合適；動(dòng)態(tài)扭矩太大; 原設(shè)計(jì)有缺陷。 方法：操作者調(diào)整操作的方法；選擇合適的生產(chǎn)工具；或者調(diào)整相應(yīng)的動(dòng)態(tài)扭矩; 更改原設(shè)計(jì)。On-site Issues and Reasons/Methods about Fasteners29第29頁，共33頁。3. Bolt/Screw rotate with nut in fastening process. Reason: The worker not operate properly; the tools not suitable; previously the nut o

43、r bolt not mounted tightly. Methods: The operator adjust operation method; select the suitable tools to process, or adjust the mounting process of nut or bolt. 螺釘和螺母在緊固過程中根轉(zhuǎn)。 原因：現(xiàn)場工人操作不當(dāng)；選取工具不合適；螺母或者螺栓沒有預(yù)先固定住。 方法：操作者調(diào)整操作的方法；選擇合適的生產(chǎn)工具；調(diào)整螺母或者螺栓的安裝操作過程。On-site Issues and Reasons/Methods about Fasteners

44、30第30頁，共33頁。KPC, PQC and QCOS in Fastening Area KPC Key Product Characteristics. KPC is an old fastening concept of different importance about critical joint torques. Now this one has been replaced by PQC in Fastening Engineering.PQC Product Quality Characteristics. PQC defines 5 different important levels for critical joint torques, they are PS1, PS2, PF1, PF2 and Standard Care.QCOS Quality Control Operation Sheets. In Fastening area QCOS is actually a kind of process method to guarantee the PQC joint quality, this is charge