《GM_9090P_2004-04_EN.pdf》由会员分享，可在线阅读，更多相关《GM_9090P_2004-04_EN.pdf（9页珍藏版）》请在三一文库上搜索。
1、 ENGINEERING STANDARDS Material Specification Rubber GM9090P Engine Coolant Hose Coupled Assemblies and Quick-Connector Assemblies 1 Scope This specification defines the requirements for coupled heater and radiator hose assemblies, and heater and radiator hose assemblies con- taining quick connector
2、s. 1.1 To properly define the performance require- ments for the assembly, the performance speci- fication number (GM9090P) is to be referenced. The hose of the assembly must meet the appli- cable hose specification as called out on the hose assembly drawing. 1.1.1 Coupling Construction. 1.1.1.1 Cou
3、pling Design. The coupling shall be designed, inserted, swaged, or crimped so that no internal tube abrasions, cuts or flaws shall result under any condition or combination of assembly component dimensioning or toleranc- ing allowed by supplier production specifica- tions, or under any condition of
4、rubber hose compression allowed by supplier production specifications. 1.1.1.2 Sharp Corners. Sharp corners shall be avoided where the coupling contacts the tube to prevent cutting of the hose when subjected to internal pressure. 1.1.1.3 Tube Insert. The tube insert must not extend past the end of t
5、he crimp shell after crimping, and the end of the tube insert must be radiused to eliminate burrs or sharp edges which might cause hose damage under condi- tions of assembly vibration or pressure impulse. 1.1.1.4 Damage. Damage to hose rubber or reinforcement generated by the crimping of the hose is
6、 not permissible under any possible pro- duction manufacturing conditions or supplier production tolerance stack-up, including varia- tions in hose compression concentricity. 1.1.1.5 Tube Collapse. Metal tube insert col- lapse during crimping is not permissible, except when this collapse is limited,
7、 predictable, con- trollable, and does not increase the potential for assembly leakage or other malfunction. 1.1.1.6 Design Restrictions. Grooves, upsets, or serrations are not permitted on the tube stem OD, or on the crimp shell ID, except that these grooves, upsets, or serrations do not cause hose
8、 cutting or other damage under any condi- tion or combination of assembly component dimensioning or tolerancing allowed by supplier production specifications, or under any condition of rubber hose compression allowed by supplier production specifications. 1.1.1.7 Skiving, Adhesives. Skiving of the h
9、ose is not permissible. Use of adhesives in the crimped joint is not permissible. 1.1.1.8 Flow Requirements. The coupling shall be designed for low flow restriction. 1.2 Typical Application. Coupled heater and radiator hose assemblies. 2 References Note: Only the latest approved standards are applic
10、able unless otherwise specified. 2.1 External Standards/Specifications. ASTM A254 ISO 11014 ASTM D380 2.2 GM Standards/Specifications. 9985809 GM9540P GM4298P GMW3001 GM6277M GMW3059 3 Requirements 3.1 Basic Test Requirements. 3.1.1 Coupled Assembly Required Tests. Coupled hose assemblies shall be t
11、ested for conformance with the following sections: Copyright 2004 General Motors Corporation All Rights Reserved April 2004 Originating Department: North American Engineering Standards Page 1 of 9 GM9090P GM ENGINEERING STANDARDS Copyright 2004 General Motors Corporation All Rights Reserved Page 2 o
12、f 9 April 2004 Table 1: Test Table Section Test # Samples 3.2 Leak (Note 1) 3.3 Cold Leak 6 3.4 Tensile 6 3.5 Burst 6 3.6 Vacuum 6 3.7 Insertion Force (Note 2) 6 3.8 Pull-Out Force (Note 2) 6 3.9 Cleanliness 6 3.10 Cyclical Corrosion 6 3.11 Salt Spray 6 3.12 Overcrimp to 3 Sigma Limits 16 3.13 Overc
13、rimp to Damage Design Dependent 3.14 Pressure/Temperature 12 3.15 Coolant Circulating 6 Note 1: Performed for all test samples before conducting test procedures 3.3 through 3.11, 3.14 and 3.15. Note 2: Performed for test samples containing Quick- Connectors only. 3.1.2 Standard Test Samples. Samples
14、 of cou- pled hose for test to the specification shall have an exposed hose length of 500 10 mm and a maximum tube length of 100 mm. Coupled hose assemblies for test to 3.15, Coolant Circulating, shall consist of a tube of length 125 mm, and lengths of hose coupled to each end of this tube of length
15、 of 137 mm. This entire assembly shall measure 400 mm in length. Configurations of coupled hose assemblies other than that speci- fied above may be tested by the supplier for the generation of Engineering Source Approvals for assemblies containing various hose sizes, hose manufacturers, and coupling
16、 constructions at the discretion of the GM Materials Engineer generating the Engineering Source Approval. Each sample must be tagged with the following information: Hose coupling assembly manufac- turer, GM specification number, and date. The testing of assemblies containing quick con- nectors shall
17、 be performed on assemblies simi- lar to the test samples used for coupled assem- blies, except for the substitution of quick- connectors at the coupled portion of the assem- bly. For the Coolant Circulating test procedure, a standard sample for test shall consist of a hose assembly of overall lengt
18、h of 400 mm, with quick-connectors on either end of the assembly. Tube ends used to connect the quick connectors to fixtures for test shall be identical to the pro- duction intent tube ends, except that, unless otherwise noted in the test procedure descrip- tion, the dimensions of the tube ends shal
19、l be the minimum dimensions allowed by the toler- ances specified for the tube ends. 3.1.3 Test Conditions. All temperatures shall be held to 20C and all pressures to -0, 34.5 kPa unless otherwise noted. 3.1.4 Approval Requirements. Approval will require the following information to be submit- ted:
20、1. Blueprints showing the design, dimensions and tolerances for all components of the as- sembly including allowed eccentricity in the hose, tube insert, and coupling OD. In addi- tion, the range of the all hose compression possible under each condition of dimensional tolerance stack-up. 2. The subm
21、ission of sectioned coupling sam- ples to demonstrate that all of the above mentioned construction requirements have been met. 3. A description of the statistical process control procedures for the coupling diameter dimen- sions and the hose compression range. 4. The value for hose compression neces
22、sary to induce: a. Hose rubber damage (any layer). b. Hose reinforcement damage. 5. Data presented in both tubular and graph form, showing values of hose compression (calculated using both linear and area meth- ods) vs. Tensile Test performance (3.4), Burst Test performance, (3.5), and fitting in- s
23、ert collapse. The dimensions of the crimped assembly components for each data point need to be listed, as well as the resultant hose compression. 6. Copies of test fixture traces, confirming pres- sure and temperature regiments imposed on the samples during test. Note: Values of hose compression mus
24、t be reported both in terms of linear compression and area compression (See Appendix A, Table 2 for the formula for each calculation). GM ENGINEERING STANDARDS GM9090P Copyright 2004 General Motors Corporation All Rights Reserved April 2004 Page 3 of 9 factors: 3.1.5 Engineering Approval Factors. En
25、gineering source approvals generated through testing to prove compliance to this specification are specific for combinations of the following Size of hose and coupling components Hose material and construction Coupling design Tube insert material, plating, finish and hard- ness Coupling shell materi
26、al, plating, finish and hardness Supplier specifications and manufacturing procedures, supplier (both hose and assem- bly) manufacturing sites. Testing of one construction of assembly can result in Engineering Source Approvals for two crimp designs or materials by placing each de- sign or material v
27、ariant on one end of the as- sembly. 3.1.6 Design Level Requirements. All tube/hose assemblies manufactured for testing to this specification for engineering source ap- proval purposes shall be completely representa- tive of production level materials, components, processes and tooling. The exceptio
28、ns are those assemblies needing to be specially manufac- tured under extremes of dimensions and/or tol- erancing to meet the test requirements of the specification. Any exceptions to this require- ment, or to any criteria referenced in Sections 1, 3, 4, 5, or 6 must be reviewed beforehand and approv
29、ed by the GM Materials Engineer issuing the approval. 3.1.7 Engineering Source Approval Testing of Minimum and Maximum Dimensioned Hoses /Components. All testing conducted on assemblies and hoses manufactured with mini- mum and maximum dimensions is to be con- ducted one time only, for the initial E
30、ngineering Source Approval. Testing to 3.10, The Cyclical Corrosion Test, is to be conducted one time only, for the initial Engineering Source Approval. 3.1.8 Coupling Assembly Required Tests. All test samples must be qualified dimensionally. All data points must be reported. For samples de- structi
31、vely tested, mode of failure must be re- ported. All test specimens must be retained by the supplier and supplied to the GM Materials Engineer for review, if requested. Test Proce- dures referencing specific minimum test values that must be met, must be met by the 3 sigma limit of the sample populat
32、ion tested. 3.1.9 Crimp Compression. Test samples throughout this specification will be referred to as minimum hose compression, nominal hose compression or maximum hose compression samples. The requirements for these conditions are described in Appendix A. If not specified, the test samples shall b
33、e of nominal hose compres- sion. 3.2 Leak Test. This test shall be conducted on test samples prior to conducting test proce- dures 3.3 through 3.11, 3.14 and 3.15. 3.2.1 Test Procedure. Six (6) hose assembly samples at nominal hose compression are to be tested. 3.2.2 Coupled Assemblies. There shall
34、be no indication of air leakage at the coupling or in the hose member when the assembly is subjected to a minimum of 825 kPa under water. Care must be taken to ensure that an apparent leak is continuous and not the short term escaping of air entrapped between the inner tube and outer cover. This is
35、accomplished by subjecting the assembly to pressure for 3 to 5 minutes. Pres- sure decay or other leak testing methods may be substituted for the air under water method when equivalence is proven and Engineering Approval is granted by the GM Materials Engi- neer issuing the Engineering Source Approv
36、al. 3.2.3 Quick-Connector Assemblies. There shall be no indication of air leakage from the connector assembly or from the hose member, after allowance for temperature compression, at low pressure 70 7 kPa, or high pressure at a minimum of 825 kPa. Air under water pressure testing may be used. Care m
37、ust be taken to ensure that an apparent leak is continuous and not the short term escaping of air entrapped between the inner tube and outer cover. This is accomplished by subjecting the assembly to pressure for 3 to 5 minutes. Pressure decay or other leak testing methods may be substituted for the
38、air under water method when equiva- lence is proven and Engineering Approval is granted by the GM Materials Engineering issu- ing the Engineering Source Approval. 3.2.4 Acceptance Determination. There shall be no evidence of air leakage under the condi- tions of the test. 3.3 Cold Leak Test. 3.3.1 T
39、est Procedure. Six (6) hose assembly samples at nominal hose compression are to be GM9090P GM ENGINEERING STANDARDS Copyright 2004 General Motors Corporation All Rights Reserved Page 4 of 9 April 2004 tested. Fill the coupled hose assembly with 50% Ethylene Glycol: 50% water solution (v:v). Weigh th
40、e filled hose assembly. Place the as- sembly in an environmental chamber at 18 2C and pressurize the assembly to 275 7 kPa. Hold the pressure and temperature for 2 h. Reduce the pressure to 0 7 kPa, re- move the assembly from the environmental chamber and allow to warm to room tempera- ture. Weigh t
41、he assembly, making sure the outer hose surface is dry. 3.3.2 Acceptance Determination. Sample must weigh within 3.0 g of original weight. 3.4 Tensile Test. 3.4.1 Test Procedure. Six (6) hose assembly samples at nominal hose compression are to be tested. Apply an increasing tensile load at ap- proxi
42、mately 25 mm/minute along the hose cen- terline. Tensile load at failure should be on a permanent recording. 3.4.2 Acceptance Determination. The load at failure either by separation of the hose speci- men from the end fittings or by rupture of the hose structure shall not be less than 668 N. 3.5 Bur
43、st Test. 3.5.1 Test Procedure. Six (6) hose assembly samples at nominal hose compression are to be tested. 3.5.2 Heater Hose Assemblies. Subject the assembly to 1725 kPa internal pressure using 50 5% Ethylene Glycol: 50 5% water solution reservoir pressurization. Linear rate of pressure rise to be 1
44、72 kPa/10 s in the range of 1379 to 1725 kPa. Hold 1725 kPa pressure for 60 5 s, then increase pressure to burst. Production assemblies containing a water valve, flow re- stricter, or any sensor assembly should have the valve or assembly removed and replaced with a straight short pipe length clamped
45、 in place. 3.5.3 Assemblies Containing Radiator Hoses. Subject assembly to 1208 kPa internal pressure using 50 5% Ethylene Glycol: 50 5% water solution reservoir pressurization. Linear rate of pressure rise to be 172 kPa/10 s in the range of 690 to 1208 kPa. Hold 1208 kPa pressure for 60 5 s, then i
46、ncrease pressure to burst. Pro- duction assemblies containing a water valve, flow restricter, or any sensor assembly should have the valve or assembly removed and re- placed with a straight short pipe length clamped in place. 3.5.4 Acceptance Determination. There shall be no indication of leakage at
47、 the coupling or in the bulk of the hose during the 60 s held period. The final burst pressure shall exceed 1725 kPa for assemblies containing heater hose (ID = 19 mm). 3.6 Vacuum Test. 3.6.1 Test Procedure. Six (6) hose assembly samples at nominal hose compression are to be tested. At 24 3C, evacua
48、te the hose and tube assembly until the internal pressure of the as- sembly is stabilized at a maximum pressure of 0.50 psi (equivalent to a maximum internal pres- sure of 25 mm Hg absolute pressure). Discon- nect the pump and hold the vacuum for 10 min- utes. 3.6.2 Acceptance Determination. The ass
49、em- bly must hold the vacuum within 3% during the 10 minute hold period. 3.7 Insertion Force Test. 3.7.1 Test Procedure. Position the connector in a compression force tester (Instron or equiva- lent) with a simulated tube end, starting entry into the connector. The simulated tube end must be equivalent in dimensioning to the production intent tube end. Additionally, the dimensions of the tube end must be the maximum values al- lowed by the tolerancing of the tube end. Apply an increasing compression load at approxi- mately 50 m