BS-EN-4015-2003.pdf

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1、BRITISH STANDARD AEROSPACE SERIES BS EN 4015:2003 Inserts, thickwall, self-locking Installation and removal procedure The European Standard EN 4015:2003 has the status of a British Standard ICS 49.030.30 ? Licensed Copy: sheffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled C

2、opy, (c) BSI BS EN 4015:2003 This British Standard was published under the authority of the Standards Policy and Strategy Committee on 7 February 2003 BSI 7 February 2003 ISBN 0 580 41219 9 National foreword This British Standard is the official English language version of EN 4015:2003. The UK parti

3、cipation in its preparation was entrusted by Technical Committee ACE/12, Aerospace fasteners and fastening systems, to Subcommittee ACE/12/1, Aerospace fasteners and fastening systems (international), which has the responsibility to: A list of organizations represented on this subcommittee can be ob

4、tained on request to its secretary. Cross-references The British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Search” facilit

5、y of the BSI Electronic Catalogue or of British Standards Online. This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations.

6、aid enquirers to understand the text; present to the responsible international/European committee any enquiries on the interpretation, or proposals for change, and keep the UK interests informed; monitor related international and European developments and promulgate them in the UK. Summary of pages

7、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 copyright date displayed in this document indicates when the document was last issued. Amendments issued since publication Amd. No. DateComments Licensed Cop

8、y: sheffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 4015 January 2003 ICS 49.030.30 English version Aerospace series - Inserts, thickwall, self-locking - Installation and removal procedure This European S

9、tandard was approved by CEN on 2 June 2002. 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

10、such national standards may be obtained on application to the Management Centre 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

11、 and notified to the Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slova

12、kia, 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 2003 CENAll rights of exploitation in any form and by any means reserved worldwide for CEN n

13、ational Members. Ref. No. EN 4015:2003 E Licensed Copy: sheffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:2003 (E) 2 Contentspage Foreword3 1Scope 3 2Normative references 3 3Insert information 4 3.1Broaching .4 3.1.1In materials with Rm 900 MPa4 3.1.

14、2In materials with Rm 900 MPa.6 4Hole serration profile.7 5Inspection requirements before installation.8 6Installation tools.8 6.1General8 6.2Drive tools for installation.8 6.2.1Air crimping tool 9 6.2.2Hand crimping tooling.10 7Checks of insert position and crimping 11 8Inspection of minimum self-l

15、ocking torque12 9Insert removal.12 10Repair14 10.1General rules14 10.2Installation of a first repair size insert.14 Licensed Copy: sheffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:2003 (E) 3 Foreword This document (EN 4015:2003) has been prepared by

16、 the European Association of Aerospace Manufacturers Standardization (AECMA-STAN). After enquiries 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,

17、prior to its presentation to CEN. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by July 2003, and conflicting national standards shall be withdrawn at the latest by July 2003. According to the CEN/

18、CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal

19、, Slovakia, Spain, Sweden, Switzerland and the United Kingdom. 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 references E

20、N 3831Aerospace series - Inserts, thickwall, self-locking, in heat resisting steel FE-PM3801 (17-4PH), MoS2 coated 1) EN 4014Aerospace series - Inserts, thickwall, self-locking - Design standard 1) 1)Published as AECMA Prestandard at the date of publication of this standard Licensed Copy: sheffieldu

21、n sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:2003 (E) 4 3 Insert information Tables 1 and 2 provide the cross reference between the insert codification, the related bolt thread and the tapped hole diameter. Table 1 Normal size insert Insert referenceBolt

22、thread diameterTapped hole diameterTapped hole reference EN3831-050-0MJ5x0,8MJ8x1EN4014-050-0 EN3831-060-0MJ6x1MJ9x1EN4014-060-0 EN3831-070-0MJ7x1MJ10x1EN4014-070-0 EN3831-080-0MJ8x1MJ11X1EN4014-080-0 EN3831-100-0MJ10x1,25MJS13x1EN4014-100-0 Table 2 First repair size insert Insert referenceBolt thre

23、ad diameterTapped hole diameterTapped hole reference EN3831-050-1MJ5x0,8MJ9x1EN4014-050-1 EN3831-060-1MJ6x1MJ10x1EN4014-060-1 EN3831-070-1MJ7x1MJ11x1EN4014-070-1 EN3831-080-1MJ8x1MJ12x1EN4014-080-1 EN3831-100-1MJ10x1,25MJ14x1EN4014-100-1 3.1 Broaching 3.1.1 In materials with Rm 900 MPa Figure 1 illu

24、strates an example of hand broaching tool which may be used in materials with a strength of Rm 900 MPa. Table 3 gives dimensions of the broach. Licensed Copy: sheffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:2003 (E) 5 Dimensions in millimetres Key

25、1J, number of teeth 2Mandrel 3Nut backed off 4Turn clockwise to remove cutter 5 Stop 6Pin up 7Mandrel stops here 8Pin down 9Body 10Cutter up 11Pilot 12Broaching complete 13 Tap drill hole 14 Load 15 Cutter up 16 View enlarged cutter up Figure 1 Licensed Copy: sheffieldun sheffieldun, na, Sat Nov 04

26、08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:2003 (E) 6 Table 3 Dimensions in millimetres Tapped hole reference A Ref. B + 0,06 + 0,02 C 0,03 E Ref. F Ref. H 1 , 0 0 + JL Ref. R1 max. EN 4014-050-0S8,5349,37186,84,124820,15 EN 4014-060-0S EN 4014-050-1S 9,5010,367,84,22784 EN 4014-070

27、-0S EN 4014-060-1S 10,49 5 11,28 20 8,84,62885 EN 4014-080-0S EN 4014-070-1S 11,4712,32219,84,73287 EN 4014-080-1S12,7313,572210,83388 EN 4014-100-0S13,46 6 14,302311,85,137 EN 4014-100-1S14,55715,392412,85,34090 0,2 3.1.2 In materials with Rm 900 MPa Figure 2 illustrates an example of a machine bro

28、aching tool which may be used in materials with a strength of Rm 900 MPa. Table 3 gives dimensions of the broach. Dimensions in millimetres Key 1J, number of teeth 2Wobbling drift holder 3Broach 4Tool Figure 2 Licensed Copy: sheffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontroll

29、ed Copy, (c) BSI EN 4015:2003 (E) 7 4 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 serration profile in the counterbore of the installation hole. Table 4 Dimensions in millimetres DimensionsKTapped hole ref

30、erence Tapped hole diameter Nominal diameter (Associated bolt) ABAC J Number of serrationmax.min. EN 4014-050-0SMJ8x1MJ58,428,02242,602 EN 4014-060-0SMJ6 EN 4014-050-1SMJ9x1MJ59,398,99272,702,1 EN 4014-070-0SMJ7 EN 4014-060-1SMJ10x1MJ610,389,982832,4 EN 4014-080-0SMJ8 EN 4014-070-1SMJ11x1MJ711,3610,

31、96323,22,6 EN 4014-080-1SMJ12x1MJ812,6212,2233 EN 4014-100-0SMJS13x113,3512,95373,63 EN 4014-100-1SMJ14x1 MJ10 14,4514,05403,83,2 Dimensions in millimetres Key 1 R: 0,1 min. Key 1 Major diameter of serration 2 Pitch diameter 3 thread Figure 3Figure 4 Licensed Copy: sheffieldun sheffieldun, na, Sat N

32、ov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:2003 (E) 8 5 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 objects, grease, oil, et

33、c. 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. 6 Installation tools 6.1 General The tools

34、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 achieved and on no account

35、 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 either the insertion or sw

36、aging of the insert to enable correct installation of the insert. 6.2 Drive tools for installation In order to facilitate the correct assembly of the inserts use the appropriate tools. Licensed Copy: sheffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:

37、2003 (E) 9 6.2.1 Air crimping tool Figure 5 illustrates 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 1Self-locking nut 2Body 3Plastic ring retainer 4Pin 5Plastic ring 6Mandrel Figure 5 Tab

38、le 5 Dimensions in millimetres Insert referenceA Thread B 05,0 0 + C 0 05,0 DE 0,5 H 05,0 0 + LM 0 1 , 0 EN3831-050-0MJ5x0,86,986762,25 EN3831-060-0MJ6x17,99 1523 7772,35 EN3831-070-0MJ7x18,91016248792,65 EN3831-080-0MJ8x19,91117259832,85 EN3831-100-0MJ10x1,2511,913182611843,25 20 Licensed Copy: she

39、ffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:2003 (E) 10 Table 6 Dimensions in millimetres Insert reference A Thread B 05,0 0 + C 0 05,0 DE 0,5 H 05,0 0 + LM 0 1 , 0 EN3831-050-1MJ5x0,87,9915237762,25 EN3831-060-1MJ6x18,91016248772,35 EN3831-070-1M

40、J7x19,91117259792,65 EN3831-080-1MJ8x111,913182611832,85 EN3831-100-1MJ10x1,2512,914192712843,25 20 6.2.1.1 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 too

41、l, screw the insert into the tapped hole until positioned; the screwing/crimping tool comes into contact with the surface, when operating the air gun. The insert comes automatically in the crimping position: 0,3 mm to 0,5 mm below the surface of the casing. Use the air gun in the percussion mode to

42、bring the upper part of the tool against the plastic ring retainer and initiate crimping of the insert. Unscrew the tool to extract it from the crimped insert. 6.2.2 Hand crimping tooling For hand crimping, use the screwing/crimping/unscrewing tool defined in 6.2.1 (figure 5) fitted with a sleeve (s

43、ee figure 6). 6.2.2.1 Procedure Screw the insert to be 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

44、surface. The insert is automatically positioned in the 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. Un

45、screw the crimping tool to extract it from the crimped insert. Key 1 Sleeve 2 Load Figure 6 Licensed Copy: sheffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:2003 (E) 11 7 Checks of insert position and crimping These checks shall be carried out with a

46、nd inspection gauge specific to each insert dimension, which shall be introduced inside the crimped counterbore (see figure 7). Dimensions are given in tables 7 and 8. Visual inspection of the crimped zone shall not reveal any cracks. Check of insert positionCheck of crimping Dimensions in millimetr

47、es Key 1Flush 2Chamfer 0,5x45 3Clear 4 Acceptable 5 Acceptable 6 Not acceptable 7 Not acceptable Figure 7 Table 7 Normal size insert Dimensions in millimetres Insert reference A 0 1 , 0 B 0 05,0 C 0,5 D 0 05,0 EF 0 05,0 G 0 1 , 0 H 0 05,0 S 0,25 T 0,25 EN3831-050-03,96,8101,355,57,952,65,964 EN3831-

48、060-04,77,8111,456,78,952,76,96,54,5 EN3831-070-05,78,8121,758,59,9537,975 EN3831-080-06,49,8131,9510,210,93,28,97,55,5 EN3831-100-07,911,8152,351212,93,610,98,56 20 Licensed Copy: sheffieldun sheffieldun, na, Sat Nov 04 08:36:01 GMT+00:00 2006, Uncontrolled Copy, (c) BSI EN 4015:2003 (E) 12 Table 8

49、 First repair size insert Dimensions in millimetres Insert reference A 0 1 , 0 B 0 05,0 C 0,5 D 0 05,0 EF 0 05,0 G 0 1 , 0 H 0 05,0 S 0,25 T 0,25 EN3831-050-13,97,8111,355,58,952,67,9564 EN3831-060-14,78,8121,456,79,952,78,956,54,5 EN3831-070-15,79,8131,758,510,939,9575 EN3831-080-16,410,8141,9510,212,93,210,97,55,5 EN3831-100-17,912,8172,351213,93,612,98,56 20 8 Inspection of minimum self-locking torque The minimum self-locking torque fo