《拧紧基础知识讲解》PPT课件.ppt

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1、美国英格索兰公司美国英格索兰公司拧紧基础知识拧紧机资料之一工具形式及选择工具形式及选择 POSITIVESPOSITIVES正版的正版的 High power to High power to weight ratioweight ratio重量比率高重量比率高 FastFast快速（速度快）快速（速度快）No ReactionNo Reaction没有反应没有反应 Non Technical Non Technical MaintenanceMaintenance非技术维修非技术维修 CompactCompact体积小体积小 InexpensiveInexpensive价格适中价格适中NEG

2、ATIVESNEGATIVES盗版的盗版的 Little or No controlLittle or No control半受半受控或不受控控或不受控 NoisyNoisy有噪音有噪音 High VibrationHigh Vibration高振动高振动冲击扳手冲击扳手冲击扳手结构冲击扳手结构外形、轮廓巨大的锤子NEGATIVESNEGATIVES消极消极消极消极t Torque Readoutt Run down speedt Two Hand Operation(angle wrenches)POSITIVESPOSITIVES积极积极积极积极ttGood RepeatabilityGo

3、od Repeatabilitytt Inexpensive Inexpensivett Low Overshoot Low Overshoot离合器型气动工具离合器型气动工具价格适宜冲劲低重复性能好运行速度下降双手操作自己读力矩 Once pre set torque Once pre set torque is delivered to the is delivered to the joint,Clutch spring joint,Clutch spring gets compressed gets compressed triggering the triggering the me

4、chanism to shut mechanism to shut off air supply to the off air supply to the motor,providing motor,providing excellent excellent repeatability.repeatability.一旦预先设定一旦预先设定的扭矩传递到结合处，离合器弹簧压缩，的扭矩传递到结合处，离合器弹簧压缩，触发空气供应切断机制运行触发空气供应切断机制运行 ，并能重复性，并能重复性工作，且效果优良。工作，且效果优良。离合器自动断气型扳手离合器自动断气型扳手扭矩推杆汽车末端离合器弹簧离合器调节螺

5、母螺丝起子POSITIVESPOSITIVES Accurate Accurate Low NoiseLow Noise CleanClean Closed-Loop FeedbackClosed-Loop Feedback ErgonomicErgonomic Low Running CostLow Running Cost Can be interfaced with Can be interfaced with PLCs and BCRsPLCs and BCRsNEGATIVESNEGATIVES High Initial InvestmentHigh Initial Investme

6、nt Torque ReactionTorque Reaction Two hand operation Two hand operation(angle tools)(angle tools)电动拧紧机电动拧紧机精确噪音低清洁闭环反馈工效性运行成本低兼具燃料装填控制系统 和BCRs初始投资高扭矩反应两手操作拧紧机控制柜拧紧机控制柜拧紧工具选择拧紧工具选择Operator ErgonomicsOperator Ergonomics(Reaction,Tool Weight,Arm(Reaction,Tool Weight,Arm Position,Frequency)Position,Freq

7、uency)Cycle RateCycle RateFastener and Drive TypeFastener and Drive TypeAccess to FastenerAccess to Fastener(Size and Space Constraints)(Size and Space Constraints)Joint CriticalityJoint CriticalityData Collection Data Collection Torque LevelTorque LevelBudgetBudgetPower SourcePower SourceMaintainab

8、ilityMaintainabilityTightening StrategyTightening Strategy严谨的策略维修能力力源数据收集结合临界预算紧固件通道扭矩水平循环率紧固件和驱动类型人机工程学的应用（反应，工具重量，力臂位置，频率）拧紧工具选择综述拧紧工具选择综述Reliable bolted joints are dependent on many factors:Reliable bolted joints are dependent on many factors:Fastener quality and typeFastener quality and typeCons

9、istency of joint materialsConsistency of joint materialsAssembly tool usedAssembly tool usedAssembly method or strategyAssembly method or strategyOperator InfluenceOperator InfluenceFrictional ScatterFrictional ScatterMaintenance of bolt clamp loadMaintenance of bolt clamp loadTool and assembly meth

10、od selection should occur early Tool and assembly method selection should occur early in the design process to be most effectivein the design process to be most effective螺栓连接的可靠性影响因素很多：紧固件质量和类型联合材料的一致性所用的集装工具集装方法或集装策略操作人员的影响摩擦散射螺栓钳负荷的维护工具和装配方法的选择应在设计过程中及早进行，这样才最有效扭矩测量术语扭矩测量术语 动态扭矩动态扭矩-Peak Torque Me

11、asured During the Installation of a Peak Torque Measured During the Installation of a Fastener Using a Power ToolFastener Using a Power Tool-The Preferred and Most-The Preferred and Most Accurate Measurement For Assembly Statistical process Accurate Measurement For Assembly Statistical process Contr

12、olControl 静态扭矩静态扭矩-Torque Value That Exist Without Producing Rotation in a Torque Value That Exist Without Producing Rotation in a FastenerFastener-Used Only as an Indication of a Minimum Torque-Used Only as an Indication of a Minimum Torque残留扭矩-Torque Measured After Fastener is Installed by Rotatin

13、g Torque Measured After Fastener is Installed by Rotating The Fastener in Tightening DirectionThe Fastener in Tightening Direction-Can Have Significant Measurement Error depending on-Can Have Significant Measurement Error depending on equipment used to Audit Torqueequipment used to Audit Torque峰顶扭矩测

14、量应用在用扭力工具进行紧固件安装中-这是统计过程控制最恰当最精确的测量方法。转矩存在的价值不产生旋转的紧固件，仅作为最低转矩的说明当紧固件按某一方向被旋紧安装后再进行扭矩测量重大测量误差的产生取决于所使用设备的审计转矩扭矩测量扭矩测量“标记法 Back-to-the-Mark”准确度准确度:高高 方便性方便性/速度速度:低低Mark then loosen Bolt.Tighten Back to Original Mark then loosen Bolt.Tighten Back to Original PositionPosition标记后柠松螺栓，再拧紧回初始位置。标记后柠松螺栓，再拧

15、紧回初始位置。Truly Checks Dynamic Tightening TorqueTruly Checks Dynamic Tightening Torque切切实实的检查动态切切实实的检查动态拧紧扭矩拧紧扭矩Works Only in Tapped HolesWorks Only in Tapped Holes这种方法仅仅用在各塞孔处这种方法仅仅用在各塞孔处Time ConsumingTime Consuming耗费时间耗费时间扭矩测量扭矩测量“Off-torque”准确度准确度:低低 方便性方便性/速度速度:中中Measure Peak Loosening Torque测量松动扭矩

16、的峰值测量松动扭矩的峰值Measurement of Off-Torque Does Not Relate Accurately to Tightening Torque Off-Torque Off-Torque紧固扭矩的测量方法缺乏准确性紧固扭矩的测量方法缺乏准确性不知道不知道扭矩测量扭矩测量带响声手动扭矩扳手 准确度准确度:低低 方便性方便性/速度速度:高高Apply Torque Until Wrench Clicks at Set TorqueApply Torque Until Wrench Clicks at Set Torque扳手点扳手点击所设扭矩之前的扭矩为适合扭矩击所设扭

17、矩之前的扭矩为适合扭矩Not a Real Audit Method-Basically a Torque Re-Not a Real Audit Method-Basically a Torque Re-Application MethodApplication Method不是一种真正的审查方法不是一种真正的审查方法,基本上是一种扭矩再应用检测基本上是一种扭矩再应用检测Only Gives Assurance That Inspected Fastener Has Only Gives Assurance That Inspected Fastener Has Been Tightened

18、Been Tightened只能用来检测早先紧固件的紧固情况只能用来检测早先紧固件的紧固情况扭矩测量扭矩测量扭矩手动扳手 准确度准确度:低低 方便性方便性/速度速度:中中Apply Torque Until Operator Senses MovementApply Torque Until Operator Senses Movement操作人员能够感应到移操作人员能够感应到移动之前的扭矩为适合扭矩动之前的扭矩为适合扭矩Read Read PeakPeak Torque on Tool Indicator Torque on Tool Indicator从指示器上读出峰值扭矩从指示器上读出峰

19、值扭矩Subject to Operators Skill and Joint ConditionsSubject to Operators Skill and Joint Conditions遵从操作技能和共同条遵从操作技能和共同条件件扭矩测量扭矩测量扭矩/角度 扳手带外部记录仪器 准确度准确度:较高较高 方便性方便性/速度速度:低低Capable of Measuring Dynamic TorqueCapable of Measuring Dynamic Torque能够测量动态扭矩能够测量动态扭矩Equipment Is Bulky and Difficult to UseEquipm

20、ent Is Bulky and Difficult to Use设备庞大很难用设备庞大很难用扭矩测量扭矩测量扭矩/角度 力矩扳手带有动态扭矩监测算法准确度准确度:高高 方便性方便性/速度速度:高高Truly Checks Dynamic Torque AfterTruly Checks Dynamic Torque After the Fastener Has Been Rotated a the Fastener Has Been Rotated a Small Amount Small Amount 紧固件已经小幅度旋转之后再切实检查动态扭矩紧固件已经小幅度旋转之后再切实检查动态扭矩动态

21、扭矩动态扭矩Peak Static Torque静态扭矩峰值Angle,Angle,q q q qResidual Torque Measured Dynamically残余扭矩的动态测量Torque,TTorque,T“Snug”Torque“事宜扭矩Capture Angle2-4角度工件连接基础知识工件连接基础知识Hard Joint-30 or lessHard Joint-30 or less -high torque rate -high torque rate 硬连接硬连接3030或更小或更小高转矩率高转矩率Soft Joint-720 or moreSoft Joint-720

22、 or more -low torque rate -low torque rate 软连接720或更大-低扭矩率连接形式连接形式 硬连接硬连接 30 30 or less rotation between snug and final or less rotation between snug and final torque torque (27 between 10%and 100%torque)(27 between 10%and 100%torque)介于适宜扭矩与最后扭矩介于适宜扭矩与最后扭矩3030度或小于度或小于3030度的旋转度的旋转 (0.27(0.27的公差的公差)。软连

23、接软连接 720 720 rotation between snug and final torque rotation between snug and final torque (650 between 10%and 100%torque)(650 between 10%and 100%torque)介于适宜扭矩与最后扭矩做介于适宜扭矩与最后扭矩做720720度的旋转度的旋转 (6.5(6.5的公差的公差)。JOINT RATES AS DEFINED BY ISO 5393连接率的定义由国际标准化组织5393界定Joint rate highly effects the final cl

24、amp load achieved by a given torque连接率对最后给定的夹负载力矩有很大的影响力Clamp Load(torque)Angle(Time)Clamp Load夹负荷夹负荷AngleTORQUETORQUE扭矩扭矩TLTLTLTHTHTHTCTCTCSNUGSNUGSNUG 27 27A AAsss 30 30A A11TLTLTHTHTCTCSNUGSNUG适宜适宜适宜适宜 720 720A A00A Ass连接形式连接形式连接形式连接形式 PREVAILING TORQUEPREVAILING TORQUENotable Torque Before Faste

25、ner Begins to SeatNotable Torque Before Fastener Begins to Seat紧固件在开紧固件在开始设定位置前应予以重视始设定位置前应予以重视Can be Hard or SoftCan be Hard or Soft或是硬链接或只是软连接或是硬链接或只是软连接ExamplesExamples例如例如-Thread Forming-Thread Forming线程的形成线程的形成-Thread Cutting -Thread Cutting 螺纹切削螺纹切削-Self Locking -Self Locking 自锁功能自锁功能-Damaged-

26、Damaged Threads-Damaged Threads-Damaged 螺纹破损螺纹破损PrevailingTorque现行扭矩现行扭矩SNUGTLTHTC拧紧基础知识拧紧基础知识扭矩和转角扭矩和转角长度长度(Feet,Meters)脚、米力力(Newtons,Pounds)牛顿,英镑扭矩扭矩=力力 x 长度长度角度90 135 拧紧基础拧紧基础 Tightening Threaded Tightening Threaded Fasteners is Basically an Fasteners is Basically an Energy Transfer ProcessEnergy

27、 Transfer Process 螺纹紧固件紧固过程可以说是能量转移的过程螺纹紧固件紧固过程可以说是能量转移的过程 Area Under Torque-Angle Area Under Torque-Angle Curve is Proportional to the Curve is Proportional to the Energy Required to Tighten Energy Required to Tighten the Fastenerthe Fastener 扭矩扭矩角度曲线以下的区域与紧固件紧固所需的能量角度曲线以下的区域与紧固件紧固所需的能量成正比。成正比。T=K

28、d FT=K d F T=TorqueT=Torque扭矩扭矩 d=Nominal Diameter d=Nominal Diameter公众认可公众认可的直径的直径 F=Force F=Force力力 K=Friction Factor K=Friction Factor 摩擦因素摩擦因素角度,q扭矩,TArea Area Energy Energy扭矩消耗到哪里去了扭矩消耗到哪里去了?螺纹摩擦力夹紧力螺帽摩擦力扭矩螺帽摩擦力螺帽摩擦力 55%罗纹摩擦力罗纹摩擦力-35%夹紧力夹紧力-10%拧紧曲线拧紧曲线扭矩上限扭矩上限扭矩下限扭矩下限合格窗口合格窗口角度下限角度下限角度上限角度上限Snu

29、g Torque Snug Torque(Threshold)(Threshold)适宜扭矩适宜扭矩(阈值）阈值）PrevailingPrevailing TorqueTorque现行扭矩现行扭矩扭矩扭矩(夹紧力夹紧力)角度角度,q q目标扭矩目标扭矩 螺栓屈服点螺栓屈服点Plastic RangePlastic Range塑性范围塑性范围Elastic RangeElastic Range弹性范围弹性范围拧紧曲线拧紧曲线Rundown破旧Rundown:Before the bolt head/nut comes into full contact with bearing area在螺栓头

30、/螺母完全接触轴承区域之前Plastic/Post-Yield塑性/标杆-效益Plastic/Post-Yield:Permanent deformation of fastener or possible yielding of threads,joint or gasket紧固件的永久变形或只是线程、连接或垫圈的形成Elastic Clamping弹性夹紧Elastic Clamping:Constant torque/angle slope where energy is transferred from tool to assembly恒量扭矩/斜率界定在能源问题转移到装配工具过程时S

31、nug适宜Snug:Fastener and joint mating surfaces are drawn into alignment 紧固件及连接点表层要对齐扭矩控制拧紧过程扭矩控制拧紧过程扭矩控制拧紧过程扭矩控制拧紧过程拧紧方法拧紧方法扭矩上限扭矩上限扭矩下限扭矩下限Snug Torque Snug Torque(Threshold)(Threshold)适宜的扭矩适宜的扭矩(阈值阈值)。扭矩扭矩(夹紧力夹紧力)角度角度,q q目标扭矩目标扭矩 The variation in clamp loads is controlled by The variation in clamp lo

32、ads is controlled by friction scatter.Using afriction scatter.Using a very accuratevery accurate wrench wrench will not help preload scatter.However,awill not help preload scatter.However,a very very inaccurateinaccurate wrench will have a detrimental wrench will have a detrimental impact on preload

33、 scatterimpact on preload scatter.负荷作用下的变形源于摩擦。使用非常精确负荷作用下的变形源于摩擦。使用非常精确的扳手不能缓解再负荷式的散射，然而对负荷分散会产生不利影响。的扳手不能缓解再负荷式的散射，然而对负荷分散会产生不利影响。扭矩控制拧紧扭矩控制拧紧扭矩控制拧紧扭矩控制拧紧拧紧方法拧紧方法扭矩控制拧紧扭矩控制拧紧拧紧方法拧紧方法Applied Torque Is Controlled Directly or IndirectlyApplied Torque Is Controlled Directly or Indirectly扭矩的应用直接或间接受控扭矩

34、的应用直接或间接受控Target Torque Is Usually 50%to 85%of Yield TorqueTarget Torque Is Usually 50%to 85%of Yield Torque目标扭矩通常介于效益扭矩的目标扭矩通常介于效益扭矩的50%-85%50%-85%Used in Elastic Range of FastenerUsed in Elastic Range of Fastener用于紧固件弹性范围内用于紧固件弹性范围内90%Of Applied Torque Is Used to Overcome Friction90%Of Applied Tor

35、que Is Used to Overcome Friction 90%90%的应用扭矩是用来克服摩擦的的应用扭矩是用来克服摩擦的Also known as:Torque,Straight TorqueAlso known as:Torque,Straight Torque据目前所知：扭矩、直扭矩据目前所知：扭矩、直扭矩Preload Accuracy 25%Preload Accuracy 25%再负荷精确度再负荷精确度25%25%Step 1:Apply a Torque to Consolidate the JointStep 1:Apply a Torque to Consolidat

36、e the JointComponents(Components(Snug TorqueSnug Torque)第一步：运用扭矩来巩固部件的连接情况第一步：运用扭矩来巩固部件的连接情况Step 2:Turn the Fastener Through a Pre-determined Step 2:Turn the Fastener Through a Pre-determined AngleAngle第二步第二步:通过预先设定的角度进行紧固通过预先设定的角度进行紧固Originally Developed for Beyond Yield Tightening,Now Originally D

37、eveloped for Beyond Yield Tightening,Now Also Used in the Elastic RangeAlso Used in the Elastic Range最初的超出拧紧区域的发展屈服最初的超出拧紧区域的发展屈服,现在也用现在也用在弹性范围内在弹性范围内Requires Application Testing to Establish Snug Torque Requires Application Testing to Establish Snug Torque and Angle Parameters and Angle Parameters

38、需要应用试验建立适宜的转矩和角参数需要应用试验建立适宜的转矩和角参数Also known as:Turn of the Nut,Torque-AngleAlso known as:Turn of the Nut,Torque-Angle 目前所知目前所知:螺母的旋转扭矩螺母的旋转扭矩-角度角度Preload Accuracy 15%Preload Accuracy 15%再负荷精确度再负荷精确度15%15%角度控制拧紧方法拧紧方法角度控制角度控制Low Angle Limit角度下线High Angle Limit角度上限Snug Torque Snug Torque(Threshold)(T

39、hreshold)Torque(Clamp Load)Angle,q q角度控制角度控制Scatter in Preload is Caused Mainly by The Scatter in Preload is Caused Mainly by The Scatter in Friction During the Torque Tightening Scatter in Friction During the Torque Tightening(Snug Torque)Portion of the Tightening(Snug Torque)Portion of the Tighten

40、ing ProcedureProcedure预分散主要由于在紧缩过程中扭矩拧紧部分产生的分散摩擦造成的。预分散主要由于在紧缩过程中扭矩拧紧部分产生的分散摩擦造成的。During the Angle Tightening Portion There is no During the Angle Tightening Portion There is no Scatter in Preload Due to Friction,Only the Scatter in Preload Due to Friction,Only the Scatter in Applied AngleScatter in

41、 Applied Angle Turned在角度紧缩部分，没有因摩擦而在角度紧缩部分，没有因摩擦而产生负荷的散射，只有应用角度旋转时的散射。产生负荷的散射，只有应用角度旋转时的散射。角度控制角度控制角度说明:Snug torque has a tolerance which can increase the Snug torque has a tolerance which can increase the initial clamp load scatter.initial clamp load scatter.适宜扭矩已为能够增加最初的预散射提供了空间。适宜扭矩已为能够增加最初的预散射提供

42、了空间。A low snug torque should be used whenever possible.A low snug torque should be used whenever possible.When a high snug torque is used,the effect of constant When a high snug torque is used,the effect of constant preload preload v v.angle is lost.angle is lost.较低的适宜扭矩应该尽量加以利用。而当使用一个高的适较低的适宜扭矩应该尽量

43、加以利用。而当使用一个高的适宜扭矩时宜扭矩时,预设的角度常量的作用会被忽视。预设的角度常量的作用会被忽视。A low snug torque will also reduce the effects of torque A low snug torque will also reduce the effects of torque scatter before the angle is counted.scatter before the angle is counted.角度计算之前，较低的适宜扭矩将角度计算之前，较低的适宜扭矩将会减少扭矩分散。会减少扭矩分散。When tightening

44、 in the plastic range of a fastener,When tightening in the plastic range of a fastener,variation in yield strength is also a factor.variation in yield strength is also a factor.在紧固件塑性范围内紧缩时，在紧固件塑性范围内紧缩时，变形也是产生角度的一个原因。变形也是产生角度的一个原因。屈服点控制屈服点控制Torque and Angle Are Monitored During TighteningTorque and

45、Angle Are Monitored During Tightening紧缩时扭矩和角度是相紧缩时扭矩和角度是相辅相成的。辅相成的。The Maximum Gradient is Stored&the Yield Point Identified When The Maximum Gradient is Stored&the Yield Point Identified When the Gradient Falls to a Fraction of the Maximumthe Gradient Falls to a Fraction of the Maximum当梯度下降达到最大值的一部

46、当梯度下降达到最大值的一部分时，最大梯度值会被记录，紧缩点也会被确定分时，最大梯度值会被记录，紧缩点也会被确定。Utilizes Maximum Load Potential of the FastenerUtilizes Maximum Load Potential of the Fastener利用紧固件的最大承载潜力利用紧固件的最大承载潜力Largely Uninfluenced by FrictionLargely Uninfluenced by Friction在很大程度上不受摩擦的影响在很大程度上不受摩擦的影响Allows Torque Angle Inspection of Ev

47、ery TighteningAllows Torque Angle Inspection of Every Tightening允许对所有紧缩政策实允许对所有紧缩政策实施扭矩转角的监控施扭矩转角的监控Bolts Can Be ReusedBolts Can Be Reused螺栓可以重复利用螺栓可以重复利用Also known as:Torque to YieldAlso known as:Torque to Yield扭矩屈服点扭矩屈服点 Preload Accuracy 8%Preload Accuracy 8%拧紧方法拧紧方法屈服点控制屈服点控制50%of Peak Gradient50

48、%的峰值梯度Torque Torque GradientGradient扭矩梯度Bolt Yield Point螺栓屈服点TorqueTorqueTorque(Clamp Load)夹负荷Angle,q q屈服点控制屈服点控制Reduced Variation in Preload After Tightening:紧缩之后减少预负荷中的变形 Preload Scatter is More Dependent on Strength Preload Scatter is More Dependent on Strength Variation Than Friction VariationVa

49、riation Than Friction Variation 比起摩擦，比起摩擦，预分散更依赖于强度预分散更依赖于强度变化变化 Bolt Strength is More Controllable Than FrictionBolt Strength is More Controllable Than Friction螺栓强度比起摩擦力可控性更强。螺栓强度比起摩擦力可控性更强。PRELOAD,N,预负荷预负荷NThread线程线程GradeSizeRange8.810.912.98.810.912.9M4 x 0.7M4 x 0.7MinimumMinimum4,4006,2007,3003

50、.14.45.3MaximumMaximum5,6007,6008,8004.367.2M5 x 0.8M5 x 0.8MinimumMinimum7,20010,00012,2006.4911MaximumMaximum9,20012,40014,6008.71215M6 x 1.0M6 x 1.0MinimumMinimum10,20014,20016,100111418MaximumMaximum13,00017,60020,500152024M8 x 1.25M8 x 1.25MinimumMinimum18,60026,20031,400253744MaximumMaximum23,