拧紧基础知识讲解-修改版.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高的功率重量比高的功率重量比FastFast速度快速度快No ReactionNo Reaction反作用力小反作用力小Non Technical Non Technical MaintenanceMaintenance不需要专门的维不需要专门的维护护CompactCompact紧凑紧凑InexpensiveInexpensive物美价廉物美价廉NEGATI

2、VESNEGATIVES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双锤式大型锤滚珠凸轮机构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 RepeatabilityGood R

3、epeatabilitytt 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低过冲可重复性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 mechani

4、sm 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，并能重复性工作，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马达末端离合器弹簧离合器调节螺母螺丝起子POSITIVESPOSITIVESAccurate Accurate Low NoiseLow Noi

5、seCleanCleanClosed-Loop FeedbackClosed-Loop FeedbackErgonomicErgonomicLow Running CostLow Running CostCan be interfaced with Can be interfaced with PLCs and BCRsPLCs and BCRsNEGATIVESNEGATIVESHigh Initial InvestmentHigh Initial InvestmentTorque ReactionTorque ReactionTwo hand operation Two hand oper

6、ation(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人体工程学运行成本低可以与控制系统和BCRs连接初始投资高扭矩反作用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,Frequency)Cycle RateCycle RateFastener and Drive TypeFastener and Dri

7、ve TypeAccess to FastenerAccess to Fastener(Size and Space Constraints)(Size and Space Constraints)Joint CriticalityJoint CriticalityData Collection Data Collection Torque LevelTorque LevelBudgetBudgetPower SourcePower SourceMaintainabilityMaintainabilityTightening StrategyTightening Strategy拧紧策略可维修

8、性动力源数据采集结合处的危险程度预算紧固件通道扭矩等级循环速率紧固件和驱动形式人机工程学的应用（反作用力，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 typeConsistency of joint materialsAssembly tool usedAssembly method or strategyOperator Inf

9、luenceFrictional ScatterMaintenance of bolt clamp loadTool and assembly method 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工具安装方法或策略操作人员的影响摩擦的传

10、递螺栓夹紧力的保持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 Measured During the Installation of a Fastener Using a Peak Torque Measured During the Installation of a Fastener Using a Power ToolPower Tool-The Preferred and Most Accurate Measurement For-The Preferred and Most Accurate Measure

11、ment For Assembly Statistical process ControlAssembly Statistical process Control峰顶扭矩测量应用在用扭力工具进行的紧固件安装中-这是统计过程控制最恰当最精确的测量方法。静态扭矩静态扭矩-Torque Value That Exist Without Producing Rotation in a FastenerTorque Value That Exist Without Producing Rotation in a Fastener在在紧固件之间不发生相对旋转的扭矩值紧固件之间不发生相对旋转的扭矩值-Use

12、d Only as an Indication of a Minimum Torque-Used Only as an Indication of a Minimum Torque 只作为扭矩最小值的象征只作为扭矩最小值的象征残留扭矩残留扭矩-Torque Measured After Fastener is Installed by Rotating The Fastener in Torque Measured After Fastener is Installed by Rotating The Fastener in Tightening DirectionTightening Dir

13、ection在紧固件拧紧后进行扭矩测量在紧固件拧紧后进行扭矩测量-Can Have Significant Measurement Error depending on equipment used to-Can Have Significant Measurement Error depending on equipment used to Audit TorqueAudit Torque由于扭矩测量设备的不同而出现明显的测量误差由于扭矩测量设备的不同而出现明显的测量误差扭矩测量扭矩测量“标记法 Back-to-the-Mark”准确度:高 方便性/速度:低Mark then loosen

14、Bolt.Tighten Back to Original Position标记后柠松螺栓，再拧紧回初始位置。Truly Checks Dynamic Tightening Torque切切实实的检查动态拧紧扭矩Works Only in Tapped Holes这种方法只适用于螺纹孔Time Consuming耗费时间扭矩测量扭矩测量“Off-torque”松动扭矩 准确度准确度:低低 方便性方便性/速度速度:中中Measure Peak Loosening Torque测量松动扭矩的峰值Measurement of Off-Torque Does Not Relate Accurately

15、 to Tightening Torque 松动扭矩与拧紧扭矩没有明确的联系扭矩测量扭矩测量定扭矩扳手 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 Torque扳手发出响声时所施加的扭矩即为设定扭矩Not a Real Audit Method-Basically a Torque Re-Application Method不是一种真正的检测方法,基本上是一种扭矩再应用检测Only Gives Assurance That Inspected Fastener Has Been Tightened只能确定检测的

16、紧固件已经被拧紧扭矩测量扭矩测量测扭矩扳手 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 Movement操作人员能够感应到移动之前的扭矩为适合扭矩Read Peak Torque on Tool Indicator从指示器上读出峰值扭矩Subject to Operators Skill and Joint Conditions收到操作者技能水平和连接条件的限制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 To

17、rque能够测量动态扭矩Equipment Is Bulky and Difficult to Use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 After the Fastener Has Been Rotated a Small Amount小幅度旋转紧固件之后能够真实地检测出动态扭矩动态扭矩动态扭矩Peak Static Torque静态扭矩峰值Angle,Angle,q q q qResidual Torque Measured Dynamically残余扭

18、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30或更小高转矩率Soft Joint-720 or moreSoft Joint-720 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 or less rotation between s

19、nug and final torque (27 between 10%and 100%torque)介于适宜扭矩与最后扭矩30度或小于30度的旋转 (0.27的公差)。软连接软连接720 rotation between snug and final torque (650 between 10%and 100%torque)介于适宜扭矩与最后扭矩做720度的旋转 (6.5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 clamp load achie

20、ved 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 Fastener Begins to

21、Seat紧固件在开始设定位置前应予以重视Can be Hard or Soft或是硬链接或只是软连接Examples例如-Thread Forming线程的形成-Thread Cutting 螺纹切削-Self Locking 自锁功能-Damaged Threads-Damaged 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力臂力臂(Feet,Meters)英尺、米力力(Newtons,Pounds)牛顿,英镑扭矩扭矩=力力 x 力臂力臂角度90 135 拧紧基础拧紧基础Tightening Threaded Fa

22、steners is Basically an Energy Transfer Process 螺纹紧固件紧固过程主要是是能量转移的过程Area Under Torque-Angle Curve is Proportional to the Energy Required to Tighten the Fastener 扭矩角度曲线以下的面积与紧固件紧固所需的能量成正比。T=K d F T=Torque扭矩 d=Nominal Diameter名义直径 F=Force力 K=Friction Factor 摩擦系数角度,q扭矩,TArea Area Energy Energy扭矩消耗到哪里去了

23、扭矩消耗到哪里去了?螺纹摩擦力夹紧力螺栓头摩擦力扭矩螺栓头摩擦力螺栓头摩擦力 55%螺纹摩擦力螺纹摩擦力-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Snug 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塑性区塑性区Elastic RangeE

24、lastic Range弹性区弹性区拧紧曲线拧紧曲线Rundown破旧Rundown:Before the bolt head/nut comes into full contact with bearing area在螺栓头/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Elasti

25、c 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Snug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

26、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 loads 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

27、,a very very inaccurateinaccurate wrench will have a detrimental wrench will have a detrimental impact on preload scatterimpact on preload scatter.夹紧力的变动收到摩擦散射的控制。使用非常精确的扳手不能缓解预紧力的散失。但是，非常不准确的扳手会对预紧力的散失产生不利影响。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 o

28、r IndirectlyApplied Torque Is Controlled Directly or Indirectly施加施加的扭矩是直接或间接地受控的Target Torque Is Usually 50%to 85%of Yield TorqueTarget Torque Is Usually 50%to 85%of Yield Torque目标扭矩通常是屈服扭矩50%-85%Used in Elastic Range of FastenerUsed in Elastic Range of Fastener在紧固件的弹性范围内使用90%Of Applied Torque Is Us

29、ed to Overcome Friction90%Of Applied Torque Is Used to Overcome Friction 施加扭矩的90%是用来克服摩擦力的Also known as:Torque,Straight TorqueAlso known as:Torque,Straight Torque也称为：扭矩、直接扭矩Preload Accuracy 25%Preload Accuracy 25%预紧力精确度25%Step 1:Apply a Torque to Consolidate the JointComponents(Snug Torque)第一步：施加扭矩来

30、巩固部件的连接 Step 2:Turn the Fastener Through a Pre-determined Angle第二步:旋转紧固件至预先设定的角度Originally Developed for Beyond Yield Tightening,Now Also Used in the Elastic Range最初是为了超出屈服区的拧紧,现在也用在弹性区内Requires Application Testing to Establish Snug Torque and Angle Parameters 需要通过试验建立适宜的转矩和角参数Also known as:Turn of

31、the Nut,Torque-Angle 也称为:螺母旋转法，扭矩-角度法Preload Accuracy Preload Accuracy 15%15%预紧力精确度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)(Threshold)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 Mai

32、nly 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 Tightening ProcedureProcedure预紧力的散失主要是由拧紧过程中摩擦力的散失引起的During the Angle Tightening Portion There is no During the Angle Tighteni

33、ng 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 Applied Angle Turned在角度拧紧的部分，没有由摩擦力引起的预紧力散失，只有转角的散射。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

34、increase the initial clamp load scatter.initial clamp load scatter.初始初始扭矩的公差能增加预紧力的散失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 pre

35、load preload v v.angle is lost.angle is lost.条件允许时应尽量选用低的初始扭矩。而当使用一个高的初始扭矩时,预紧力与转角的恒定关系将不再有效。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.低的初始扭矩也会减小转角施加前的扭矩散失。

36、When tightening 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.在紧固件塑性区内工作时，屈服强度的变化也是一个影响因素。屈服点控制屈服点控制Torque and Angle Are Monitored During TighteningTorque and Angle Are M

37、onitored During Tightening拧紧时需要监控扭矩和角度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当梯度下降到梯度最大值的一小部分时，最大梯度和屈服点同时被记录下来。Utilizes

38、 Maximum Load Potential of the FastenerUtilizes Maximum Load Potential of the Fastener利用紧固件的最大承载潜力Largely Uninfluenced by FrictionLargely Uninfluenced by Friction在很大程度上排除了摩擦的影响Allows Torque Angle Inspection of Every TighteningAllows Torque Angle Inspection of Every Tightening允许对所有的紧固实施扭矩转角的监控Bolts C

39、an Be ReusedBolts Can Be Reused螺栓可以重复利用Also known as:Torque to YieldAlso known as:Torque to Yield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%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

40、 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 VariationVariation Than Friction Variation 比起摩擦，预紧力分散更依赖于强度变化Bolt Strength is More Controllable Than FrictionBolt Strength is More C

41、ontrollable Than Friction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 0.7MinimumMinimum4,4006,2007,3003.14.45.3MaximumMaximum5,6007,6008,8004.367.2M5 x 0.8M5 x 0.8MinimumMinimum7,20010,00012,2006.4911MaximumMaximum9,20012,40014,6008.71215M6 x 1.0M6 x 1.0

42、MinimumMinimum10,20014,20016,100111418MaximumMaximum13,00017,60020,500152024M8 x 1.25M8 x 1.25MinimumMinimum18,60026,20031,400253744MaximumMaximum23,80032,20037,800365160M10 x 1.5M10 x 1.5MinimumMinimum29,80041,60050,000527388MaximumMaximum38,00051,20060,0007199119M12 x 1.75M12 x 1.75MinimumMinimum4

43、3,40060,70072,90092128156MaximumMaximum54,40074,90087,700127173207M14 x 2.0M14 x 2.0MinimumMinimum59,40083,300100,000144205244MaximumMaximum75,600102,000120,000200280335M16 x 2.0M16 x 2.0MinimumMinimum82,500115,000138,000228322383MaximumMaximum105,000141,000166,000310450520M18 x 2.5M18 x 2.5MinimumM

44、inimum99,200139,000167,000305430510MaximumMaximum127,000171,000201,000420595710GradeM6 x 1.0M6 x 1.0MinimumMinimum10,20010,20014,20014,20016,10016,100111114141818MaximumMaximum13,00013,00017,60017,60020,50020,500151520202424夹紧力和理想扭矩夹紧力和理想扭矩 EXPECTED TORQUE,Nm预期的扭矩预期的扭矩,海里海里Clamp Load Scatter夹负荷分散精密力

45、矩扳手精密力矩扳手M10气动冲击扳手气动冲击扳手M14气动定扭气动定扭矩扳手矩扳手M12最小夹紧力最小夹紧力最小夹紧力最小夹紧力电动扳手电动扳手屈服点控制屈服点控制M8 8%15%25%30-40%工具和螺栓选择工具和螺栓选择屈服点控制屈服点控制Joint May Not Be Critical Enough to Warrant its Cost 与所花的费用相比，接合不够重要Should Not Use When:以下情况不能使用：Bolt Yield Strength Joint Compressive Strength螺栓屈服强度大于联合抗压强度时Bolt Yields Somewhe

46、re Other Than Threads螺栓除螺纹以外的地方发生了屈服Head Shears螺栓头掉了Nut Strips螺母的螺纹剥离Applications Where Frequent Disassembly is Required频繁拆卸的场所Joints With Unpredictable Stiffness Qualities连接的强度不可预知If Yield is the Most Accurate,Why Not Always Use it?如果屈服点控制是最准确的,为什么不常用呢?拧紧错误拧紧错误拧紧错误拧紧错误FOUR MAJOR ERRORS DURING BOLT

47、TIGHTENING:螺栓紧固中的四大错：Human errors 人为操作错误 Tightening method errors 紧固方法不当 Improper tool errors 工具不适宜 Joint parts errors 连接部位错误Forgot to tighten忘记拧紧Improper tools used使用了不恰当的工具Wrong specifications规格错误Wrong tightening procedure紧固方法错误Wrong selection of tools工具的选取不当Inaccuracy 不精确Mechanical failure 机械故障Ou

48、t of parts tolerance超出了部件的承受力Bad material材料不好Insufficient lubrication润滑不充分拧紧错误拧紧错误CLASSIFICATION&CAUSE FOR LOOSENING OF BOLTS螺栓松动分类及原因螺栓松动分类及原因拧紧错误拧紧错误CHARACTERISTICS DIAGRAM OF DEFECTIVE JOINT缺陷连接特征图缺陷连接特征图拧紧错误Tightening faults can be caused by the joint,Tightening faults can be caused by the joint

49、,the tool or the operatorthe tool or the operator拧紧错误可由紧固件、工具或操作人员引起These faults typically show up as major These faults typically show up as major deviations from normaldeviations from normal这些缺点通常显示为相对正常的偏离The detection of tightening faults is best done The detection of tightening faults is best d

50、one by uncovering deviations from normal angleby uncovering deviations from normal angle紧固故障的检测最好不要覆盖正常角度的偏离Modern DC controllers have the capability to Modern DC controllers have the capability to monitor or control angle to flag these process monitor or control angle to flag these process errorser