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SYSTEM
CONTENT
TORQUE/CLAMPING FORCE
TYPES OF JOINTS
TORQUEING STRATEGY
SELECTION OF TOOLS
PERFORMANCE OF TOOLS
MONITORING & CONTROLLING OF TORQUE OF
JOINTS
HOW WAS THE PROCESS DURING FORD ESCORT ?
REASONS FOR INEFFECTIVE JOINTS
WHAT SHOULD BE STRATEGY FOR START UP?
PROBLEMS IN SCORPIO-TCF
TYPE OF JOINTS
depending upon torque rate
HARD JOINT: Tool must get rid of kinetic energy very
quickly. The torque coming from K.E.of the rotating parts must
be added to the stall torque
SOFT JOINT : Hose clamps, a joint with long screw is also
regarded as a soft joint due to torsion effect. Washer & gasket
make joint softer
TORQUEING STRATEGY
TORQUE CONTROL
Impact tools
Hydropulse
Stall type
Initial Cost
Low
Mod
Mod
High
Quality
Low
Mod
Mod
High
Productivity
High
High
Low
Low
Ergonomic
Noisy, no
reaction
Low
Less noise, no
/
reaction
Mod
Cont.Reaction
Reaction for a
moment
High
Complexity.
Operator
dependenc
y
Life cycle
cost--
Yes
Low
Yes/
No
Mod
High
No
No
Low
Low
TORQUE MONITORING
Before making joint
During making of joint (Dynamic measurement i.e. output
of tool )
After the joint (Residual measurement)
Minimum torque measurement-attribute data using click
wrench
Fastener
Top flange/ Bottom flange
Assembly process
Equpment
Joint design
Sequential Securing
When more than one fastener is used :
Concave parts will INCREASE the torque of the first
fastener when the second is tightened.
Convex parts will DECREASE the torque of the first
fastener when the second is tightened
Use multiple nutrunner
Joint relaxation
Two types of relaxation : Temporary relaxation & component yielding
Temporary relaxation occurs when components are not quite flat or
contain high spots.
Torque applied increases very rapidly& matl.of the component
deforms at very slower rate.This can be corrected by using slower tool
or tightening by hand.
Component yielding : occurs when the clampload created by the
fastener exceeds the compressive strength of the parts in the joint. The
speed of the tool can momentarily create a torque (and clamp force)
above the yield point of the joint. The compressive forces in the joints
will cause a cold flowing of the material until the force (clamp load) is
equal to the material strength.
Approve a residual specification or redesign the joint.
Operator Variation
Premature release of the trigger
Double clicking
socket slip off
Variation in parts
Residual torque variation is caused by :
Underhead contact area because a large hole is used for
adjustment
Parts not parallel & galling occurs under the fastener
Surfaces not consistent, so varying degree of galling
Stick and slip--finish problem
Economics
Interruption in prod.
Rejects
Physical exhaustion
Labour cost
Maint. cost
Tool investment
Interruption inprod.
Rejects
Physical exhaustion
Labour cost
Maintenance cost
Tool investment
SCORPIO START UP
1) Started with identifying right tool for each application in EP shed
involving process, production, desgner, maintenance engineer & atlas
copco.
2) Selection criteria decided :Go for Clutch type tools wherever possible,
and Pulse tools for high torque. Battery tools for interior trims.
3) Wherever troque valuse were not given by designer, we considered
fastener specs with designers approval
4) Revision of specs depending upon the field failure & actual
observation while tightening.
5) Fine tuning the specs to use one tool at various application with
designers approval.
6) Electrical tool with tray to replace number of air tools
7) 100% Tool initial capability check in PE crib on standard joint.
YIELD CONTROL
A fastener in yield can be of smaller diameter than one set
below its yield.
Consistent torque depends upon bolts matl.
No safety factor for a shock load which tends to stretch the
fastener further & doesnt return back even if load is
removed.
Designer must make sure that service load will never
exceed clamp load
Precision bolts required
FASTENER SPECS
DYNAMIC DURING SECURING 1) Torque mean
2)Variance
RESIDUAL TORQUE :1)Upper & lower inspection limit
2) Min. torque acceptable(i.e. dynamic or residual
measurement must be above this value) This can also be
used for a GO-NOGO inspection system.
SNUG LEVEL
Point at which you start building up load.
RESIDUAL TORQUE
Measure of the torque on a secured fastener
STATIC TORQUE
Torque value which exist when a fastener is in a static state.
No method of measuring it.
TORQUE PROCESS POTENTIAL STUDY
TPPS determines the dynamic process potential & establishes
residual (audit) torque limits. Done on every fastener
operation.