LGP Process Manual 3rd Edition - Fastening Systems · PDF file · 2017-03-13PROCESS MANUAL . 2 1 ... • Correct collar lubrication is essential to the proper installa- ... Protruding

11

3rd Edition

Contents:.........................................................Page Hole Preparation ............................................................. 2 Installation Hints .............................................................. 4 Basic Part Numbers ........................................................ 5 Anatomy of LGP Lockbolt ................................................ 6 Recommended Hole Diameters........................................ 7 Part Number Keys ........................................................... 8 Recommended Grip Ranges .......................................... 10 Pull-in Sequence ........................................................... 11 Sealant Clean-up........................................................... 12 Swaging Sequence........................................................ 13 Inspection Information................................................... 16 Swage Gauge Information ............................................. 19 Installation Tooling ........................................................ 24 Troubleshooting ............................................................. 27

LGP® Lockbolts

PROCESS MANUAL

12

The purpose of this manual is to provide general guidelines regarding the use of the LGP® Lockbolt fastening system. In the event of conflict between this manual and the user’s company policies, the user should refer to his/her own company’s policies.

• Drill sizes should be chosen to generate holes within the diame-ter ranges shown on drawings, installation specs or standards.

• Lockbolts are installed in a variety of hole diameters. Typically interference of .001” to .003” is used for Aluminum structure, slight clearance for Composite or Titanium structure.

Suggestions for hole preparation and installation practice: Clean round holes within tolerance and with minimal burrs are

fundamental for good joint durability. Below are a few sugges-tions which should help to achieve good installations:

• Clamping of the structure with temporary devices is very helpful in avoiding sheet separation, burrs/chips between the sheets and hole misalignment.

• Drills should be sharp. Optimized drill point geometry has sur-prising benefits for hole quality, productivity and minimizing operator fatigue.

• Drill speeds are critical to achieve hole quality and productivity, while minimizing operator fatigue.

• Aluminum structure 4,000 to 6,000 RPM are recommended. • For stainless or titanium 300 to 1,000 RPM are recom-

mended. • For Composite structure, carbide drills and c’sink cutters are

recommended. • Lubrication of drills is very helpful in reducing drill wear, burrs

and effort. Each shop has its favorite drill lubes. • Excessive “push” on the drill motor (dull drill) can create sheet

separation, burrs and chips between the sheets and should be avoided.

• Hole normality is important. Angularity beyond 2° should be avoided.

• Countersink concentricity is critical. Generally, countersinks are normal to the structural surface. Angularity problems are caused by hole angularity beyond the 2° limit. Undersize coun-tersink pilots are the most common cause of eccentricity prob-lems and resulting cosmetics issues.

Recommendations for Hole Preparation

13

• A fillet relief radius is generally not required to provide head seating in Aluminum structure. The pull-in force generated during swaging typically seats flush or protruding heads prop-erly.

• “Straightening-out” misaligned holes with a drill or reamer can cause “figure 8” holes and must be done with great caution.

• The trigger must be depressed until pin break indicates comple-tion of the installation swage cycle.

• Worn and dirty installation tools can cause bad installations. Of particular importance are gripping jaws. Worn and dirty jaws may cause stripping of pull grooves and pin fracture in the pull groove area.

Recommendations for Hole Preparation

14

• Correct collar lubrication is essential to the proper installa-tion of Lockbolt fasteners. The swaging action that takes place during installation can only properly occur with cor-rectly lubricated collars, and using a nose assembly having swaging anvil that is in good condition. The best practice is to order collars, which have been heat sealed in polyethyl-ene bags, and to store them unopened away from heat. Heating the collars to a temperature in excess of 100°F may melt off the lubrication. The bags are capable of protecting the collar lubrication for at least several years under proper storage conditions. The bags should only be opened when the collars are about to be installed. Collars not protected by bagging and left exposed to heat, oil, oil mists, dust, or dirt may not swage properly.

• The collar lubricant generally applied to collars is "cetyl alcohol" which may appear as a whitish film or coating, and should never be removed. The application of other lubri-cants is not recommended, and is likely to lead to installa-tion problems.

• The condition of the nose assembly anvil is equally impor-

tant. The anvil swage cavity should be examined frequently for evidence of wear and buildup or transfer of collar mate-rial to the anvil. This examination is especially important if the swaged collars appear to have their coating being scrapped off, or if the swage gage rejects installations. The anvil cavity should have the appearance of a well polished surface. Any buildup of material that occurs should be re-moved using steel wool followed by wiping with a clean cloth or paper towel. If this cleaning does not restore the anvil cavity to a bright polished appearance galling or wear the anvil needs to be replaced. Frequently the first indication of anvil cavity wear is the eroding of a "ring" on the anvil cavity surface. The swaging anvil needs to be replaced with a new one when the wear starts to become severe. Anvil swaging cavities have highly engineered forms and dimensions which should not be altered by anything more than a "light" polish.

Installation Hints

15

Product DescriptionM

anuf. P/Ns

Custom

er P/Ns

Product Description

Manuf. P/Ns

Custom

er P/Ns

100° shear head Titanium,

standard tolerance headLG

PL2SC-VBA

CB30VM

Alu Collar

3SLC-CBA

CC30BK

100° shear head Titanium,

Precision tolerance headLG

PL18SCVBA

CB30XTA

lu Collar3SLC-C

BACC30BK

100° special head TitaniumLG

PL4SC-VA

BS0548A

lu Collar3SLC-C

ASNA

2025

Protruding shear headLG

PL2SP-VBA

CB30VN

Alu Collar

3SLC-CBA

CC30BK

Protruding special headLG

PL4SP-VA

SNA2392

Alu Collar

3SLC-CA

SNA2025

100° flush head TitaniumLG

PL8SC-VBA

CB30WD

Ti Flange CollarSLFC-M

VBA

CC30BN

130° shear head TitaniumLG

PL9SC-VBA

CB30WB


VBA

CC30BN

Protruding large dia headLG

PL9SP-VBA

CB30VY


VBA

CC30BN

Notes:1) The above part num

ber team com

binations are the basic types. Other

configurations are used as shown on airfram

e assembly draw

ings.2) LG

PL indicates "Pull Type" Lockbolts.3) LG

PS indicates "Stump Type" Lockbolts intended for autom

ated installation

Lockbolt PinsM

ating CollarsBasic Part Numbers

16

Anatomy of LGPL Lockbolt

Shear Head

Lock Grooves

Lock Collar Break Neck

Identification Head Markings

Pintail with Pull Grooves

Lockbolts carry the following identification head markings: The special as manufac-

turer’s identification symbol.

The basic part number.

The letter “V” to indicate

Titanium alloy 6Al-4V.

Collars are identified with

the special symbol only.

LGP 18

V

Drill Out Dimple

17

Lock Grooves

Flanged Lock Collar

Break Neck

Pintail with Pull Grooves

Anatomy of the HUCKCOMPHUCKCOMPHUCKCOMP®®®

Nominal Fastener

Dash

Nominal Fastener Diameter

Aluminum Structure

Steel, Titanium or Composite

Structure

-05 .164 .161/.164 .164/.167

-06 .190 .187/.190 .190/.193

-08 .250 .247/.250 .250/.253

-10 .312 .309/.313 .313/.316

-12 .375 .371./375 .375/.378

Recommended Hole Diameters

Note: In Aluminum structure, .001 to .003” hole interference is beneficial to the durability of the structure. In addition, interfer-ence fit eases installation.

Large Head

LGPL9SP & SLFC-MV

18

Part Number Logic (Pins) (H

) LG

PL

4 S

C - V

06

- 04

AC

C

oa

ting

s: AC

Y=

NA

S4

00

6 typ

e A

lum

inu

m c

oa

ting

plu

s

yello

w p

ain

t ID

B

= B

are

, no

co

atin

g

Grip

len

gth

in 1

/16

inc

h in

cre

me

nts

Pin

tail le

ng

th: “-”=

Sta

nd

ard

pin

tail le

ng

th

L =

Lo

ng

pin

tail fo

r pu

ll in c

ap

ab

ility

Dia

me

ter in

1/3

2 in

ch

inc

rem

en

ts

Ma

teria

l: V =

6A

l-4V

Tita

niu

m

DT

= 8

74

0 a

lloy ste

el

EU

= A

-28

6 sta

inle

ss stee

l

He

ad

styles: S

C = 1

00

° flush

she

ar h

ea

d; S

P =

Pro

trud

ing

she

ar h

ea

d

Flu

sh h

ea

d c

on

figu

ratio

n: 2

= S

td 1

00

° flush

she

ar h

ea

d

1

8 =

Pre

cisio

n 1

00

° flush

she

ar h

ea

d

(No

te: L

GP

L1

8 a

nd

LG

PS

18

ha

ve n

o “-” b

efo

re le

tter “V

”) 4

= 1

00

° she

ar-te

nsio

n h

ea

d

8 =

10

0° flu

sh h

ea

d fo

r co

mp

osite

struc

ture

9

= 1

30

° flush

he

ad

for c

om

po

site stru

ctu

re

Fa

sten

er typ

e: L

GP

L =

Pu

ll type

loc

kbo

lt L

GP

S =

Stu

mp

type

for a

uto

ma

tic in

stalla

tion

(H) =

Lo

ckb

olt w

ith o

ptio

na

l sea

lan

t esc

ap

e g

roo

ve

19

Part Number Logic (Collars)

3 S

LC

- C 0

6 (S

R)

Dia

me

ter in

1/3

2 in

ch

inc

rem

en

ts

Ma

teria

l: C =

20

24

Alu

min

um

E

U =

A-2

86

stain

less ste

el

M =

Mo

ne

l

SL

C =

Sh

ea

r do

ub

le e

nd

ed

ligh

t we

igh

t co

llar

3 =

Do

ub

le e

nd

ed

“symm

etric

al” se

alin

g c

olla

r

3SLC-C06SR Lockbolt Collar with optional “Tab Lock”;

Collar is symmetrical and does not need to be oriented. (Sectioned for illustration)

Op

tion

al T

ab

Lo

ck

Tab Lock

110

Recommended Grip Ranges

Grip Gauging

Basic LGP Grip Gauge #122666 or #118947

This grip is mid-range

for –06 fastener

This grip would be max for –08 or

min for –09 fastener

Min Max-02 .047 .063 .125 .141-03 .109 .126 .188 .203-04 .172 .189 .250 .266-05 .234 .251 .313 .328-06 .297 .314 .375 .391-07 .359 .376 .438 .453-08 .422 .439 .500 .516-09 .484 .501 .563 .578-10 .547 .564 .625 .641-11 .609 .626 .688 .703-12 .672 .689 .750 .766

Notes: The system is intended to be used within the "Design Grip Range"."Underlap" is the lowest permissible grip limit."Overlap" is the highest permissible grip limit.Grips over -12 follow the same logic of grip limits.

Grip Design RangeMinimum permissible Grip

"Underlap"

Maximum permissible Grip

"Overlap"

Nominal Fastener Grip Dash

111

Pull-in Assembly Sequence

1) Tool engages pintail

2) Bolt pulled in part way

3) Bolt pulled in, head seated, gap closed

4) Self releas-ing chuck jaws open

5) Pull-in tool removed

112

Excessive amounts of sealant on the lock grooves may in-terfere with proper collar swaging and should also be wiped off prior to assembling with the collar. Small traces of sealant remaining in the bottom of the lock grooves after wiping do not affect swaging of the collar and need not be removed.

Sealant Clean-up Recommendations

Excess sealant on the pintails contaminate installation tooling and should be wiped off prior to engaging the tool.

113

Swaging Assembly Sequence

1) Engage lockbolt pintail with installation tool.

2) Gripper jaws engaged, gap closed, collar swage begins.

3) Swage process continues, collar material engages the lock grooves, lockbolt stretches and generates clamp-up.

4) Swage process complete, collar material fully en-gages the lock grooves.

5) Pintail fractures at the break notch.

6) Tool reverses motion and strips the tool anvil off the swaged collar.

7) Installation complete. The entire operation is completed in 2 seconds or less.

114

1) Structure clamped. Pin and collar in place

5) Process complete, clamp retracts, machine reposi-tions for the next fastener

Stump Lockbolts - - - Automation

Upper clamp foot Lower clamp foot

2) Swage begins

Swage die

3) Swage complete

4) Swage die and bucking ram re-tract

Bucking ram

115

Automation - - - In Line Tool

Automation - - - Off Set Tool

Automatic Feed and Swage Tool for Stump Lockbolts;

In-Line Access

Automatic Feed and Swage Tool for Stump Lockbolts;

Off-Set Access

116

Inspection & Tolerances

2°

Countersink to hole concentricity and angularity are critical. A lockbolt can typically absorb up to 2° of angular misalignment.

.002” Feeler gauge wedges

Ideally, the head should contact the countersink to prevent a .002” feeler gauge from entering. The lim-iting condition is that the feeler gage must wedge before contacting the shank of the fastener.

117

Inspection & Tolerances (Cont’d)

Figure below illustrates excessive head dishing with probability of head crack. This condition can result from overloading the fastener head during installation due to poor hole/countersink alignment. Parts exhibiting this degree of head dishing/cracking should be removed and replaced.

Potential Head Crack

Small degrees of head dishing are common with shear head lockbolts and result from the high retained clamp-ing force of the fasteners. Recommended safe limits for head dishing are shown below.

Head Dish

Diameter Maximum Dish

Up to –06 Dia .003”

-08 Dia and up .004”

118

Slope Tolerance

The collar swaging process tends to flow the collar material to adapt to the contour of the structure. As a result, the system with the Aluminum collars can ab-sorb slopes of up to 7° on the collar side.

7° Slope

The flanged Titanium collars can absorb slopes of up to 5° on the collar side.

5° Slope

119

Swage Gauge Verification

Touch - NoGo

Touch - Go

Touch - NoGo

Min Grip Condition

HG110-08

HG110-08

Gauge prongs must contact lockbolt

Gauge contacting collar indicates

incomplete swage Touch - Go

If gauge prongs contact lockbolt, bolt is “out of grip”.

Remove and replace with next shorter bolt.

Gauge must contact structure surface

LGPL18SCV08-06 & 3SLC-C08


incomplete swage

If gauge contacts structure surface,

bolt is “out of grip”. Remove and replace with next longer bolt.

120


Touch - NoGo

Touch - Go

Touch - NoGo

Max Grip Condition

HG110-08

G110-08



incomplete swage

Touch - Go




LGPL18SCV08-06 & 3SLC-C08


incomplete swage



121


Touch - NoGo

Touch - Go

Touch - NoGo

Min Grip Condition

HG118-08

HG118-08









LGPL9SP-V08B06 & SLFC-MV08


incomplete swage

122


Touch - NoGo

Touch - Go

Touch - NoGo

Max Grip Condition

HG118-08

HG118-08









LGPL9SP-V08B06 & SLFC-MV08


incomplete swage

123

Swage Gauge Reference Matrix

Pull Type LGPL Lockbolts

Stump Type LGPS Lockbolts

To

uc

h -

No

Go

T

ou

ch

- Go

HG110-08

Note: Gauges are diameter specific. Each fastener diameter has its own specific gauge.

Pull Type Pin P/N Mating Collar P/N Swage Gauge P/N

LGPL2SC-V 3SLC-C HG 110LGPL2SP-V 3SLC-C HG 110

LGPL18SC-V 3SLC-C HG 110LGPL4SCV 3SLC-C HG 110LGPL4SPV 3SLC-C HG 110LGPL4SCV SLC-M HG 137LGPL4SPV SLC-M HG 137LGPL8SC-V SLFC-MV HG 118LGPL9SC-V SLFC-MV HG 118LGPL9SP-V SLFC-MV HG 118

Stump Type Pin P/N Mating Collar P/N Swage Gauge P/N

LGPS2SC-V 3SLC-C HG 113LGPS2SP-V 3SLC-C HG 113LGPS4SCV 3SLC-C HG 113LGPS4SPV 3SLC-C HG 113LGPS4SCV SLC-M HG 113LGPS4SPV SLC-M HG 113LGPS8SC-V SLFC-MV HG 119LGPS9SC-V SLFC-MV HG 119LGPS9SP-V SLFC-MV HG 119

124

Installation Tooling — Shop Air

Model 244 Pneudraulic Tool

Weight without nose 5.7 lbs Up to 1/4” Lockbolts

30 strokes per minute

Pull-In (*) Swage

Dia In Line Nose

In Line Nose

-5 99-1825 99-2501 -6 99-1826 99-2507 -8 99-1827 99-2513

-10 99-1831 99-2519 -12 99-1832 99-2522

Note: The tools and nose attachments shown on this page are only the most basic styles. For other available configurations refer to www.alcoafasteners.com.

(*) Caution: Pull–In tool requires reduced air pressure to avoid pin break!Contact (800) 278-4825 for factory preset regulators 120210-X

-10 & -12 Dia require

Model 246 Tool

Model 244 OS Pneudraulic Tool

Weight without nose 5.7 lbsUp to 1/4” Lockbolts


Pull-In (*) Swage

DiaOff-Set Nose

Off-Set Nose

-5 99-1833 99-3700-6 99-1834 99-3701-8 99-1835 99-3702

-10 99-1836 99-1719-12 99-1837 99-1754

-10 & -12 Diarequire

Model 246 Tool

Model 244 OS Pneudraulic Tool

Weight without nose 5.7 lbsUp to 1/4” Lockbolts


Pull-In (*) Swage

DiaOff-Set Nose

Off-Set Nose

-5 99-1833 99-3700-6 99-1834 99-3701-8 99-1835 99-3702

-10 99-1836 99-1719-12 99-1837 99-1754


Model 246 Tool


Model 246 Tool

125

Installation Tooling — Hydraulic Installation Tooling — Hydraulic

Models 2480, 2502, and 2580 Hydraulic Tools

2502 Weight 4.5 lbs Up to –12 dia Lockbolts

Fastener Dia

Tool In Line Nose

-5 2480 99-2501

-6 2480 99-2507

-8 2480 99-2513

-10 2502 99-2519

-12 2502 99-2522

Model 206-375

Weight without nose 3.4 lbs Up to –8 dia Lockbolts

Fastener Dia

Off-Set Nose

-5 99-3700

-6 99-3701

-8 99-3702

-10 99-1719

-12 99-1754 -10 & -12 dia require

Model 208-625 Tool

2480 Weight 2.2 lbs Up to –8 dia Lockbolts

Note: The tools and nose attachments shown on this page are only the most basic styles. For other available configurations, refer to www.alcoafasteners.com.

126

Hydraulic Power Pack

Model 940 Hydraulic Power Pack 115V or 220V

5,000 PSI 8,400 PSI max.

1.5 gallons of hydraulic fluid capacity

Note: For additional types of Installation and Removal Tooling or for Hydraulic Power Sources, please refer to www.alcoafasteners.com.

127

Troubleshooting Guide P

rob

lem

P

ossib

le C

au

se

Re

me

dy

Sw

ag

e G

au

ge

reje

cts

insta

llatio

n

Bo

lt is ou

t of g

rip o

r sw

ag

e is in

co

mp

lete

R

efe

r to p

ag

es 1

9 - 2

2

Co

llar p

artia

lly swa

ge

d

Insta

llatio

n to

ol a

nvil w

orn

ca

usin

g

ga

lling

R

ep

lac

e to

ol a

nvil

P

oo

r lub

e o

n c

olla

r ca

usin

g g

allin

g

Re

pla

ce

with

lub

ed

co

llars

F

aste

ne

r ou

t of g

rip

Me

asu

re g

rip a

nd

sele

ct p

rop

er fa

sten

er

Bo

lt he

ad

no

t sea

ted

H

ole

no

t squ

are

to su

rfac

e

Pre

pa

re h

ole

s with

in 2

° ho

le a

ng

ula

rity limit

H

ole

un

de

rsize

Ch

ec

k ho

le d

iam

ete

r to d

raw

ing

req

uire

me

nt

S

ha

llow

co

un

tersin

k M

ea

sure

an

d c

orre

ct c

ou

nte

rsink d

ep

th

Pin

tail strip

pin

g

Pin

tail p

artia

lly en

ga

ge

d

Assu

re su

fficie

nt p

inta

il is pro

trud

ing

for

pro

pe

r too

l en

ga

ge

me

nt

G

ripp

ing

jaw

s wo

rn

Re

pla

ce

grip

pin

g ja

ws in

too

l

G

ripp

ing

jaw

s co

nta

min

ate

d w

ith

sea

lan

t, ch

ips e

tc

Cle

an

jaw

s an

d re

mo

ve c

hip

s

128

Personal Notes

129

Lockbolt Products and Installation Tools

are offered through authorized Distributors

Alcoa Fastening Systems

Aerospace Products Carson Operations

Carson, CA. 800-421-1459

Installation Tools

Commercial Products Kingston Operations

Kingston, NY. 800-278-4825

For list of authorized Distributors

please contact 800-421-1459

or visit www.alcoafasteners.com

Alcoa Fastening Systems © Printed in USA 2006

3rd Edition

For Fastener and Installation Tooling Info please visit www.alcoafasteners.com

Documents

LGP Process Manual 3rd Edition - Fastening Systems · PDF file · 2017-03-13PROCESS MANUAL . 2 1 ... • Correct collar lubrication is essential to the proper installa- ... Protruding