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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
Ti Flange CollarSLFC-M
VBA
CC30BN
Protruding large dia headLG
PL9SP-VBA
CB30VY
Ti Flange CollarSLFC-M
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
Gauge contacting collar indicates
incomplete swage
If gauge contacts structure surface,
bolt is “out of grip”. Remove and replace with next longer bolt.
120
Swage Gauge Verification
Touch - NoGo
Touch - Go
Touch - NoGo
Max Grip Condition
HG110-08
G110-08
Gauge prongs must contact lockbolt
Gauge contacting collar indicates
incomplete swage
Touch - Go
If gauge contacts structure surface,
bolt is “out of grip”. Remove and replace with next longer bolt.
Gauge must contact structure surface
LGPL18SCV08-06 & 3SLC-C08
Gauge contacting collar indicates
incomplete swage
If gauge prongs contact lockbolt, bolt is “out of grip”.
Remove and replace with next shorter bolt.
121
Swage Gauge Verification
Touch - NoGo
Touch - Go
Touch - NoGo
Min Grip Condition
HG118-08
HG118-08
Gauge prongs must contact lockbolt
Gauge contacting collar indicates
incomplete swage Touch - Go
If gauge contacts structure surface,
bolt is “out of grip”. Remove and replace with next longer bolt.
If gauge prongs contact lockbolt, bolt is “out of grip”.
Remove and replace with next shorter bolt.
Gauge must contact structure surface
LGPL9SP-V08B06 & SLFC-MV08
Gauge contacting collar indicates
incomplete swage
122
Swage Gauge Verification
Touch - NoGo
Touch - Go
Touch - NoGo
Max Grip Condition
HG118-08
HG118-08
Gauge prongs must contact lockbolt
Gauge contacting collar indicates
incomplete swage Touch - Go
If gauge contacts structure surface,
bolt is “out of grip”. Remove and replace with next longer bolt.
If gauge prongs contact lockbolt, bolt is “out of grip”.
Remove and replace with next shorter bolt.
Gauge must contact structure surface
LGPL9SP-V08B06 & SLFC-MV08
Gauge contacting collar indicates
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
30 strokes per minute
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
30 strokes per minute
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
-10 & -12 Diarequire
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
ContentsHole PreparationInstallation HintsBasic Part NumbersAnatomy of LGP LockboltRecommended Hole DiametersPart Number KeysRecommended Grip RangesPull-in SequenceSealant Clean-upSwaging SequenceInspection InformationSwage Gauge InformationInstallation ToolingTroubleshooting