HeliCoil牙套工具

Insert Systems Cre ati ng th e F utu re Wo rld wi de . DODGE GRIPCO HELI-COIL NPR PARKER-KALON POP TUCKER WARREN At Emhart , creating the future is about growth, about change and about taking risks. It is who we are and what we do. Our focus is to reduce the overall product assembly costs of our customers by anticipating needs and meeting those needs with technology and market-driven solutions. Emhart is a global leader in the design and creation of unique assembly technologies, delivering depth and breadth of service and product through a flexible, cross-functional global organization. Owning The Customer’s Total Experience We provide every customer with the capability to satisfy every aspect of fastening and assembly technology. From concept through installation, around the corner and around the globe, Emhart develops and delivers solutions for challenging assembly applications. Technology Optimization Emhart has the ability to objectively match customer priorities, applications and manufacturing environment with the most appropriate assembly technology and fastening systems. We provide this capability through Application Engineers, and Mobile, Stationary and Virtual Innovation Centers located around the world. Each is electronically linked, capable of sharing application data and new design concepts with each other as well as with our customers. System Integration Emhart provides technological solutions in over 100 different countries. For each of these countries and for every application, we deliver innovative, integrated systems solutions from concept and design through system integration, worldwide. Product Consultancy Emhart employs Application Analysis and Value Engineering to demonstrate how our technology can enhance the assembly process, and Value Analysis to detail the cost/benefit relationship of applying our technologies. Innovative Services Emhart is infused with the spirit and culture of innovation. From our Stationary Innovation Centers to our unique Mobile Innovation Centers, Emhart has built a worldwide service and technology infrastructure to support our customers, 24 hours a day, seven days a week. 3C E R T I F I E D ISO 9001 • OS 9000 ISO 14001 Emhart Teknologies Heli-Coil Bulletin 2003 • Tel. (203) 924-4737 • Fax (800) 732-3116 Mexico Tel 52-5-326-7100 • Fax 52-5-326-7141 www.emhart.com W ir e I n s e rt s Wire Inserts Heli-Coil® precision formed wire inserts are readily recognized and highly regarded products in the industry. Since its inception in 1938, Heli-Coil has been identified as an industry leader offering products with superior performance, reliability and integrity. Our strict quality programs ensure that we meet the latest industry standards of QS and ISO, as is evident in our track record of consistently passing audits without technical findings. Our SPC and detailed inspection programs elevate our quality levels well above our competitors. Heli-Coil wire inserts are manufactured with over 60 years of experience. We are dedicated to exceeding our customer’s expectations by providing innovative value- added design and engineering services, on-time deliveries and excellent customer service support. Heli-Coil is committed to developing superior products manufac- tured to only the highest quality standards. We are more than just a supplier, we are a business partner. Heli-Coil® is a registered trademark of Emhart Teknologies, Inc. 4 Emhart Teknologies Heli-Coil Bulletin 2003 • Tel. (203) 924-4737 • Fax (800) 732-3116 Mexico Tel 52-5-326-7100 • Fax 52-5-326-7141 C E R T I F I E D ISO 9001 • OS 9000 ISO 14001 www.emhart.com Contents Page • Heli-Coil Inserts Description................................................................... 5, 6, 7 • Technical Data Materials ...................................................................... 8 Coatings and Plating ................................................... 9 Locking Torque Data .................................................... 10 Corrosion Protection ................................................... 11 Insert Specifications .................................................... 12, 13 Design Considerations ................................................. 14 Process Procedures ...................................................... 15 • Drilling Recommended drill sizes & specifications ................. 16, 17 • Tapping Tapping depths and Pitch diameters ........................... 18, 19 Tap Part Numbers ........................................................ 20, 22 Tap Dimensions............................................................ 21, 23 • Gaging Gaging practice & part numbers ................................. 24, 25 • Installation Tooling Types and service ......................................................... 26 Hand Inserting Tools.................................................... 27 Power Inserting Tools .................................................. 28, 29, 30 Tang Break-Off & Extraction Tools ............................. 31 • Tangless® Inserts .......................................................................... 32 Tools ............................................................................. 33 • Heli-Coil Kits Thread Repair Kits & Master Sets ............................... 34 Tangless® is a registered trademark of Advanex Inc. 5C E R T I F I E D ISO 9001 • OS 9000 ISO 14001 Emhart Teknologies Heli-Coil Bulletin 2003 • Tel. (203) 924-4737 • Fax (800) 732-3116 Mexico Tel 52-5-326-7100 • Fax 52-5-326-7141 www.emhart.com Heli-Coil screw thread inserts Heli-Coil inserts are preci- sion formed screw thread coils worked into a diamond shape. The resultant surface finish is a mirror-like 8-16 micro inches. This wire is then wound into a spiral coil which when installed into Heli-Coil tapped holes, pro- vides permanent conventional 60º internal screw threads. This assembled insert accom- modates any standard bolt or screw (MIL-S-7742) and MIL-S- 8879 (UNJ controlled radius root) male threaded members. (See page 8 for material avail- ability.) Heli-Coil inserts are larger in diameter before installation than the tapped hole. During installation the inserting tool applies torque to the tang re- ducing the diameter of the leading coil permitting it to en- ter the tapped thread. After in- stallation each high tensile stainless steel coil of the insert expands outward with a spring- like action permanently an- choring the insert. Size Range: • UNC #2 through 1-1/2 • UNF #2 through 1-1/2 • Metric Coarse M2 through M39 • Metric Fine M8 through M39 Inserts are also available in UNEF, UNS, 8UN, 12UN, 16UN, Spark Plug and Pipe Thread. Types of Inserts There are two designs of Heli-Coil inserts… STANDARD, which provides a smooth free-running thread; and, SCREW-LOCK which provides self-locking torque on the male member by a series of “chords” on one or more of the insert coils. They are available in inch series coarse and fine and metric series, coarse and fine. Inch series Screw- Lock inserts are dyed red for identification. Illustration of the Retention Principle Screw-Lock Heli-Coil Insert Standard Heli-Coil Insert 6 Emhart Teknologies Heli-Coil Bulletin 2003 • Tel. (203) 924-4737 • Fax (800) 732-3116 Mexico Tel 52-5-326-7100 • Fax 52-5-326-7141 C E R T I F I E D ISO 9001 • OS 9000 ISO 14001 www.emhart.com Heli-Coil screw thread inserts Heli-Coil inserts provide a positive means for protecting and strengthening tapped threads in any material. The unique design features of the insert offer many benefits… • Stronger Assemblies. Tapped threads are strength- ened because the inherent flexibility of the insert provides a more balanced distribution of dynamic and static loads throughout the length of thread engagement. This flexibility also compensates for variation in lead and angle error allowing each coil to carry its share of the load. • No Thread Wear. Thread life is dramatically increased even after repeated assembly and disassembly, because the insert hardness and surface finish practically eliminate erosion of the thread form due to friction. • Corrosion Resistance. Under normal environmental conditions, Heli-Coil inserts minimize galvanic action within the threaded assembly because of their superior cor- rosion resistance. • Design Flexibility. Bolt tensile strength can be balanced against parent mate- rial shear strength, assuring bolt failure rather than parent material damage. Five insert lengths are available in each thread size. • Eliminate Stress. Virtually no stress is intro- duced into the parent material because there is no staking, locking, swaging or keying in place — the outward spring-like action of the insert holds it in place. • Minimize Space & Weight Heli-Coil inserts allow use of smaller bosses, flanges and fasteners than any other insert. Heli-Coil inserts can generally be incorporated in existing designs, where no provision has been made for an insert, without increasing boss size. • Minimize Total Cost. Cost savings abound. Lower insert cost, lower installation cost, and Heli-Coil inserts provide design flexibility by allowing a wide choice of parent materials while main- taining maximum threaded assembly strength. • True Clamping Torque. Maximum clamping action and bolt tension are assured with minimum wrench torque, be- cause of the mirror-smooth surface finish of Heli-Coil inserts. • Wide Temperature Range. Heli-Coil stainless steel inserts can be used in temperatures ranging from–320ºF to +800ºF. • Quality & Reliability. Stringent Quality Assurance and Engineering Standards are rigidly enforced in all phases of the manufacturing process. This assures integrity of your product design. High Production Heli-Coil inserts are available mounted on plastic strips and wound onto reels (500 or 1000 inserts per reel). With power installation tooling, use of strip feed inserts will substantially increase installation rates by minimizing handling. Universal Acceptance Heli-Coil Standard and Screw- lock Inserts are the original — and have an extensive background of tension, torque, shear, vibration and fatigue tests conducted by American industry’s leading companies as well as the U.S. Military. Successful applications in the fields of aviation, electron- ics, industrial, automotive and military equipment provide a wealth of experience and confi- dence in the performance and reliability of Heli-Coil inserts. Total Design Service In addition to the benefits listed above, Heli-Coil provides a wide range of support to solve fasten- ing problems. This manual is one of them — the following pages are presented in a manner to make it easy to “design-in” Heli-Coil inserts to take advantage of the extraordinary benefits they provide. Additionally, our Sales Engineers, Applications Engineers and Design Engineers are available for consultation of specific designs. When the product gets to the manufacturing phase, our exten- sive experience in production tooling and installation tech- niques ensures that you can indeed make your product better with Heli-Coil inserts. FEATURES & BENEFITS… 7C E R T I F I E D ISO 9001 • OS 9000 ISO 14001 Emhart Teknologies Heli-Coil Bulletin 2003 • Tel. (203) 924-4737 • Fax (800) 732-3116 Mexico Tel 52-5-326-7100 • Fax 52-5-326-7141 www.emhart.com Heli-Coil screw locking thread inserts Military Standards Heli-Coil inserts and tooling comply with the following Stan- dards and Specifications: • NASM 122076 thru NASM 122275. Insert, corro- sion resistant Helical Coil Coarse Thread (Inch Series) • NASM 124651 thru NASM 124850. Insert, corro- sion resistant Helical Coil Fine Thread (Inch Series) • NASM 21209. Insert Screw Thread – Self Locking (Inch Series) • NASM 33537. Insert – Stan- dard Dimensions, Assembly • NASM 8846. Insert, Screw Thread, Helical Coil • MA1565. Insert, Screw Thread, Helical Coil (Metric Series) Screw-Lock Inserts: • Positive self-locking torque, complying with NASM 8846, MA1565 and MIL-N-25027. • A resilient locking mechanism (applies to Heli-Coil screw-lock inserts) that grips the bolt and prevents it from loosening under vibration or impact. • Repeated assembly and disas- sembly without appreciable loss of self-locking torque. • Savings in space, weight and money, through the elimina- tion of lock wiring, lock nuts, lock washers, chemical com- pounds, plastic pellets/patches and other locking mechanisms. Hi-Torque Inserts: • Similar to Screw-Lock except higher prevailing torque com- pensates for reduced friction in highly lubricated applications. • Ideal for higher vibration applications. • Approximate 40% increase in prevailing torque levels. • Available in #10 through 3/8" UNF only • Meets AS3094, 3095, 3096, 3097 Stud-Lock Inserts: • Highest prevailing torque insert available. • Enables use of threaded rod for space-saving stud applications. • Allows for any class fit of threaded rod. • Eliminates inconsistencies caused by interference-fit studs. • Available for both straight and step studs, #10 through 1/2" UNC and UNF. • Meets AS3080, 3081, 3082, 3083 LOCKING FEATURES & BENEFITS… • MA1567. Insert, Screw Thread, Helical Coil (Metric Series), Standard Dimensions, Assembly • MA3279, 3280, 3281. Insert, Screw Thread, Helical Coil (Metric Series), Screw-Locking • A-A-59158. Tools for insert- ing and extracting Helical Coil Inserts • FED-STD-H28. Screw Thread Standards for Federal/Services • AS3094 thru 3097 • AS3080 thru 3083 Special Locking Torque Inserts Locks Adjustment Screws. This simple design allows permanent, positive adjustment of screws in any position, secure against vibration or impact. Inaccessible or Miniaturized Assemblies. Heli-Coil Screw-Lock insert permits the installa- tion of the lock from the front or top. No blind fumbling for assembly of lock washers or lock nuts behind or under- neath. Lock Set Screws. Positively locks assembly against loosening at desired adjustment – protects threads against stripping under high torque – permits use of light housing materials. The locking action is achieved by one or more of the insert coils having a series of straight segments or “chords”. When the bolt enters the “grip” coil, these chordal segments flex outward, creating pressure on the bolt. The pressure is exerted between the flanks of the bolt thread to establish an extensive positive and consistent self-locking torque over more cycles than any other prevailing torque mechanism. Heli-Coil offers three types of locking inserts for multiple appli- cations… Note: Heli-Coil Hi-Torque and Stud-Lock inserts are made to order only. Contact Heli-Coil Applications Engineering at (203) 830-3274 for Hi-Torque and Stud- Lock part numbers and application assistance. 8 Emhart Teknologies Heli-Coil Bulletin 2003 • Tel. (203) 924-4737 • Fax (800) 732-3116 Mexico Tel 52-5-326-7100 • Fax 52-5-326-7141 C E R T I F I E D ISO 9001 • OS 9000 ISO 14001 www.emhart.com Heli-Coil insert material Heli-Coil inserts are available in a wide choice of materials to suit specific application needs. Contact Heli-Coil Applications Engineering to determine the correct material for your specific application. 304 Stainless Steel • Standard, general purpose material • Stocked in most sizes • Ideal for original equipment applications, repair, and over- haul Inconel X750 • Used in areas exposed to high temperatures • Typical uses: gas turbine engines, nuclear applications, well drilling • Non-magnetic Phosphor Bronze • Ideal for salt water applications • Non-magnetic • Excellent electrical conductivity Nitronic 60™ • Superb galling resistance • Compatible with stainless steel screws • Ideal for use in vacuum envi- ronments • Requires no additional coatings or plating • Particle free • Non-magnetic Material Spec: AS7245 Temperature range: up to 800ºF Tensile: 200,000 – 250,000 PSI Hardness: RHc 43-50 Corrosion resistance: Moderate Magnetic Permeability: 2-10 G/o (depending on wire size) Material Spec: AS7246 Temperature range: up to 1,000ºF Tensile: 200,000 PSI Hardness: RHc 43-50 Corrosion resistance: High Magnetic Permeability: <1 G/o Temperature range: up to 250ºF Tensile: 140,000 Hardness: HRB 95 Corrosion resistance: High Magnetic Permeability: <1 G/o Material Spec: UNS S21800 Temperature range: up to 500ºF Tensile: 200,000 PSI Hardness: RHc 43-50 Corrosion resistance: Moderate Magnetic Permeability: <1 G/o Titanium • Superior strength-to-weight ratio • Corrosion resistant • Excellent low temperature stability Nitronic 60™ is a trademark of AK Steel Material Spec: AMS 4957 & AMS 4958A Temperature range: up to 600ºF Tensile: 150,000 to 220,000 PSI Hardness: RHc 35-43 Corrosion resistance: High Magnetic Permeability: non-magnetic 9C E R T I F I E D ISO 9001 • OS 9000 ISO 14001 Emhart Teknologies Heli-Coil Bulletin 2003 • Tel. (203) 924-4737 • Fax (800) 732-3116 Mexico Tel 52-5-326-7100 • Fax 52-5-326-7141 www.emhart.com Heli-Coil insert coatings & plating Coatings/ Plating Benefits Dry Film Provides additional lubrication in high friction applications Lubricant High temperature resistance (400ºF) Highly recommended with Heli-Coil Screw-Lock inserts Mildly corrosion resistant Material Spec: AS5272 Color: Grey Cadmium Provides high corrosion resistance Plating Provides lubrication to prevent galling (Not recommended for new design due to its toxic nature) Material Spec: QQ-P-416 Type II Color: Iridescent yellow - Free-Running Color: Olive drab - Screw-Lock Primer- Prevents galvanic corrosion between insert and parent material Free™ Eliminates need for zinc primers Eliminates locking torque issues associated with primers Improves installation productivity Provides additional lubrication facilitating insert installation Material Spec: None Color: Glossy black Silver Recommended to reduce galling of threads at high temperatures Plating For use up to 1200ºF Material Spec: QQ-S-365 Color: Silver white Color Facilitates verification of insert installation Coding Allows for quick identification of similar size inserts Available in blue, green, red, and black* * All Heli-Coil Inch Screw-Lock inserts are supplied with a red coloring in accordance with NASM 21209 10 Emhart Teknologies Heli-Coil Bulletin 2003 • Tel. (203) 924-4737 • Fax (800) 732-3116 Mexico Tel 52-5-326-7100 • Fax 52-5-326-7141 C E R T I F I E D ISO 9001 • OS 9000 ISO 14001 www.emhart.com Heli-Coil screw lock torque data Heli-Coil Screw-Lock inserts meet the locking torque value of Tables I and II shown below. The values shown conform to NASM 8846 (inch series) or MA1565 (metric series) requirement. * These sizes are not included in NASM 8846. Torque values shown are interpolated from sizes that are included. All torque data derived for stainless inserts only. IMPORTANT NOTE: When using heat-treated steel screws or stainless steel screws with a Screw-Lock insert, an anti-seize compound MUST be applied to the screw or insert to minimize galling and maximize cycle life. To im- prove the wear life of the screws in Screw-Lock insert applications, specify Dry Film Lubricant (Molybdenum Disulfide), cadmium plating or Primer Free coating be applied to the insert. INCH COARSE 1 (.073)-64 15 oz-in 2 oz-in 2 (.086)-56 20 oz-in 3 oz-in 3 (.099)-48 32 oz-in 7 oz-in 4 (.112)-40 48 oz-in 10 oz-in 5 (.125)-40 75 oz-in 13 oz-in 6 (.138)-32 6 lb-in 1.0 lb-in 8 (.164)-32 9 lb-in 1.5 lb-in 10 (.190)-24 13 lb-in 2.0 lb-in 12 (.216)-24* 24 lb-in 3.0 lb-in 1/4 (.2500)-20 30 lb-in 4.5 lb-in 5/16 (.3125)-18 60 lb-in 7.5 lb-in 3/8 (.3750)-16 80 lb-in 12.0 lb-in 7/16 (.4375)-14 100 lb-in 16.5 lb-in 1/2 (.5000)-13 150 lb-in 24.0 lb-in 9/16 (.5625)-12 200 lb-in 30.0 lb-in 5/8 (.6250)-11 300 lb-in 40.0 lb-in 3/4 (.7500)-10 400 lb-in 60.0 lb-in 7/8 (.8750)-9 600 lb-in 82.0 lb-in 1 (1.00