螺栓夹紧力报告Word版.docx

1、螺栓夹紧力报告Word版SummaryPurpose The ISDe engine local cylinder head capscrew preload was performed to validate whether preload could meet the requirement of assembly specification (81KN6KN). This file documented the ISDe engine local cylinder head capscrew preload measurement result.目的为了验证ISDe发动机国产缸盖螺栓拧紧

2、后产生的预紧力是否满足安装规范要求(81KN6KN)，本次试验对ISDe发动机国产缸盖螺栓预紧力进行了测试。本文件归档ISDe发动机国产缸盖螺栓预紧力测试结果。 Conclusions1: According to assembly specification, the thread below the hex flange of cylinder head capscrew only should be lubricated .But the actual condition was that the bottom surface of hex flange was lubricated w

3、rongly in the first group. The bottom surface of the hex flange was what was called bearing surface .It leaded the decrease of friction coefficient. So the data of the first one was unauthentic.2：By analysing the data of preload which dont include the data from the first one，Cpk of preload for the n

4、ext five engines were 0.95, 0.98, 2.21, 1.87, and 1.89. The data of the case show that the engines assembled the same local cylinder head capscrews matching local cylinder gaskets had better process capability than the ones matching imported cylinder gaskets. 3：Because the local cylinder head capscr

5、ews bottom surface of hex flange was lubricated in the first group which didnt match the assembly specification. So by analysing the data of preload which didnt include the first group, the average preload was 80.475KN ，the variation of preload was between 75KN and 87KN. The preload met the assembly

6、 specification.结论 1：根据安装规范,缸盖螺栓应仅润滑六角法兰以下的螺纹区域, 但实际情况是，第一组的螺栓六角法兰下端面被错误的润滑了，六角法兰下端面即所谓的承压面，这导致了摩擦系数的降低。因此第一组的数据是不可信的。2：通过对排除第一组份数据的预紧力数据分析，后五台发动机螺栓预紧力Cpk值分别是0.95, 0.98, 2.21, 1.87, 1.89。本例中的数据表明：装配同一种发动机国产缸盖螺栓配合国产缸垫所表现出的过程控制能力优于配合进口缸垫所表现出的过程控制能力。3: 因为第一台发动机国产缸盖螺栓的六角法兰下端面得到润滑,这不符合安装规范，因此通过对不包含第一组的预紧力

7、数据分析，预紧力平均值是80.475KN。预紧力在75KN和87KN之间。预紧力符合安装规范。ActionsFor document下一步行动存档End of Summary1.0试验方法 由于在发动机上无法直接测量缸盖螺栓装配后的预紧力，因此采用超声波法测量缸盖螺栓伸长量，从而间接计算得到缸盖螺栓预紧力。具体步骤为：（1）先在试验室对同一批螺栓拧紧过程中的预紧力伸长量关系进行标定；（2）对拟装配缸盖螺栓测量螺栓的原始长度；（3）当缸盖螺栓在发动机上按照规范拧紧后，再测量缸盖螺栓的伸长量；（4）根据在试验室标定的螺栓预紧力伸长量关系确定螺栓的当量预紧力。1.1预紧力伸长量试验室标定1.1.1

8、试验条件1.1.1.1 待试螺栓螺栓零件号：3927063螺纹规格：M121.75-6g；杆部长度：130mm；细杆部直径：10.830.1mm螺栓材料：SCM435螺栓强度等级：12.9螺栓表面处理：磷化处理螺栓生产厂家：东风汽车紧固件有限公司 1.1.1.2 陪试件条件陪试件均直接采用缸盖和缸体材料制造。垫片材料：HT250垫片表面粗糙度要求：Ra3.2垫片表面处理：无垫片内孔直径：14mm垫片内孔倒角处直径：16mm螺母规格：M121.756H螺母材料：HT250螺母表面处理：无1.1.1.3 试验条件夹持高度：112.25mm拧紧转速：5r/min润滑方式：螺纹部分涂15W40润滑油试

9、验螺栓、陪试垫片、陪试螺母均只使用一次。1.1.1.4 环境条件温度：16 湿度：40RH1.1.1.5 试验机配置及精度试验机：Schatz-Analyse 螺纹紧固件试验分析系统试验机规格：54132777扭矩转角传感器型号及测量精度：5413-1200/500-S 0.5%轴向力螺纹扭矩传感器型号及测量精度：5413-1963A/150 100kN/150Nm 0.5%1.2 螺栓预紧力伸长量标定结果表1 缸盖螺栓预紧力伸长量标定数据预紧力KN伸长量mm123456平均植400.26950.26780.26230.27160.26300.27530.2683500.33780.33410

10、.33470.33750.33380.34280.3368600.40660.40560.40720.40680.40420.41040.4068700.48050.48070.48350.48570.47960.48410.4824800.56250.56070.56850.56520.56070.56290.5634900.68260.66360.68200.68710.67780.67720.6784图 1 缸盖螺栓预紧力伸长量标定数据的平均值曲线1.3 预紧力伸长量标定结果分析由图1可以看出缸盖螺栓的装配预紧力在80KN以下处于一段线性阶段；对于80-90KN的一段，采用另一段的线性段

11、。因此对于测得的螺栓伸长量(mm)可以按如下公式计算预紧力(KN)： Clamp force = 1.81 + 262 L (L 0.5636) = 70.8732+ (L-0.2636) 9.6540/0.1139 (0.5636L0.6784 )1.4 发动机装配后预紧力测量 2008年3月26日在西区装配现场对6台ISDe四缸机缸盖螺栓装配后的伸长量进行了测量。6台ISDe四缸机全部是采用的东风汽车紧固件有限公司螺栓。1.4.1 缸盖螺栓装配条件缸盖总成零件号: 缸体零件号: 进口气缸垫零件号: 国产气缸垫零件号: 拧紧机生产厂家：拧紧机扭矩控制精度：3%拧紧机角度控制精度：1螺栓润滑方

12、式：螺栓拧紧工艺步骤如下：Step1：拧紧至70Nm6NmStep2：松开3605Step3：拧紧至105Nm 3NmStep4：再拧紧90 5监控力矩:135Nm200Nm装配预紧力：81KN6KN1.4.2 缸盖螺栓位置及编号 将每台发动机使用的缸盖螺栓由1到18编号，不同号码的螺栓在发动机上位置如图2所示。图 2 缸盖螺栓在发动机上位置及编号排气管侧432156789141312111015161718进气管侧1.4.3 六台发动机缸盖螺栓现场伸长量测量数据在ISDe发动机装配车间对6台四缸发动机缸盖螺栓的原长装配后的伸长量拧紧力矩、松开后的残余伸长量进行测量,测量数据见表2表4表 2

13、六台发动机缸盖螺栓伸长量测量数据第一台（进口缸垫）第二台（进口缸垫）螺栓编号原长mm伸长量 mm力矩Nm残余伸长量mm预紧力KN原长mm伸长量 mm力矩Nm残余伸长量mm预紧力KN1141.11320.6530164.30.073287.9234141.12100.5849178.20.037082.15142141.08390.6421167.80.061386.9995141.15340.5946166.00.038782.97353141.07040.6501166.10.067387.6776141.05480.5769182.00.036581.47334141.19180.6299

14、169.30.056785.9655141.18150.5735177.20.027881.18515141.18290.6104167.10.046884.3127141.16620.5395180.50.016277.09256141.18890.6172171.30.047084.8891141.06750.5767171.50.031981.45637141.15430.6210172.50.049785.2111141.17030.5495178.90.024278.44258141.14080.6304168.30.052786.0079141.02950.5637177.60.0

15、29280.35459141.05610.6326174.90.057186.1943141.12130.5865176.50.032282.287010141.15200.6420169.20.060486.9911141.10780.5622180.30.032880.157011141.06750.6362165.70.059386.4995141.16880.5653171.30.026680.490112141.08890.6404168.50.054286.8555141.15570.5661173.10.030480.557913141.06290.6433166.10.0614

16、87.1013141.05860.5653174.90.029980.490114141.14350.6219171.30.062785.2874141.16090.5436169.70.022977.646015141.14950.6089167.90.046984.1856141.07520.5553173.10.028379.225516141.11720.6073170.50.045484.0499141.08200.5438170.30.018577.673017141.11090.5552172.70.011679.2120141.50370.5674167.90.025480.6

17、68118141.10430.5876184.60.032482.3802141.11050.5439173.40.024877.6865平均值0.6239169.90.052685.43020.5644174.60.028580.1117标准差0.02424.62.11950.01624.61.7715表 3 六台发动机缸盖螺栓伸长量测量数据第三台（进口缸垫）第四台（国产缸垫）螺栓编号原长mm伸长量 mm力矩Nm残余伸长量mm预紧力KN原长mm伸长量 mm力矩Nm残余伸长量mm预紧力KN1141.07490.5611177.00.021580.0085141.08180.5811177.40

18、.040781.82932141.20120.5657172.70.019380.5240141.04560.5823174.10.035481.93103141.10460.5813178.10.032881.8462141.03780.5803169.30.034981.76154141.08910.5751175.20.033581.3207141.11850.5839169.70.037682.06665141.09300.5556171.90.242079.2660141.01260.5658175.10.033180.53256141.13230.5503184.20.017278

19、.5505141.08100.5943179.70.035082.94817141.11950.5459182.70.007577.9565141.09690.5712177.30.036880.99028141.17350.5653173.30.024880.4901141.09330.5749175.00.033181.30389141.10880.5598176.90.020779.8330141.07850.5674179.50.035880.668110141.17780.5501172.40.012978.5235141.02870.5827175.40.031881.964911

20、141.09820.5426173.70.013177.5110141.02610.579170.90.033981.651312141.14090.5675165.90.025580.6766141.07770.5736173.10.026281.193613141.07040.5702173.10.024780.9054141.12840.5828176.30.034481.973414141.07650.5579174.70.024279.5765141.08420.5667172.90.032580.608815141.16820.5415176.50.015277.3625141.0

21、0820.5679171.30.030180.710516141.15950.5658171.30.023980.5325141.08200.5611176.50.032180.008517141.13830.5386186.60.016976.9710141.02230.5711178.10.034580.981718141.11890.5452168.70.021677.8620141.05570.5567180.30.027679.4145平均值0.5578175.30.021179.42870.5746175.10.033681.2521标准差0.01235.21.48430.0095

22、3.40.8547表 4 六台发动机缸盖螺栓伸长量测量数据第五台（国产缸垫）第六台（国产缸垫）螺栓编号原长mm伸长量 mm力矩Nm残余伸长量mm预紧力KN原长mm伸长量 mm力矩Nm残余伸长量mm预紧力KN1141.17230.5892178.40.031482.5158141.13800.5765167.80.036481.43942141.12280.5707169.40.026780.9478141.03370.5799168.40.035181.72763141.11450.5798176.30.029381.7191141.07200.5706181.60.027680.939341

23、41.16740.5752182.20.029781.3292141.07920.5837176.80.036682.04965141.09900.5562181.30.026079.3470141.04020.5701178.90.032880.89696141.11050.5648178.90.029180.4477141.12940.5675175.10.028980.67667141.01330.5762175.70.030181.4140141.07570.5681171.70.028580.72748141.15190.5759169.70.027181.3885141.07680

24、.5696175.60.027880.85469141.06630.5596180.30.027379.8060141.11300.5626174.30.032280.211010141.14080.5545181.70.019379.1175141.05460.5539174.80.023179.036511141.00890.5756173.10.034581.3631141.01100.5842167.10.031882.092012141.12510.5824172.30.030181.9395141.13470.5942163.10.037082.939613141.16010.56

25、78169.50.030580.7020141.18890.5618170.50.019380.103014141.00600.5535176.10.028078.9825141.11410.5812167.70.034981.837815141.12450.5672169.30.031280.6511141.99270.5556172.10.030979.266016141.08560.5701175.10.024280.8969141.10760.5711163.10.031480.981717141.04640.5656173.70.026780.5155141.98040.561917

26、2.30.031580.116518141.10120.5583173.40.026379.6305141.09390.5599170.80.033979.8465平均值0.5690175.40.028280.70630.5707171.80.031180.8746标准差0.01014.41.00350.01095.01.02362.0数据处理过程下文阐述中所列的英文和数字的表达意思如下：elongation代表伸长量；length代表原长；clamp force代表预紧力；torque代表拧紧力矩；1，2，3，4，5，6分别代表6台不同发动机；范例1：elongation1表示第一台发动机上缸盖螺栓的伸长量。范例2：clamp force2表示第二台发动机上缸盖螺栓的预紧力。凡此种种，依例类推。2.1分析各台缸盖螺栓数据是否正态分布理论上同一批次螺栓的相关数据应该服从正态分布，现利用统计分析软件Minitab对以上结果进行分析。分析数据包括伸长量；原长；预紧力；拧紧力矩。其中伸长量；原长；拧紧力矩为测量所得；预紧力为根据标定结果计