What is Torque Participant Manual

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2008 Ingersoll Rand Company

Proprietary Notices and Disclaimer

PROPRIETARY NOTICES
2008 Ingersoll Rand Company CONFIDENTIAL AND TRADE SECRET INFORMATION. This manual contains confidential and trade secret information owned by Ingersoll Rand Company (hereinafter referred to as Proprietary matter. In consideration of the disclosure of the Proprietary Matter herein to the authorized recipient hereof, the recipient shall treat the Proprietary Matter as secret and confidential; shall not disclose or give such Proprietary Matter to third parties without express written authorization of INGERSOLL RAND; shall not use the Proprietary Matter except to the extent necessary to use or service the equipment disclosed herein; shall disclose such Proprietary Matter only to those of its employees whose use of knowledge of the Proprietary Matter is necessary. This manual shall be returned upon request by Ingersoll Rand Company. The unauthorized use of this manual may be punishable by law.

DISCLAIMERS
PROVIDED AS IS. THIS MANUAL AND THE CONTENTS HEREOF ARE PROVIDED AS IS AND WITHOUT ANY IMPLIED WARRANTIES.

Table of Contents
Course Overview .................................................................................................................... 4 Definition of Terms .................................................................................................................. 5 Requirements of a Reliable Joint ............................................................................................ 6 The Fastener ........................................................................................................................... 7 Joint Type ............................................................................................................................. 11 Joint Design .......................................................................................................................... 12 Assembly Tool Consideration ............................................................................................... 14 Fastening Basics ................................................................................................................... 16 Tightening Strategy ............................................................................................................... 17 Torque Control ...................................................................................................................... 19 Torque Control with Angle Monitoring ................................................................................... 20 Angle Control ........................................................................................................................ 21 Yield Control ......................................................................................................................... 22 Prevailing Torque Tightening Strategy .................................................................................. 23 Drag Torque Strategy ........................................................................................................... 24 Notes ..................................................................................................................................... 25 Sales & Product Support ....................................................................................................... 27

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Course Overview
Business Rationale
This training course is designed to give you a better understanding of the precision fastening tools and knowledge to better sell the tools.

Course Agenda
Day One Introduction Torque Overview Controller Overview Tool Overview Peripheral Overview Day Two Programming of Controller On Screen ICS Loading Software Loading to Controllers Day Three Programming of Controllers Through ICS ICS Multisync and Powerhead Programming

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Definition of Terms
Algorithm Angle CFM Dynamic Load Friction Coefficient Friction Factor Galling Gradient HP Inspection MPa Preload or Clamp Load Prevailing Torque PSI Rc Scatter Service Loads Snug or Threshold Torque Static Load Stick-slip Tensile Strength Tension Stresses Threshold or Snug Torque Torque Torsion Stresses Windows Yield controlled tightening Yield Strength A computable set of steps to achieve a desired result. In tightening, a method of determining a fixed point on the tightening curve by measurement of various tightening parameters The angular rotation turned by the fastener during the tightening process Cubic Feet per Minute. A measure of flow (usually used for air flow) External load on the joint changes when the joint is in service A ratio of the frictional force and normal reaction between two contacting sliding surfaces, for threaded fasteners its numerical value, is usually in the 0.08 to 0.30 range. A factor used to calculate the expected fastener clamp load, its value, k, is normally in the 0.15-0.20 range. Very high friction under the bolt head or not The rate of change of torque over a fixed value of angle often referred to as the joint rate. Horsepower. A unit of power output. Fixed upper and lower values of torque, angle or gradient that are used for accept/reject MegaPascals. Metric (ISO) unit of mechanical stress. 1 Mega Pascal = 1 Newton of force per square millimeter of the fasteners cross-sectional area. (N/mm) The initial tensile clamping load induced in the fastener by tightening Torque generated by the fastener during run-down before any fastener preload is generated. Unit of mechanical stress. Pounds of force per square inch of the fasteners crosssectional area. Measured hardness on the Rockwell C scale The spread of resulting torque values. Usually three Standard Deviations above and below the set-point Loads imposed on the bolted joint from external sources A torque value below the final tightening torque from which point computation of the angle turned or the torque gradient is commenced External load on the joint is constant when the joint is in service Very high friction conditions in the threads causing them to bind (stick) and then release (slip) as torque is applied. Often occurs as an oscillation. The maximum stress that a fastener can be subjected to before it fractures. Stresses in the fastener acting along the axis of the fastener A torque value below the final tightening torque from which point computation of the angle turned or the torque gradient is commenced The effort required to overcome friction between the threaded fastener and the clamped parts in order to generate clamp load or tension in the fastener Shear stress on the fastener originating from the applied torque Inspection parameters at the end of the tightening process. (They are also used for the basis of calculation of capability indices Cp and Cpk.) Tightening the fastener to its yield point under combined tension and torsion stresses using a special algorithm. The stress that a fastener is subjected to before it is forced to deform a certain amount (usually 0.2% of fastener grip length)

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Summary
Millions of nuts and bolts (threaded fasteners) are assembled every year to join parts together. Fasteners are a critical element of most mechanical assemblies. The behavior of a bolted joint is influenced by many factors including the initial level of fastener preload, or clamp load, that is developed during tightening. When a bolt is tightened, it develops tensile stresses (clamp load) and torsion stresses. It is the tensile load that compresses the clamped parts and keeps the joint together. To properly understand the fastening process requires a working knowledge of the requirements of a bolted joint.

Requirements of a Reliable Joint

There are five major areas to consider in achieving a reliable bolted joint: The fastener quality Calculation of the required clamping load Knowledge of the application and joint dynamics Controlled tightening process Maintenance of bolt clamp load under the action of the service conditions.

Fastener Quality The quality is often considered a given in these days of supplier ISO certification and SPC techniques applied to most manufacturing processes. However, the integrity of the fastened joint can be compromised by fasteners with material or thread defects, particularly if the external loads are dynamic. Calculation of the Required Clamping Load It is necessary to calculate what the fastener clamp load should be to withstand the external loads that the assembly must sustain. Calculations based on mathematical models are available. Application and Joint Dynamics The application dynamics must be established. For example, will the joint be subjected to elevated or cryogenic temperatures, corrosion; thermal expansion effects of dissimilar materials and are the external loads static or dynamic? Controlled Tightening Process A controlled tightening strategy should be specified. Maintenance of Fastener Clamp Load If dynamic transverse forces are present, the fastener may require some form of self-locking.

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The Fastener
Influence of the Fastener There are many different types of threaded fastener available for the designer to specify. Certain aspects of fastener features or functions may influence the tightening method or equipment specified. The following chart illustrates some of the important aspects:

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Functional Design What forces will the fastener be subject to: tension, shear or bending? If the forces are significant, we may need to use a fastener that can better withstand them or a tightening strategy that will ensure maximum clamping load from the fastener after tightening. Thread Types What type of threads does the fastener have? Thread forming screws, if being tightening with a DC electric fastening system, will need to be carefully selected as there will be a significant prevailing torque throughout the tightening process. Washers Different types of washers can affect the torque-tension relationship. Driving Recess Will there be a problem locating or engaging the fastener drive? Head Style Once the fastener drive is engaged, will alignment be a problem? The driver must be perpendicular to the fastener, with no side loading, in order for the torque reading to be precise. Strength Grade What is the strength grade of the fastener, does the companion thread have sufficient strength and engagement? Materials Are the materials of the fastener and companion threads compatible, will there be any problems in engaging the fasteners together? Finish and Coating Are the fasteners plain or plated? What is the plating? Zinc is frictional, particularly if both the bolt and nut are zinc plated. Cadmium plate has higher lubricity. Prevailing Torque Does the fastener have a locking element or locking compound? The compounds physical characteristics can be affected by speed and may change during fastener rundown. Friction Frictional variations caused by the surface finish and lubrication conditions of the joint components can cause many inconsistencies in the tightening processes and the resulting clamp load scatter. This is illustrated using the following graph.

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Torque-Preload Relationship The Torque-Preload relationship for a bolted joint is shown below. When the bolt is tightened to a constant torque, T, the resulting preload or clamp load, Fp, obtained, depends on the friction coefficient, , of the bolt and clamped parts. The example shown shows two different friction coefficients, = 0.10 (oily bolt) and = 0.18 (dry bolt). The preload obtained with the oily bolt, Fp 2, is much greater than that obtained with the dry bolt, Fp1, although the applied torque was identical. The amount of clamp load scatter that you can get within a batch of bolts tightened to the same torque can be 25-30%.

Fp 2

= 0.10

Preload Fp 1 = 0.18

Torque

Thread types Threads are most commonly manufactured by thread rolling between two dies. It is a very repeatable process and the finished product, when done correctly, produces high quality parts. If it is not done correctly, thread defects can be produced that can cause premature failure under alternating loads. The important characteristics of threads are shown below. It is important not to have thread defects, particularly below the pitch diameter, as they can become the source of cracks in dynamic applications and lead to failure. There are numerous thread types and standards for both inch and metric fasteners. In very generalized terms, threads are usually classified as coarse pitch or fine pitch. Coarse threads have fewer tendencies to cross thread and assemble quicker than equivalent fine threads. They are more tolerant to damage and have greater stripping strength. They tap better into brittle materials that tend to spall during machining. Fine threads can support higher clamping loads due to their increased stress area and are more resistant to self-loosening due to transverse vibration. They tap better into hard materials or thin wall applications.

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Fastener Strength Grades Two systems are in common use for grading inch fasteners, the SAE system and the ASTM standards. The SAE system designates grades with numbers from 1 through 8. These numbers have no direct relationship to strength except that increasing numbers represent increasing strength. The ASTM standard grades are designated by their specification number and there may exist differences in grade within these specification groups depending on fastener size or material.
Strength Grade SAE grade 5 SAE grade 8 ASTM A325 type 1 ASTM A490 type 1 Nom size thru 1 inch thru 1 inch thru 1 inch thru 1 inch Yield Strength PSI (min) 82,000 130,000 92,000 120,000

Inch Fastener Marking

Tensile Strength PSI (min) 120,000 150,000 120,000 150,000

For metric fasteners, the ISO standards use a numbering system that reflects the minimum tensile and yield strength. This system uses a decimal number for each strength grade. The number on the left-hand side of the decimal point indicates 1/100th of the tensile strength in MPa and the number on the right hand side the yield strength as a percentage of the tensile strength. It is usual to mark the heads of the inch fasteners to indicate their grade as shown aboveusing a number of lines on the bolt head face. In most cases, the manufacturers name or logo is also present. Metric fasteners are marked with their grade: 8.8, 10.9 or 12.9.

Metric Fastener Marking Grade

10.9
ACME
Manufacturer

Strength Grade ISO 8.8 ISO 10.9 ISO 12.9

Nom size All All All

Yield Strength MPa (nom) 640 900 1080

Tensile Strength MPa (nom) 800 1000 1200

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Joint Type
Influence of the Joint The type of joint will need to be considered when choosing a tightening strategy and fastener tightening system. Joints are classified as being soft, medium or hard. Specification ISO 5393, which is a specification that describes how tools are tested, defines soft and hard joints by their joint rate or the amount of angle to turn the fastener through to reach the target torque. An example of a hard joint is a spark plug in a gasoline engine, once it seats you cannot turn it without the torque rising rapidly. An example of a soft joint is a flange coupling with an O-ring or cork gasket where you have to turn the fastener through a large angle to reach torque. Most joints that you will encounter will fall between these two extremes. A guideline would be that most joints, once snugged or brought together by tightening the fastener, would reach their final torque in the 60- 180 angle range. We will see that not all tools are suitable for all joints. The same applies to tightening strategies, some strategies work better on hard joints than soft joints.

JOINT TYPES
JOINT RATES AS DEFINED BY ISO5393
Target torque

Joint rate highly effects the final clamp load achieved by a given torque Hard Joint
Clamp Load (torque)

30 or less rotation between snug and final torque (27 between 10% and 100% torque)

Torque

Angle (Time) Clamp Load

Soft Joint 720 rotation between snug and final torque (650 between 10% and 100% torque)

Normal angle for most joints 60- 180

Angle
Angle

103

TOOL DIVISION

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Joint Design
For successful joint performance, the designer needs to ensure that certain design parameters are met. Thread Engagement The chart on the left shows the required thread engagement, as a factor of the bolt diameter, for four typical joint materials. This shows that for an internal thread manufactured from steel, heat treated to 40 Rc, would require between 0.9 and 1.1 times the fastener diameter of thread engagement. In, addition, there should be at least three unengaged threads so that the most heavily stressed threads, which are the first engaged threads, do not coincide with the first thread of the fastener. It is recommended that a number of unengaged threads, at least three, are designed in the joint. This insures that the most heavily stressed first engaged threads do not coincide with the incomplete thread contour of the thread run out.

THREAD ENGAGEMENT
Material Type Cast Iron Steel, 200 HV Steel, 400 HV Aluminum Alloys
d = bolt diameter

Minimum Thread Engagement 1.25 - 1.75 d 1.0 - 1.5 d 0.9 - 1.1 d 2.0 - 2.5 d
Minimum of 3 Unengaged Threads

The actual minimum required thread engagement depends upon material shear strength, thread fineness and bolt strength grade. Values should be determined by actual tests.

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Nuts Where nuts are used, the nuts should have sufficient resistance to thread stripping. When a nut is tightened onto a bolt, the nut compresses and dilates. This can reduce the effective thread engagement. Flanged nuts reduce this effect as well as providing greater bearing areas and resultant lower bearing stresses. Nut strength classes should be matched to the companion bolt strength. In general, these nuts will have a lower strength than the bolt. The higher strength bolt threads resist distortion and contain the nut threads from elastic displacement under load. Bearing stresses The bearing stresses under the bolt head and nut face (where applicable) should not exceed the compressive yield strength of the material on which the fastener is seated. This will minimize embedding and galling effects due to excessive surface pressures. The following table provides guidelines for various material types.

MATERIAL TYPE CAST IRON STEEL 20 Rc STEEL 40 Rc ALUMINUM ALLOYS

MAXIMUM ALLOWABLE BEARING STRESSES (KSI) 80 70 160 30

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Assembly Tool Consideration

Air System Considerations It takes both pressure and flow to make an air tool work. The air compressor must deliver more air than the tools connected to it will consume. The volume of air is expressed in CFM. Theoretically, compressors greater than 25HP will deliver 4 CFM/HP. In practice, however, due to efficiency losses from leaks, wear etc. the figure is closer to 3CFM/HP. Therefore, in practical terms, a compressor will deliver a volume 3 times its motor horsepower. The dynamic air pressure at the tool must be 90psi (6.2 Bar) or the tool may not perform as specified. For every 10psi drop in dynamic air pressure, there will be an 11% drop in output torque from the tool. Anything that restricts the airflow can also affect the performance. As an example, think of a threelane highway narrowing down to a single lane for roadwork. Traffic is slower. When a given volume of air is forced through a narrow passage, it slows down. An air hose that is too small or a narrow air fitting can be a restriction. It is important to insure that the length of the air hose does not exceed the maximum values as follows: HOSE DIAMETER MAXIMUM LENGTH (FEET) 8 10 25

&

In cases where longer lengths are required, a larger diameter should be used. DC Electric Systems Considerations DC electric tools are the current state-of-the-art for the assembly and control of threaded fasteners. They provide numerous benefits that enhance the entire fastening process. DC electric tools are very accurate, clean and quiet, ergonomic and have a high power-to-weight ratio. These systems are more expensive than air tools but have lower operating costs. They can be programmed to conduct advanced tightening strategies and can interface with other intelligent devices. If the tools are to be used with thread forming fasteners or prevailing torque fasteners, they must be carefully selected and sized accordingly. With these types of applications, the tools are providing torque throughout the entire tightening cycle, not just at the end. Under these operating conditions the motor can heat up so a tool with sufficient torque output should be chosen. As an example, if the prevailing torque of a fastener is 20 Nm and the final tightening torque is 30Nm, do not use a 35Nm tool but rather specify one good for at least 50Nm. This will insure that the tool will not overheat during service.

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The following Tables provide a brief comparison between the various tool types:
Tool Mechanism Torque Control Joint Speed Reaction Vibration Operator $ range Air Screwdrivers (S) and Nutrunners (N) Direct (stall) Positive jaw Cushion clutch clutch 8-120 inlb (S) 14-165 inlb 3-100inlb(S) 2-125 Nm (N) (S) 3-130inlb(N) none none adjustable soft/med soft/med soft/hard 250-2800 250-2800 250-2800 high high low none high low skilled skilled unskilled 200-800 200-800 200-800 Precision shut-off clutch 3-100inlb(S) 5-25Nm(N) adjustable soft/hard 250-2800 low none unskilled 200-800 Air Pulse Impulse 3-330Nm adjustable med/hard 5000-10000 none low skilled 1300-10,000 Air Impact Impact 20-60,000Nm none soft/hard 5000-14500 none high skilled 125-1200 DC Clutch 0.2-60inlb adjustable soft/hard 300-2000 low none skilled 500-1000 DC Transducer shut-off 2-450Nm adjustable soft/hard 100-1300 high none skilled 12,000

Application Guideline for Ingersoll-Rand Tightening Tools The information provided in these tables is a guideline only as the performance of the tightening tools are very often dependent upon the characteristics of the joint being assembled.
TOOL TYPE APPLICATION/ CONTROL APPLICATION CONTROL APPLICATION CONTROL APPLICATION CONTROL APPLICATION CONTROL APPLICATION CONTROL APPLICATION CONTROL APPLICATION CONTROL APPLICATION CONTROL HARD JOINT GOOD FAIR FAIR FAIR GOOD GOOD VERY GOOD VERY GOOD GOOD GOOD GOOD POOR VERY GOOD VERY GOOD EXCELLENT EXCELLENT SOFT JOINT GOOD FAIR GOOD FAIR GOOD GOOD VERY GOOD VERY GOOD POOR POOR FAIR POOR VERY GOOD VERY GOOD EXCELLENT EXCELLENT JOINT TYPE SELF-TAPPING POOR POOR GOOD GOOD GOOD GOOD VERY GOOD VERY GOOD UNSUITABLE UNSUITABLE UNSUITABLE UNSUITABLE VERY GOOD VERY GOOD EXCELLENT EXCELLENT SHEETMETAL POOR POOR GOOD GOOD GOOD GOOD VERY GOOD VERY GOOD UNSUITABLE UNSUITABLE UNSUITABLE UNSUITABLE VERY GOOD VERY GOOD EXCELLENT EXCELLENT WOODSCREWS GOOD POOR GOOD FAIR FAIR FAIR UNSUITABLE UNSUITABLE UNSUITABLE UNSUITABLE UNSUITABLE UNSUITABLE UNSUITABLE UNSUITABLE NOT JUSTIFIED

AIR DIRECT/STALL AIR POSITIVE JAW AIR CUSHION CLUTCH PRECISION SHUT-OFF AIR PULSE W/O CONTROL AIR IMPACT WRENCH DC CLUTCH DC TRANSDUCER

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Fastening Basics
Torque and Angle A fastener is tightened by applying a torque and rotating it through a rotational angle as shown above. The torque is a product of the force applied and the distance from the fastener that it is applied. This is measured in Newton-Meters (Nm) in the metric system and foot-pounds or inch-pounds (ft.lbs, in.lbs) in the English system. The challenge of this module is to understand the fundamentals and the options available. Achieving this knowledge and understanding will help you to identify applications where controlled or more advanced tightening strategies will help you to solve a customer's problem and sell a solution. What happens when we tighten a bolt in a joint by applying torque ?

We get two equal and forces opposite forces

Joint compression

Bolt tension called preload or clamp load

A tensile force is generated in the fastener and an equal and opposite compression force applied to the joint.

90

Angle
135

Force
(Newtons, Pounds)

Factoid: Angle = rotational travel 1 second on your watch = 6

Distance
(Feet, Meters)

Torque = Force x Distance

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Tightening Strategy
Tightening Strategy Considerations When deciding on a tightening strategy, the choices are governed by the tightening system available or the budget dollars approved for the purchase of new equipment. If only very basic fastener tightening systems are available, there will be few, if any, choices. However, if modern DC Electric systems can be used, then tightening strategies can be developed to produce the best solution for the customer. Most budgets reflect the criticality of the application; a number of criteria are used in making this assessment. These criteria may or may not be related: Safety related where failure may result in catastrophe, death or injury. Reliability related where failure may result in disability of the equipment Customer satisfaction related where failure may result in end-customer displeasure. The quality of the assembly is greatly influenced by the fastener preload and accuracy. The initial fastener preload level required (preload is the initial tensile clamping load generated by the assembly tightening tool) has to be determined at the joint design stage. This is a complicated process; particularly if the joint is to be exposed to service loads, thermal expansion effects due to dissimilar materials or preload loss during service conditions. Some joints rely on all fasteners to have similar levels of preload. Connecting rods in engines and cylinder heads both require all bolts to have a low scatter in preload between the fasteners to avoid bore distortion in the assemblies. Conversely, some joints do not warrant in-depth analysis, as preload level and accuracy are not important. In these cases, simple assembly tools and tightening strategies are chosen. Tightening Strategy to Achieve Fastener Clamp Load There are a number of different tightening strategies available, depending upon the assembly tool selected. Not all-manual or power tools are capable of torque or angle measurements, and are not intended for this purpose. The simplest assembly tool is the common screwdriver, in which the applied torque is guessed and the subsequent clamping load on the fastener is proportional to the strength of the operator. However, this wrist powered manual tool and tightening strategy (guessing) does an adequate job on thousands of applications. Most industrial applications or mass production assembly techniques require tools and tightening strategies that provide more control on fastener preload, and often some form of feedback to the operator that the tightening of the bolted joint was completed satisfactorily.

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For these applications controlled tightening tools are required. The tightening tools require torque transducers and angle measurement capability. An electronic controller is also required to process the raw data generated from the transducers. These can be air tools but in the majority of cases are DC Electric tools. Many automotive and Tier 1companies are making a total switch from air to controlled DC tools. The tightening signature is a plot of torque versus angle and is used to evaluate the tightening process. The terms showed on this example are used throughout this module.

TIGHTENING SIGNATURE
YIELD TORQUE TORQUE ANGLE ACCEPTANCE WINDOW HIGH TORQUE LIMIT TARGET TORQUE

TORQUE

LOW TORQUE LIMIT TORQUE GRADIENT T A LOW ANGLE LIMIT

THRESHOLD TORQUE

HIGH ANGLE LIMIT

TARGET ANGLE MEASURED FROM THRESHOLD TORQUE

ANGLE

Tightening threaded fasteners is an energy transfer process, and the energy transferred from the tool to the fastener is mainly consumed in overcoming the frictional resistance between the parts. As much as 90% of the supplied energy may be absorbed in overcoming friction, leaving only 10% to generate clamping load. Because of this, the most common tightening strategy, Torque Control, has severe limitations in providing accurate preload.

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Torque Control
Torque control is the most common tightening strategy in use because it is easy to apply, control and check. It can be measured directly with a transducer, or indirectly using a clutch or stall tool. The relationship between the applied torque and the preload is shown in the empirical formula: T = Fp x d x k Where: T = torque, Fp = preload, d = fastener diameter, k = friction factor (normally a value of 0.150.20 is used in the equation.) A target torque is selected to reach a nominal preload equivalent to about 70% of the fastener yield strength. The major drawback with this method is that the resulting clamp load achieved is greatly influenced by friction. Friction is difficult to predict and control, and depends on many variable factors. These include surface finish on the fasteners and joint components, surface coatings, plated finishes, and lubrication. Even the speed of tightening delivered by the assembly power tool can indirectly contribute to the frictional variations. If a higher value is chosen, there is a danger that under low frictional conditions the fastener could be tightened to well beyond the yield point and experience excessive plastic deformation (over tightening). The scatter in preload using this tightening strategy is typically 30%.

TORQUE CONTROL WITH ANGLE MONITORING

YIELD TORQUE

TARGET TORQUE

HIGH TORQUE LIMIT

TORQUE

LOW TORQUE LIMIT

TARGET TORQUE IS TYPICALLY 60-70% OF YIELD TORQUE

LOW ANGLE LIMIT

CLAMP LOAD SCATTER 30%

THRESHOLD TORQUE

HIGH ANGLE LIMIT

ANGLE FROM THRESHOLD TORQUE TO FINAL TORQUE

ANGLE

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Torque Control with Angle Monitoring

An improvement over standard torque control is torque control with angle monitoring. To do this, a tool with both torque and angle transducers is required. This method has no effect on the level or scatter in fastener preload that is achieved, but provides a check that the assembly tightening process was completed as expected. By monitoring the angle turned from a pre-selected snug or threshold torque, usually about 30-50% of the final tightening target torque, many defects like crossed threads, bottomed-out bolts, or distorted joint components can be detected with this tightening strategy. Checks for: Improper assembly Shallow Hole Cross Threading Stripped Threads Again, the scatter in preload using this tightening strategy is typically 30%. The below examples are of where monitoring the angle can detect faults in the tightening process

You can see that monitoring the angle can detect a lot of tightening defects. However, a lot of customers dont use it or dont know how to set it up. This can be done by running tests on known good joints, calculating the average and standard deviation, then applying 2.5 or 3 times the standard deviation to calculate the angle high and angle low limits.

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Angle Control
To reduce the amount of preload scatter produced by torque controlled tightening, a tightening strategy that uses the relationship between the thread pitch and the angle turned during tightening is used. This tightening strategy is called Angle Control or Turn-of-the Nut tightening. The procedure for this tightening strategy starts with tightening the fastener to an initial threshold torque and then turning the fastener to a pre-determined angle of rotation. Once the joint is consolidated, the angle turned is proportional to the amount of fastener elongation, which in turn is proportional to the preload achieved. Friction is not an influence in this portion of the tightening strategy, other than it determines the final torque at the end of the process, which is merely monitored for quality purposes. This strategy was originally developed for yield tightening before transducerized tools and yield algorithms were available. Now it is now used in the elastic range of the fastener, using target preloads below the yield point of the fastener. The relationship between angle turned and fastener elongation is as follows: l = 360 l = elongation, = angle turned, P = thread pitch The final preload is a result of the two steps of the angle strategy. The first step is that controlled by the snug torque; which is influenced by friction as with torque controlled tightening. The second step is that controlled by the angle turned which is independent of friction. This strategy relies on the fact that for every 360 of rotation that the fastener is turned, it will stretch one thread pitch (less the compression of the clamped parts); 90 will stretch the fastener of the thread pitch. The scatter in preload using this tightening strategy is typically 15%.

ANGLE CONTROL WITH TORQUE MONITORING

YIELD TORQUE

HIGH TORQUE LIMIT

TORQUE

LOW TORQUE LIMIT LOW ANGLE LIMIT

TARGET ANGLE IS TYPICALLY CHOSEN TO PRODUCE A FINAL TORQUE 60-70% OF YIELD TORQUE CLAMP LOAD SCATTER 15%

THRESHOLD TORQUE

HIGH ANGLE LIMIT

TARGET ANGLE MEASURED FROM THRESHOLD TORQUE

ANGLE

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Yield Control
Tightening to the yield point of the fastener utilizes the maximum preload capacity of the fastener. This strategy calculates the yield point of the fastener under the action of combined tension and torsion stresses. This is achieved by monitoring the rate of change of torque over fixed angle increments. The value obtained is the torque gradient, and as the yield point is reached the torque gradient declines rapidly and the tightening process is halted. Typically, the amount of permanent fastener elongation obtained is 0.025 - 0.050 mm. (0.001-0.002 in). The preload developed depends on the tensile yield strength of the fastener material and the shear stresses developed from frictional forces generated in the threads during tightening. The relationship is as follows: Y = + 3 Y = tensile yield strength of fastener = tensile stress = shear stress This method is much less influenced by friction and joint variations and at the end of the tightening process the final torque and angle can be inspected to check that they fall within pre-determined limits. In this way, every tightening cycle is 100% checked. The torque gradient is monitored from the snug point. The gradient will rise until the fastener yield point is approached where it will start to fall. When it falls to 50% of the maximum stored value, the tightening process is halted. The scatter in preload using this tightening strategy is typically 8%.

YIELD CONTROL WITH TORQUE AND ANGLE MONITORING

TORQUE-ANGLE CURVE OF BOLT TIGHTENED BY COMBINED TORSION AND TENSION STRESSES

TORQUE AT YIELD POINT

YIELD POINT HIGH TORQUE LIMIT

LOW TORQUE LIMIT

TORQUE

PEAK TORQUE GRADIENT 50% OF PEAK GRADIENT TORQUE GRADIENT

YIELD TIGHTENING CLAMP LOAD SCATTER 8%

LOW ANGLE LIMIT

THRESHOLD TORQUE

T A

HIGH ANGLE LIMIT

ANGLE FROM THRESHOLD TORQUE TO YIELD POINT

ANGLE

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The following table summarizes the main differences between the three major tightening strategies: Torque Control Accuracy of clamp load is 30% Recommended to use angle inspection for fault detection Target preload is typically 70% of fastener yield point Largely influenced by friction Accuracy of clamp load is 15% Application testing is required to establish tightening parameters Snug torque should be selected as low as possible but sufficient to consolidate the joint Usually used in elastic range of fastener Not always possible with high prevailing torque applications Accuracy of clamp load is 8% Utilizes maximum clamp load of fastener Difficult to reproduce in service Joint study is required to prove feasibility Not suitable for applications requiring frequent disassembly and re-tightening

Angle Control

Yield Control

Prevailing Torque Tightening Strategy

This is useful for thread forming applications where the thread forming torque may have a value similar to, or even greater than, the final tightening torque. This strategy monitors the initial peak prevailing or driving torque to ensure that it falls between expected limits (cut-in zone). It then checks the subsequent mean and peak prevailing torque as the thread is formed (prevailing zone). Finally as the fastener seats, the final tightening strategy is invoked which may be torque control, angle control or yield controlled tightening (tightening zone). For gasketed joints, such as a cylinder head or flanged joint, more even sealing can often be obtained by tightening all fasteners to a pre-torque. This pre-torque is usually about 30-50% of the final torque. Once all of the fasteners reach this pre-torque then the final tightening strategy is applied. In some cases there may be more than one pre-torque level. Another strategy sometimes employed is to tighten all the fasteners, then back them all out and then re-tighten them again. This procedure helps to flatten out any burrs in the threads and improve the frictional conditions, thus reducing preload scatter.

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In many applications multi-spindle tools are used, usually for cycle rate considerations but also to give improved joint performance. An example of this is the connecting rod where dual spindles are used. In this application, it is important to synchronize the spindles so that they complete the tightening strategy at the same time. This gives more even clamping and reduced bore distortion of the bearings.

Drag Torque Strategy

Drag torque is the torque required to overcome the inherent friction or pressure force resistance in the movement of an assembly or mechanical component through some predetermined angle. This technique is often used as a quality inspection procedure. A typical application is the measurement of engine crankshaft-turning torque in the automotive industry. In this application, there is usually an initial high inertial torque to get the crankshaft moving, and while this value can be measured, it is actually the dynamic torque following this initial torque spike that is the parameter required. Similar applications exist for measuring the frictional torque in bearings and hubs. Application considerations As we have seen, there are numerous tightening strategies available. The choice will be governed by the capability of the system available and the complexity and criticality of the application. The majority of industrial applications specify torque controlled tightening. As we educate our customers more, they will begin to monitor the angle during the tightening process to detect faults. Fault detection is often referred to as 'poke yoke' (Japanese term) or error proofing. Some customers in automotive applications have migrated to angle controlled tightening to reduce the scatter in fastener preload. Yield controlled tightening is restricted to applications where the customer truly understands this technology and wants to get the maximum clamping load with the minimum of scatter. Examples are connecting rod, cylinder head and main bearing bolts in high-end automotive engines. The increased use of light alloys in automotive and other industrial segments and the cost savings achieved by eliminating the need to machine the companion internal threads has demanded the availability of custom strategies like the prevailing torque strategy.

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Notes
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Notes ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________

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Sales & Product Support

Customer Service
Phone Number: 800-998-0872 Addresses questions regarding: Orders Delivery Stock Price Some tool recommendations When you call be sure to have: Order Number or Purchase Order Number Complete model number Complete application / problem description Identified potential troubleshooting issues, repair problems, or quality (incorrect part)

Technical Support
When you call be sure Addresses questions regarding: Application support Configurations Options or accessories Troubleshooting Competitive Cross-Over to have: Complete model number A complete description of application or problem Describe potential troubleshooting issues, repair problems, quality (incorrect part)

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Product Marketing Literature Product Literature and the irtools.com Web Site Purpose: To support you in your sales efforts Product Specifications Features Benefits Product Nomenclature Model Numbers Accessories Product support phone numbers To Order Product Literature Locate the publication number; typically this in on the lower right corner of the publications back cover. Then either call or email Ken Cook at: Phone: 1-800-376-8665, then press 2 Email: irlitorders@kencook.com

Inform the representative who you are, e.g., Ingersoll Rand Employee or Distributor Provide them with the count and where you would like to have the brochures shipped to. Quick Cross Competitive Crossover 1. Go towww.irtools.com > Contact Us > Quick Cross Competitive Crossover 2. Choose the type of products you want crossed over. 3. Complete and submit the online form.

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Product Warranty Standard one (1) year product warranty, Cables have a 2 year product warranty Free of defects in material and workmanship for a period of one (1) year from the original date of purchase. This warranty does not cover damage from repairs made or attempted by other than Ingersoll Rand Certified Service Centers, abuse, normal wear and tear, lack of maintenance, or accidents

Product Repair & Service Center Locations Always recommend a Certified Service Center Certified Service Technicians Genuine Ingersoll Rand Parts Go towww.irtools.com > Service & Support > Service Locator

Service Locator Customer Training Offered

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Course Test Part I To assure that we have met the stated objectives, please complete the course test provided by your instructor. We will review the correct answers once everyone as completed their test. Participant Satisfaction Survey We value your feedback and we need to have it to make future improvements to this course. Please complete the Participant Satisfaction Survey provided by your instructor.

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