Mechanical fastening, joining, and assembly

372 Pages·2013·16.255 MB·English

by  James A Speck

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James A. Speck
Boca Raton London New York
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Version Date: 20140909
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Contents
Preface to the Second Edition ...............................................................................ix
Preface to the First Edition ....................................................................................xi
Acknowledgments ..............................................................................................xiii
Author .....................................................................................................................xv
1 Fastener Functions and Assembly Testing ................................................1
1.1 The Fastener Design Role .....................................................................1
1.2 Analysis of a Simple Metal Assembly ................................................3
1.3 Fastening a More Complex Assembly..............................................13
1.4 Fastening Real-World Applications ..................................................19
1.5 Fastener Statics ....................................................................................28
Reference .........................................................................................................33
2 Fastener Types and Their Production .......................................................35
2.1 Tension Fasteners ................................................................................36
2.1.1 Pan Head .................................................................................36
2.1.2 Truss Head ..............................................................................37
2.1.3 Hex Head ................................................................................39
2.1.4 Socket Screws .........................................................................40
2.1.5 Blind Rivets .............................................................................42
2.1.6 Some Dimensions for Blind Rivets ......................................42
2.1.7 Self-Clinching Studs ..............................................................43
2.1.8 Weld Studs ..............................................................................45
2.1.9 Grooved Pins ..........................................................................46
2.1.10 Split Knurl Drive Screws.......................................................47
2.1.11 Type “U” Drive Screws .........................................................47
2.1.12 Self-Threading Screws ...........................................................47
2.1.13 Locking Threads ....................................................................49
2.1.14 Cold-Heading Manufacturing Process ...............................49
2.1.15 Roll-Threading/Forming Process ........................................51
2.1.16 Heat Treating of Metal Fasteners .........................................52
2.1.17 Checking Fastener Hardness ...............................................55
2.1.18 Screw Machining ...................................................................56
2.1.19 Other Tension Fasteners ........................................................57
2.2 Compression Fasteners .......................................................................58
2.2.1 Set Screws ...............................................................................58
2.2.2 Washers ...................................................................................58
2.3 Shear Fasteners ....................................................................................60
2.4 Adhesives .............................................................................................60
2.5 Fastener Manufacturing Methods ....................................................61
iii
iv Contents
2.5.1 Roll-Threading and Other Screw-Threading
Processes .................................................................................71
2.5.2 Some Additional Thoughts on Adhesives ..........................73
2.5.3 Some Additional Thoughts on Welding .............................74
2.6 Fastener Dynamics .............................................................................74
Reference .........................................................................................................76
3 Fastening and Joining Mechanics .............................................................77
3.1 Metal Joints ..........................................................................................77
3.1.1 Rigid Metal Joints ..................................................................78
3.2 Nonmetal Joints ...................................................................................93
3.2.1 Snap Fit Assembly .................................................................94
3.2.2 Adhesive Assembly ...............................................................94
3.2.3 Blind Rivet Assembly ............................................................95
3.2.4 Self-Threading Screw Assembly ..........................................95
3.2.5 Some Additional Thoughts ..................................................97
3.3 Applications View of Fastener Functions ........................................98
3.4 Fastener Strength of Materials ........................................................103
3.4.1 Engineering Model Method ...............................................107
Reference .......................................................................................................113
4 Economic Factors in Fastener/Assembly Decisions .............................115
4.1 Build Quantities ................................................................................117
4.1.1 Tools, Fixtures, and Equipment .........................................120
4.1.2 Assembly Site .......................................................................121
4.1.3 Assembly Documentation and Training ..........................121
4.1.4 Assembly Fastening Material Supply Channels .............122
4.2 Assembly Robustness .......................................................................122
4.3 Legal Considerations and Constraints ...........................................124
4.3.1 Consensus Standards ..........................................................126
4.3.2 Some Fastener Cases ...........................................................126
4.3.2.1 Jet Engine Mounting Bolt ....................................126
4.3.2.2 Propeller Screw .....................................................127
4.3.2.3 Motorcycle Disk Brake Rotor Screws ................127
4.3.2.4 Fractured Valve Screws .......................................128
4.3.3 Bogus Bolting .......................................................................128
4.4 Economic Factors in Fastener/Assembly Decisions .....................133
4.5 Engineering Economics ...................................................................138
Suggested Reading ......................................................................................144
5 Assemblies under Dynamic Loading .....................................................145
5.1 Mass Effects .......................................................................................149
5.1.1 Four-Bolt I.C. Engine Main Bearing Supports .................149
5.1.2 Mass Effects of Oil Pan and Gasket Screws .....................150
5.1.3 Testing for Dynamic Loading Applications ....................153
Contents v
5.2 Vibration .............................................................................................154
5.3 Fatigue ................................................................................................157
5.4 Some Additional Dynamic Tests ....................................................158
5.4.1 Some Thoughts on Dynamic Loading ..............................160
5.5 Difference between Static and Dynamic Strength .......................161
5.6 Fastener Chemistry ...........................................................................164
Reference .......................................................................................................165
6 Assembly Sites and Systems ....................................................................167
6.1 Accessibility .......................................................................................167
6.2 Reusability Factors ............................................................................169
6.3 Assembly Training ............................................................................179
6.4 Degree of Automation ......................................................................180
6.5 Automatic Assembly Machines ......................................................184
6.5.1 Station Tooling......................................................................186
6.5.2 Ergonomics ...........................................................................187
6.5.3 Designed-In Flexibility........................................................187
6.5.4 Seamless Handoff ................................................................187
6.5.5 Setting Quantitative Targets ..............................................187
6.6 Smart Machines and Robots ............................................................187
6.7 A Renewed Look at Modern Assembly .........................................190
6.7.1 The Engineer and the Accountant .....................................190
6.7.2 The Engineer and the Attorney .........................................191
6.8 Fastener Numerical Methods ..........................................................194
6.8.1 General Rules for Numerical Proficiency .........................194
6.8.2 Numbering Systems ............................................................195
6.8.3 Geometry ..............................................................................195
6.8.4 Algebra ..................................................................................195
6.8.5 Trigonometry ........................................................................196
6.8.6 Statistics .................................................................................196
6.8.7 Calculus—Differential and Integral .................................197
6.8.8 Differential Equations .........................................................197
6.8.9 Linear and Other Programming Techniques ..................198
Reference .......................................................................................................198
7 Fastener Materials ......................................................................................199
7.1 Steels ...................................................................................................199
7.1.1 AISI 1010 ................................................................................200
7.1.2 Response to Temperature: Annealing ..............................201
7.1.2.1 Typical Fastener Application ..............................201
7.1.2.2 AISI 1018 ................................................................201
7.1.3 Response to Temperature: Carbonitriding and
Tempering .............................................................................202
7.1.3.1 Typical Application ..............................................202
7.1.3.2 AISI 1038 ................................................................202
vi Contents
7.1.4 Response to Temperature: Through or Neutral
Hardening .............................................................................203
7.1.4.1 AISI 4037 ................................................................203
7.1.5 Response to Temperature ...................................................203
7.1.5.1 AISI 4140 ................................................................203
7.1.5.2 AISI 8640 ................................................................204
7.1.5.3 AISI 52100 ..............................................................205
7.1.5.4 H-11 .........................................................................205
7.2 Stainless Steels ...................................................................................206
7.2.1 Type 302 HQ .........................................................................206
7.2.2 Type 303 .................................................................................207
7.2.3 Type 305 .................................................................................208
7.2.4 Type 410 .................................................................................208
7.2.5 Type 430 .................................................................................209
7.2.6 17-4 PH ...................................................................................209
7.2.7 A 286 ......................................................................................210
7.3 Nonferrous Materials .......................................................................211
7.3.1 Spectrographic Analysis .....................................................211
7.3.2 Carbon Analysis ...................................................................212
7.3.3 Magnetic Screening .............................................................212
7.3.4 Eddy Current Techniques ...................................................212
7.3.5 Brass Alloys ..........................................................................212
7.3.6 Aluminum Alloys ................................................................213
7.4 Other Fastener Materials ..................................................................214
7.4.1 Titanium ................................................................................214
7.4.2 MP35N ...................................................................................214
7.4.3 Monel .....................................................................................214
7.4.4 Hastelloy ...............................................................................214
7.4.5 AerMet 100 ............................................................................215
7.4.6 Notes on Fastener Metallurgy ............................................217
7.4.7 Brazing Alloys ......................................................................217
7.4.8 Nonmetallic Fastener Materials .........................................217
7.5 Fastener Materials in Today’s Environment ..................................218
7.6 The Fastener Laboratory ..................................................................221
7.7 Electrical Theory and Fastening, Joining, and Assembly ...........226
Reference .......................................................................................................230
8 Environmental Factors and Corrosion ...................................................231
8.1 Corrosion of Fasteners and Assemblies .........................................231
8.2 Corrosion Protection .........................................................................235
8.3 Corrosion Testing ..............................................................................241
8.4 Some Thoughts on Sustainability ...................................................242
8.5 Application Engineering Project Management ............................243
8.6 Thermodynamics ..............................................................................245
Suggested Reading ......................................................................................248
Contents vii
9 Assembly Analysis .....................................................................................249
9.1 Circular Areas ...................................................................................249
9.1.1 Pins, Shoulders, Shear Areas ..............................................249
9.1.2 Hexagonal Area....................................................................249
9.1.3 Circular Volume ...................................................................250
9.1.4 Hexagonal Volume...............................................................250
9.1.5 Volume of a More Complex Shape ....................................251
9.1.5.1 Fastener Geometry ...............................................251
9.1.6 Calculate Part Weight, Individual, Per Hundred,
Per Thousand ........................................................................254
9.1.7 Calculate Fastener Elastic Elongation ...............................256
9.1.8 Calculate Upset Volume ......................................................257
9.1.9 Find the Largest Head Diameter per Upset .....................257
9.1.10 Calculating a Compound Fastener Shape ........................259
9.1.11 Estimating Screw Slot Torque ............................................259
9.1.12 Calculating Strip-to-Drive Ratios ......................................260
9.1.13 Evaluating Drive Torque/Horsepower .............................262
9.1.14 Calculating a Knurl Pitch ...................................................263
9.1.15 Finding a Screw Diameter from a Target
Clamp Load ..........................................................................264
9.1.16 Calculating Pin Shear Strengths ........................................264
9.1.16.1 Single Shear ...........................................................265
9.1.16.2 Double Shear .........................................................265
9.1.17 Calculating Torque–Tension Operating Charts ...............266
9.1.18 Estimating Assembly Efficiency ........................................266
9.2 Work from the Workshop ................................................................268
9.2.1 Calculating Heading Upset Volumes and
Diameter Ratios ....................................................................270
9.3 D & D 100 ...........................................................................................274
References .....................................................................................................275
Appendix A: Fastening, Joining, and Assembly Glossary .......................277
Appendix B: Ingenious Fasteners and Assemblies .....................................281
Appendix C: Some Frequent Fastener Questions and Answers ..............291
Appendix D: Article from American Fastener Journal ..............................297
Appendix E: Some Additional Problem Solution Ideas and
Summary Thoughts ...........................................................................................349