test report experimental verification of fastening systems...

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Test Report

Experimental verification of fastening systems

Testing of HEICO-LOCK® HLS-30 Wedge Lock Washers according to DIN 65151/ DIN 25201-4

Test Report No.: A229/14

Order No.: 402214081

Issued by Department Metals

Laboratory for Mechanical and Technological Testing

Test Report

Testing of HEICO-LOCK ® HLS-30 Wedge Lock Washers according to DIN 65151/ DIN 25201-4 Test Report No.: A229/14

AQM/2 11 IMA Materialforschung und Anwendungstechnik GmbH, Wilhelmine-Reichard-Ring 4, 01109 Dresden of 10

Test Specimen: 1 Series HLS-30 Wedge Lock Washers Customer: Heico Befestigungstechnik GmbH

Herr Tobias Hübing Ensestraße 1-9 59469 Ense Deutschland

Order no. of the Customer: N/A (Purchase Order 01 Aug 2014) Test Specimen received on: 31 Jul 2014 Test Period: 06 Aug 2014 – 02 Sep 2014 In Charge: Dipl.-Ing. (FH) Lars Stolle Distribution List: 1 x Heico Befestigungstechnik GmbH

2 x IMA GmbH Dresden Authorized Dresden, 15 Oct 2014 IMA Materialforschung und Anwendungstechnik GmbH Signed Roth Dr.-Ing. Marcel Roth Department Metals This test report A229/14 is the English version of the report A229/14 from 03 Sep 2014. The test results refer exclusively to the specimen under test. The publication of parts of this test report and any reference to tests for advertising purposes is subject to written permission by IMA Materialforschung und Anwendungstechnik GmbH in any case. Opinions and interpretations are not part of the accreditation. The results contained in this report may only be published or passed on to third parties with reference to the IMA Materialforschung und Anwendungstechnik GmbH.

Test Report



Table of content

1 Task ........................................................................................................................................... 4

2 Specimen ................................................................................................................................... 4

3 Test set-up ................................................................................................................................. 5

3.1 Pre Tests ............................................................................................................................ 6

3.2 Vibration Tests (Verification) ............................................................................................... 6

4 Results ....................................................................................................................................... 7

4.1 Pre Tests ............................................................................................................................ 7

4.2 Vibration Tests .................................................................................................................... 8

5 Conclusion ................................................................................................................................. 9

Annex 1 Test Records Annex 2 Images of Test Objects

Test Report



1 Task

Objective target is to verify the loosening resistance of HEICO-LOCK® HLS-30 wedge lock washers under transverse loading conditions - vibration test. The task is the execution of Junker vibration test on one series in accordance with the requirements of DIN 65151 and DIN 25201-4.

2 Specimen

The required bolts (acc. to DIN EN ISO 4017) and the wedge lock washers (HEICO-LOCK® HLS-30) were provided by the customer. The nuts (acc. to DIN EN ISO 4032) and the shims (acc. to DIN EN ISO 7093-1, 200 HV) were provided by the contractor. Figure 2-1 shows the test objects required for the tests.

Bolt RFL 8.8

Nut LE 8

HEICO-LOCK® HLS-30 Wedge Lock Washers

Figure 2-1 Test Objects

Test Report



3 Test set-up

The test rig (Figure 3-1) is built according to the requirements of DIN 65151 “Dynamic testing of the locking characteristics of fasteners under transverse loading conditions (vibration test)”. The bolt, the wedge lock washer element and the shim were inserted together in the transverse upper part of the test rig. The nut was located in the stiff part of the test rig. The surfaces of the test objects were lubed with SAE 30. The test objects were inserted and tensioned until the required clamp load. The measurement of the tightening torque was done with an electronic torque sensor (IMA Ident.-No.: A2M1018). During the test, the clamp load, the tightening torque, the amplitudes of actuator (default amplitude) and the upper part of the test rig (effective amplitude) was measured. The test parameters (set according to the requirements of DIN 25201-4) are shown in Table 3-1 and in the test record of Annex 1.

Table 3-1 Test Parameter

Parameter Pre Tests (EV) Vibration Tests (NV)

Specimen ID A229/14 EV 08-10 A229/14 NV 01-12

Thread Size M30 M30

Required Number of Specimen (acc. DIN 25201-4)

minimum 3 valid 12

Locking Element without HEICO-LOCK® HLS-30

wedge lock washers

Figure 3-1 Test Rig

Test Report



Property Class Bolt/ Nut

8.8/ 8 8.8/ 8

Shims (acc. to DIN EN ISO 7093-1)

Shim 200 HV Shim 200 HV

Clamp Length Ratio (Clamp Length [mm])

1.7 (51)

1.7 (51)

Clamp Load [kN] (acc. to DIN 25201-4/ VDI 2230)

146 146

Amplitude 1.0 x ∆u 1.0 x ∆u

Lubrication Oil (SAE 30) Oil (SAE 30)

Surface/ Coating Bolt Nut Locking Element

blank (RFL 8.8)*

blank (LE 8)* zinc coated (HEICO-LOCK® HLS-30)*

Test Frequency [Hz] 12.5 12.5

*detailed information not available

The used types of bolts are shoulder studs M30 x 100 mm.

3.1 Pre Tests Pre testing is required to determine to effective transverse amplitude of unsecured bolted joints without securing system as a reference for the verification – vibration tests. According to the test standard, unsecured bolted joints have to become lose after 300 ± 100 cycles. Pre testing is successful after three valid runs.

3.2 Vibration Tests (Verification) In the verification tests an amount of twelve valid runs of secured bolted joints, including bolt, locking element, washer and nut have to be done. Each test requires new parts. The vibration test is accomplished up to the complete loss of clamp load, up to a number of 2000 cycles or up to the fatigue failure of the bolted joint. A sufficient securing effect is given when the residual clamp load after 2000 cycles is more than 80 % of the clamp load prior to the test and the curve does not indicate a complete loss of the clamp load.

Test Report



4 Results

4.1 Pre Tests The test records are stated in Annex 1. A fully loosening of the bolted joints was reached at a default amplitude of sV = 0.80 mm and verified three times (A229/14 EV 08-10). The values are specified as averages of the three tests.

Table 4-1 Results of the Pre Tests

Pre Tests unsecured

Specimen ID A229/14 EV 08-10

Clamp Load ‚Start‘ FV,Start [kN]/ [%]

146

Tightening Torque MA [Nm] (at FV,Start)

815

Friction Coefficient µ 0.15

Clamp Load ‚Rest‘ FV,Rest [kN]/ [%FV,Start] after 300 ± 100 Cycles

0

Result Default Amplitude s v,leer = 0.80 mm

Test Report



4.2 Vibration Tests The test records are stated in Annex 1. Table 4-2 summarizes the results of the 12 vibration tests (values are averages of the 12 tests).

Table 4-2 Results of the Vibration Tests

Vibration Tests Secured with HEICO-LOCK ® HLS-30

Specimen ID A229/14 NV 01-12

Clamp Load ‚Start‘ FV,Start [kN]/ [%]

146

Tightening Torque MA [Nm] (at FV,Start)

1010

Default Amplitude sv,leer [mm]

0.80

Effective Amplitude sv,eff [mm]

0.50

Clamp Load ‚Rest‘ FV,Rest [kN]/ [%FV,Start] after 2000 Cycles

122

Friction Coefficient µ 0.17

Result No Loosening of Bolted Joints

Securing Effect 84 %

Test Report



5 Conclusion

The securing system HEICO-LOCK® HLS-30 Wedge Lock Washers was tested according to the requirements of the standards DIN 65151 and DIN 25201-4 and provides fully resistance to loosening under vibration loads (Figure 5-1).

Figure 5-1 Clamp Load after 2000 Cycles

Test Report



In Pre Testing (A229/14 EV 08-10) there was observed a fully loss of clamp load. The loosening of the bolted joints was effected by the relative movements between the test objects. The defined clamp load of 146 kN was reached at a tightening torque average of 815 Nm. The friction coefficient were determined between µ = 0.14 and µ = 0.15. In the Vibration Tests there was recorded a loss of about 5 – 10 % within the first 50 cycles, caused by relaxation processes of test rig parts and the bolted joint. Within 2000 cycles of testing there was determined a further loss of clamp load until a max. of 20 %. A fully loss of the clamp load can be excepted (Annex 1 – Vibration Tests A229/14 NV 01-12) because of the flat gradient of the clamp load-cycle curves. There can be found no irregularities on the test objects after testing. Fretting can be excepted. Significant marks on the surfaces of the shims and the bolt heads were found after testing caused by the ribbed profile of the wedge lock washers. There can be found no marks of friction due to rotation of the test objects. The average of the tightening torques of the secured bolted joints was 20 % above the unsecured bolted joints. The average of the friction coefficients was determined to µ = 0.17. Furthermore the lower effective transverse displacement indicates higher friction. Reviewed Signed Roth

Created Signed Stolle

---------------------------------------------------------------------------------- ----------------------------------------------------------------------------

Dr.-Ing. Marcel Roth

Head of Department Metals

Dipl.-Ing. (FH) Lars Stolle

Department Metals Materials Testing

Annex 1 Test Records


Page 1 of 6

Pre Tests A229/14 EV 08-10



Page 2 of 6



Page 3 of 6

Vibration Tests A229/14 NV 01-06



Page 4 of 6



Page 5 of 6

Vibration Tests A229/14 NV 07-12



Page 6 of 6

Annex 2 Images of Test Objects

Testing of HEICO-LOCK ® HLS-30 Wedge Lock Washers according DIN 65151/ DIN 25201-4 Test Report No.: A229/14

Page 1 of 5

Pre Tests A229/14 EV 08-10 Test No. 1: A229/14 EV-08

Test No. 2: A229/14 EV-09

Test No. 3: A229/14 EV-10



Page 2 of 5

Vibration Tests A229/14 NV 01-12 Test No. 1: A229/14 NV-01

Test No. 2: A229/14 NV-02

Test No. 3: A229/14 NV-03



Page 3 of 5

Test No. 4: A229/14 NV-04

Test No. 5: A229/14 NV-05

Test No. 6: A229/14 NV-06



Page 4 of 5

Test No. 7: A229/14 NV-07

Test No. 8: A229/14 NV-08

Test No. 9: A229/14 NV-09



Page 5 of 5

Test No. 10: A229/14 NV-10

Test No. 11: A229/14 NV-11

Test No. 12: A229/14 NV-12

test report experimental verification of fastening systems...

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