TORQUE MANAGEMENT

SYSTEM

Prepared by : Rashpal Singh (TCF-Scorpio)

CONTENT

TORQUE/CLAMPING FORCE
TYPES OF JOINTS
TORQUEING STRATEGY
SELECTION OF TOOLS
PERFORMANCE OF TOOLS
MONITORING & CONTROLLING OF TORQUE OF
JOINTS
HOW WAS THE PROCESS DURING FORD ESCORT ?
REASONS FOR INEFFECTIVE JOINTS
WHAT SHOULD BE STRATEGY FOR START UP?
PROBLEMS IN SCORPIO-TCF

Torque v/s Force

Torque is indirect way of measuring the clamping force. You
cant be sure that the clamping force is always accurate simply by
keeping a check on the torque.
Total torque needed to install fastener equal to :
Pitch torque + thread torque + bearing friction torque
Friction is necessary to keep assy from unscrewing, shock loads,
vibrations can relieve clamp load momentarily, may relieve friction
too & allowing the fastener to unscrew.
Same torque may result into different clamping force , depending on
the variations on friction.

TYPE OF JOINTS
depending upon torque rate
HARD JOINT: Tool must get rid of kinetic energy very
quickly. The torque coming from K.E.of the rotating parts must
be added to the stall torque
SOFT JOINT : Hose clamps, a joint with long screw is also
regarded as a soft joint due to torsion effect. Washer & gasket
make joint softer
TORQUEING STRATEGY

TORQUE CONTROL

TORQUE TIGHTENING WITH ANGLE CONTROL

ANGLE TIGHTENING WITH TORQUE CONTROL
YIELD POINT STRATEGY

Selection of power tools

Criteria

Impact tools

Hydropulse

Stall type

Clutch shut off

Initial Cost

Low

Mod

Mod

High

Quality

Low

Mod

Mod

High

Productivity

High

High

Low

Low

Ergonomic

Noisy, no
reaction
Low

Less noise, no
/
reaction
Mod

Cont.Reaction

Reaction for a
moment
High

Complexity.

Operator
dependenc
y
Life cycle
cost--

Yes
Low

Yes/
No
Mod

High

No

No

Low

Low

Hydropulse v/s Angle nut runners

Angle tools with mech. Clutch shut off have high torque
accuracy and independent of joint rigidity. Scatter is
achieved 2% in case of Atlas copco screw drivers
and about 10-15 % in most of the cases.
Ideal for confined spaces and awkward positions.
Power tool variation due to :
1) Lubrication.
2) Pressure setting/regulator
3) Setting in case of DC tool

Power Tool Variation

Lub.
Pressure setting/regulator
Setting in case of DC tool

TORQUE MONITORING
Before making joint
During making of joint (Dynamic measurement i.e. output
of tool )
After the joint (Residual measurement)
Minimum torque measurement-attribute data using click
wrench

FORD ESCORT TORQUE

MONITORING PROCESS
A) Specified dynamic torque is installed with preset tools (on static transducer) on
joints.
B) Where required preset breakback tools are used. Some for torqueing and
some for confirmation purpose.
C)Torque is monitored by using inline transducer while making a joint (on the job)
This is a dynamic torque installed on the joints. If reqd. tool is reset on the joint.
This is because tool behave differently on different joints. 3 readings of each
application is recorded every day for CC joints.
D)Residual torque is confirmed by QA. Value is given in process sheet.
E) Electronic tool used for critical joints without breakback as print out/ direct read
out is available.
F) Exceptional case : Steering assy had high relaxation. Hand torqueing was
recommended but we were using a Tool, set to higher specified limit.
G) 100% Torque control tools.

INEFFECTIVE JOINT WHY ?

Fastener
Top flange/ Bottom flange
Assembly process
Equpment
Joint design

CASUAL FACTORS OF NATURAL VARIATION

P.T. variation
Variation in the parts of assy
Interaction from sequential securing
Joint relaxation
Operator variation
Measuring equip. variation
Residual torque measurement variation
Torque inspector variation

How to reduce scatter on joint ?

Select lowest possible speed to reduce inertia of moving parts
Two speed tightening
Two speed tightening
Final torque in steps takes care of Deformation in material due to
torque, where number of bolts are tightened. It reduces relaxation
of joints

Torque monitoring : To monitor the operation,

dynamic measurement is taken. Goal is to drive dynamic torque
Cp and Cpk to 1.33 or better.
When periodic dynamic torque measurement is not possible,
residual limits are used to detect concerns, not to adjust the
process.

Sequential Securing
When more than one fastener is used :
Concave parts will INCREASE the torque of the first
fastener when the second is tightened.
Convex parts will DECREASE the torque of the first
fastener when the second is tightened
Use multiple nutrunner

Joint relaxation
Two types of relaxation : Temporary relaxation & component yielding
Temporary relaxation occurs when components are not quite flat or
contain high spots.
Torque applied increases very rapidly& matl.of the component
deforms at very slower rate.This can be corrected by using slower tool
or tightening by hand.
Component yielding : occurs when the clampload created by the
fastener exceeds the compressive strength of the parts in the joint. The
speed of the tool can momentarily create a torque (and clamp force)
above the yield point of the joint. The compressive forces in the joints
will cause a cold flowing of the material until the force (clamp load) is
equal to the material strength.
Approve a residual specification or redesign the joint.

Residual Torque measurement

Residual torque can be higher because of static friction
spike.(Higher torque than true torque, but most often a
lower torque than the tightened torque)
Hard joint needs little rotation to increase the torque
significantly
Risk of the operator reading off the instrument from the
wrong angle.

Operator Variation
Premature release of the trigger
Double clicking
socket slip off

Variation in parts
Residual torque variation is caused by :
Underhead contact area because a large hole is used for
adjustment
Parts not parallel & galling occurs under the fastener
Surfaces not consistent, so varying degree of galling
Stick and slip--finish problem

HOW TO GO ABOUT SETTING TORQUE

MANAGEMENT SYSTEM ?
1) If torque values are given by designer, these are Dynamic
torque. Residual (audit) limits are not generally given by our
designers.
2) Do TPPS to set residual limits.
3) Torque surveillance : 1) Dynamic torque measurement by
inline transducers. SPC can be done to control & monitor.
Reaction plan-100% hand check if reqd.-residual torque
audit for calibration check.
4) Residual torque surveillance--no spc required--reaction
plan--find out what is changed?

How to determine capability of

process ?

Assure the following

Correct tool size
Installation
Lubricator
Tool set to mean of specs
Correct parts are used
Record DYNAMIC torque value & corresponding RESIDUAL values
Calculate Pp & Ppk.
Compare 6 sigma range of the data to the engineering specs range. Pp will be
1 if two ranges are the same. To obtain Pp 1.33, the engineering specs range
must be at least 8 sigma.
The residual measurement will determine the RESIDUAL(Audit) torque
limits that must be used for inspection. (Mean & range determined by the
process potential study)

How to improve the capability of a

process ?
Residual torque measures the results of the fastening
process. If the power tool & the operator are in control &
stable :
Acknowledge that there is a difference, accept the results
of a study & use for inspection
Result not acceptable. A change in design of the
components are required.

If immediate TPPS is not possible :

Take 50 residual samples. If no reading are found out of
spec.,begin regular torque surveillance.
If reading fall below lower spec, instruct production to
begin 100 % hand check with a click wrench. Investigate
& correct before going for regular torque surveillance.

A suitable torque for the joint ?

On many occasions, sufficient info about the load in question is not available. .For
this reason, it is customary for the designer to dimension on the basis of experience
and to specify the torques in accordance with the recommendations issued by the
screw manufacturer.
1. Degrease a few new screws with white spirit. Then tighten the screw to the specified
torque less 10%
2. Expose the product to a service life test at maximum load, vibrations and jolts.
Note any play in joints. Adjust the torque specs & repeat the test with new screws.
3. Check the margin to screw failure by tightening screws lubricated with low friction
grease.Start up by tightening to the maximum specified torque plus 10%.
Note if the tightening angle is excessive,i.e. screw starts to give. To complete the
check, increase the torque until the screw fails or until the thread is stripped off.
4. Insert the specs on the drawing.

Economics
Interruption in prod.
Rejects
Physical exhaustion

Labour cost

Maint. cost
Tool investment

Interruption inprod.
Rejects
Physical exhaustion
Labour cost

Maintenance cost
Tool investment

SCORPIO START UP
1) Started with identifying right tool for each application in EP shed
involving process, production, desgner, maintenance engineer & atlas
copco.
2) Selection criteria decided :Go for Clutch type tools wherever possible,
and Pulse tools for high torque. Battery tools for interior trims.
3) Wherever troque valuse were not given by designer, we considered
fastener specs with designers approval
4) Revision of specs depending upon the field failure & actual
observation while tightening.
5) Fine tuning the specs to use one tool at various application with
designers approval.
6) Electrical tool with tray to replace number of air tools
7) 100% Tool initial capability check in PE crib on standard joint.

SCORPIO TCF ISSUES ON

TORQUE
Accessability issue & no standard tool available in the market.
Operators used certain types of tools, which are the second best. Now
they are reluctant to adapt to little heavier tools, which is the best one for
that application.
Operator forgets to tighten one of the joints if he has to tigten number of
joints.
Cant go beyond 12nm for single hand tigtening (pistol tool) for clutch
shut off tool. Pulse tool dont give same result on different joint.
Torque integrity is 98% ie Tools within control limits.

YIELD CONTROL
A fastener in yield can be of smaller diameter than one set
below its yield.
Consistent torque depends upon bolts matl.
No safety factor for a shock load which tends to stretch the
fastener further & doesnt return back even if load is
removed.
Designer must make sure that service load will never
exceed clamp load
Precision bolts required

FASTENER SPECS
DYNAMIC DURING SECURING 1) Torque mean
2)Variance
RESIDUAL TORQUE :1)Upper & lower inspection limit
2) Min. torque acceptable(i.e. dynamic or residual
measurement must be above this value) This can also be
used for a GO-NOGO inspection system.

TOP /BOTTOM FLANGE

Flatness/Surface finish affect the contact area, friction
therefore the torque on the fastener
GASKET
Material, thickness affect the rate at which the gasket will
relax & release tension in the fastener
FASTENER FINISH
Small change in friction will cause large change in the torque
applied to the fastener, hence clamping force
AUDIT(Residual) TORQUE
Tightening direction, measured after turning 2-4 degrees
BREAKAWAY TORQUE
Peak torque at which the fastener (already tightened)starts to
rotate
DYNAMIC TORQUE
Torque during the securing process. Installation torque spec.
are given as dynamic torque value.

SNUG LEVEL
Point at which you start building up load.
RESIDUAL TORQUE
Measure of the torque on a secured fastener
STATIC TORQUE
Torque value which exist when a fastener is in a static state.
No method of measuring it.
TORQUE PROCESS POTENTIAL STUDY
TPPS determines the dynamic process potential & establishes
residual (audit) torque limits. Done on every fastener
operation.