DLA MIL-DTL-87218 E-2012 CABLE LOCKCLAD FOR AIRCRAFT CONTROL.pdf

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1、Comments, suggestions, or questions on this document should be addressed to Defense Logistics Agency Aviation, DLA Aviation-VEB, 8000 Jefferson Davis Highway, Richmond, VA 23297-5616 or e-mailed to STDZNMGTdla.mil. Since contact information can change, you may want to verify the currency of this add

2、ress information using the ASSIST database at https:/assist.dla.mil. . AMSC N/A FSC 1640 INCH-POUND MIL-DTL-87218E 27September 2012 SUPERSEDING MIL-DTL-87218D w/Amendment 2 27 March 2007 DETAIL SPECIFICATION CABLE, LOCKCLAD, FOR AIRCRAFT CONTROL This specification is approved for use by all Departme

3、nts and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers the requirements for lockclad control cable material used in aircraft flight controls and aircraft control cable assemblies that include lockclad as a portion of the assembly. Lockclad is defined as the resu

4、lting material of swaging aluminum alloy tubing onto MIL-DTL-83420, type I, nonjacketed wire rope to the extent necessary to comply with the elongation and coefficient of thermal expansion properties specified herein. 1.2 Classification. The lockclad will be of the following types and classes, as sp

5、ecified (see 6.2). 1.2.1 Types. The types of lockclad are as follows: Type I - Lockclad manufactured with MIL-DTL-83420, type I, composition A carbon steel, zinc or tin over zinc coated wire rope. Type II - Lockclad manufactured with MIL-DTL-83420, type I, composition B corrosion resistant steel wir

6、e rope. 1.2.2 Classes. The classes of lockclad have been assigned for various base cable sizes and construction and aluminum cladding outside diameter for ease of reference. These classes are identified in table I. Provided by IHSNot for ResaleNo reproduction or networking permitted without license

7、from IHS-,-,-MIL-DTL-87218E 2 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examp

8、les. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of the documents cited in sections 3 and 4 of this specification, whether or not they are listed. 2.2 Government documents. 2.2.1 Specifications

9、and handbooks. The following specifications and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-DTL-781 - Terminal, Wire Rope Swa

10、ging, General Specification for. MIL-DTL-5688 - Wire Rope Assemblies; Aircraft, Proof Testing and Prestretching of. MIL-DTL-6117 - Wire Rope Assemblies, Aviation, Swaged Type. MS20667 - Terminal, Wire Rope, Swaging, Fork End. MS20668 - Terminal, Wire Rope, Swaging, Eye End. MIL-DTL-83420 - Wire Rope

11、, Flexible, for Aircraft Control, General Specification for. DEPARTMENT OF DEFENSE HANDBOOK MIL-HDBK-1599 - Bearings, Control System Components, and Associated Hardware Used in the Design and Construction of Aerospace Mechanical Systems and Subsystems. (Copies of these documents are available online

12、 at https:/assist.dla.mil/ or from the Standardization Documents Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.2.2 Other government documents. The following other government documents form a part of this document to the extent specified herein. Unless otherwise specifi

13、ed, the issues of these documents are those cited in the solicitation or contract. STANDARDIZATION DOCUMENTS SD-6 - Provisions Governing Qualification. (Copies of this document are available online at https:/assist.dla.mil/ or from the Standardization Documents Order Desk, 700 Robbins Avenue, Buildi

14、ng 4D, Philadelphia, PA 19111-5094.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-87218E 3 2.3 Non-government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, th

15、e issues of these documents are those cited in the solicitation or contract. SAE INTERNATIONAL SAE AMS-WW-T-700/6 - Tube, Aluminum Alloy, Drawn, Seamless, 6061. (Copies of this document are available from http:/www.sae.org/ or from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001

16、.) 2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a

17、 specific exemption has been obtained. 3. REQUIREMENTS 3.1 Qualification. Lockclad (see 6.4.6) material furnished under this specification shall be products that are authorized by the qualifying activity for listing on the applicable qualified products list before contract award (see 4.2.3 and 6.3).

18、 The qualifying activity will be advised of any plant relocation, changes in key personnel, or major process change(s) (e.g. changes in lubricant and/or jacketing material, changes in the lubricant application process, etc.) for requalification testing determinations. 3.2 Materials. 3.2.1 Base wire

19、rope. The base wire rope shall be in accordance with MIL-DTL-83420. 3.2.2 Aluminum cladding. The aluminum cladding of lockclad shall be 6061-T4 or 6061-T6 extruded aluminum alloy tubing, conforming to SAE AMS-WW-T-700/6, of uniform quality and thickness, clean, smooth, and free of defects or foreign

20、 materials. The original tubing size and wall thickness shall be selected by the lockclad manufacturer as required to manufacture lockclad that will meet the requirements set forth herein. 3.2.3 Lubricants. Lubricants required in wire rope shall not be removed prior, during, or after swaging (see 6.

21、4.10) operations. Lubricants added to the interior of the tubing prior to swaging shall be chemically compatible with lubricant in the base cable. Lubricants applied to the exterior of the aluminum or to the swaging tooling prior to swaging shall be removed after swaging and prior to shipment of loc

22、kclad control cable assemblies. 3.2.4 Terminals. Terminals shall conform to the requirements specified in 4.2.2 or as specified in the contract (see 6.2). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-87218E 4 3.3 Design and construction. 3

23、.3.1 Design. MIL-HDBK-1599, Requirement 206 should be used as guidance for the application and installation of the lockclad cable. 3.3.2 Construction. 3.3.2.1 Base wire rope construction. Construction of base wire rope shall be in accordance with MIL-DTL-83420. 3.3.2.2 Lockclad diameter. The aluminu

24、m tubing shall be uniformly cold worked (swaged) over the base wire rope to the dimension specified in table I and sufficiently to meet the performance requirements herein. Tolerance of the outside diameter of the lockclad after swaging shall be as specified in table I. 3.3.2.3 Lockclad concentricit

25、y. The cladding after swaging shall be concentric around the base wire rope such that the thickness of the clad material does not vary more than 10 percent around the circumference of the base wire rope. 3.3.2.4 Cladding placement. The length, location, and length tolerances of cladding on a base wi

26、re rope length shall be as specified on the lockclad control cable assembly drawing or MS sheet. Sections of lockclad which are not separated on the control cable assembly drawing or MS sheet shall be one continuous section of aluminum tubing as opposed to two or more sections. Relative to lockclad

27、control cable assemblies which include sections of bare base wire rope (see 6.4.1), the after swage lengths of cladding must be determined prior to swaging. Once cladding has been swaged, it shall not be stripped from base wire rope under any circumstances or in any amount. 3.3.2.5 Lockclad straight

28、ness. The lockclad assembly shall be straight within 0.062 inch for each 5 feet of length when the lockclad assembly is loaded to 10 percent minimum breaking strength (MBS) (see 6.4.7) of the base cable. The MBS shall be in accordance with MIL-DTL-83420. 3.3.2.6 Terminal Swaging. When cable assembli

29、es require installation of terminals conforming to MIL-DTL-781, swaging of the terminals shall be accordance with MIL-DTL-6117. 3.4 Performance. 3.4.1 Breaking strength. The cladding of lockclad shall not be considered to be additive to the MBS of the base wire rope (see 6.4.2) whether terminals are

30、 swaged to the base wire rope or directly to the cladding. The MBS for the base wire rope is specified in MIL-DTL-83420. Lockclad assemblies shall be tested for ultimate tensile strength per MIL-DTL-6117. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,

31、-,-MIL-DTL-87218E 5 3.4.2 Elongation. The clad portion of all lockclad material and control cable assemblies furnished in accordance with this specification shall be in accordance with the elongation and SV values (see 6.4.9) specified in table II. 3.4.3 Coefficient of thermal expansion (see 6.4.3).

32、 The clad portion of all lockclad material furnished in accordance with this specification shall be in accordance with the values specified in table II. 3.4.4 Endurance. The bare base wire rope portions of lockclad cable assembles shall meet the endurance requirements of MIL-DTL-83420. The clad port

33、ions of lockclad assemblies are not subject to flexing or bending by application and are not subject to endurance requirements. 3.4.5 Proof loading. All lockclad control cable assemblies shall be proof loaded in accordance with MIL-DTL-5688. 3.4.6 Temperature limits. The base wire rope and the cladd

34、ing after assembly into lockclad shall meet the temperature requirements specified in MIL-DTL-83420 for the wire rope. The cladding or swaging of the cladding shall maintain properties specified herein in a temperature environment of -65 F to 200 F. 3.4.7 Weight. The finished lockclad material shall

35、 not exceed the maximum weight specified in table I. 3.5 Identification. 3.5.1 Lockclad assemblies. As a minimum and unless otherwise specified by the procuring agency, the following information shall be marked with permanent ink, chemical etching, electro-etching or laser marking on the outside dia

36、meter of the cladding in an axial direction of all lockclad assemblies starting not less than one inch nor more than six inches from one end of the cladding or one section of cladding nearest a terminal: a. The complete part or assembly number of the lockclad assembly as specified on the assembly dr

37、awing or specification. b. The lockclad manufacturers name, trademark, or Commercial and Government Entity Codes (CAGEs). If the latter is used, the five digit code must be preceded by the letters “CAGE“. More than one method may be used. 3.6 Workmanship. All details of workmanship and finish shall

38、be in accordance with the best practice of aircraft quality. Unclad lengths of wire rope of lockclad assemblies shall meet the workmanship requirements of MIL-DTL-83420 before and after swaging of the cladding material and terminals. In addition, the cladding and assemblies shall conform to paragrap

39、hs 3.6.1 and 3.6.2. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-87218E 6 3.6.1 Cladding after swaging. There shall be no kinks, bends, or abrupt changes in direction of the cladding. There shall be no scratches, die marks, flat spots, or

40、discontinuities in the finished cladding when inspected with the unaided human eye. 3.6.2 Lockclad control cable assemblies. At all transition points (see 6.4.11) of cladding and bare base wire rope there shall be no kinks, abrupt changes in direction, broken wires, or other evidence of damage to th

41、e base wire rope. 4. VERIFICATION 4.1 Classification of inspection. The inspection and testing of the base wire rope shall conform to the requirements of MIL-DTL-83420. The inspection and testing of the cladding and assemblies of lockclad shall be classified as follows: a. Qualification inspection (

42、see 4.2). b. Conformance inspection (see 4.3). c. Retention of qualification (see 4.2.4) 4.2 Qualification inspection. 4.2.1 Qualification test sample. The number of samples shall be as specified in table III. 4.2.2 Specimen for breaking strength test for swaging of cladding. Three assemblies of eac

43、h type and class of lockclad for which qualification is desired (types and classes per table I) shall be manufactured in the following configuration using equipment and procedures which will be or are being used for production lots: a. Length of cladding: 4 to 10 feet. b. Overall length of assembly:

44、 1 to 2 feet longer than cladding. Cladding shall be approximately centered over the overall length of the assembly. c. Terminals: Swage one MS20667 or MS20668 terminal on each end of the lockclad assembly. d. Proof loading: Proof load each of the three assemblies as specified in MIL-DTL-5688. 4.2.3

45、 Qualification testing. The qualification tests shall include all of the examinations and tests designated in table IV. 4.2.4 Retention of qualification. The manufacturer, at regular intervals, must be able to demonstrate that the company still has the capabilities and facilities necessary to produc

46、e the QPL items in accordance with this specification and in accordance with the provisions governing qualification specified in SD-6. This will include the performance of the following tests: Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-8

47、7218E 7 4.2.4.1 Five year testing. Every 5 years, the manufacturer shall perform the following tests: a. Examination of product (see 4.4.1) b. Elongation (see 4.4.3) c. Concentricity (see 4.4.8) 4.2.4.2 At changes in processes or cladding material. Following any major change in tooling, processing p

48、rocedure or cladding material, the manufacturer shall perform the following tests: a. Examination of product (4.4.1) b. Elongation (see 4.4.3) c. Thermal expansion (see 4.4.4) d. Concentricity (see 4.4.8) 4.2.5 Rejection and retest. The failure of any specimen during qualification testing shall be c

49、ause for complete requalification of the type and class of lockclad experiencing failures. 4.3 Conformance inspection. Conformance inspection shall consist of individual tests (4.3.1) and sampling plan (4.3.2). 4.3.1 Individual test. Individual test shall consist of the following: a. Examination of product (4.4.1). 4.3.2 Sampling plan. The sampling plan shall consist of the following: a. Breaking stre