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### R rodeS 1 il" ~ 

# ,_.:,. .~ . SEx1AL
OR7612YAL JSSI%E DATE 

### .:'./30/04 PSC,1: 

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## " BF ~ S\O

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~ EERING CO. C WicfirrA r.%us.Te\.-ks REPORT n # 

### 204 11JiG,iO ~

, Moueis: r'.T-802, :T-842"-
P. EVIS?C\ 's.^vG: Rev "n" - 3/24/0; - Rewritten to add cold worl: steps and rearn using C1tC achinery. Rev ^B" - 4/22/04 -:,ddec! a?ter:ate reatrer part nu..,oers, revised order o: cold work/-ine rea:r. to .-: rove hole finis!:. F:ev "C" - I1/16/04 - R^_vised section 1.4 to add locatir,g pi n. 

### PRODUCTION SPAR CAP MACHINING PROCEDURES - LINE REAMING AND COLD WORKING 

### REFERENCE: (1) - Fatigue Technology Inc. Process Specification 8101D (2) - Snow Engineering Co. Drawing 20975 SH 2"Wing Installation AT-802" (3) - Snow Engineering Co. Drawing 21082 "Blocks - Wing Attach - 802" (4) - Snow Engineering Co. Drawing 21083 "Machining - Lwr Spar Cap- 802" (5) - Snow Engineering Co. Drawing SK544 "Line Ream Tooling - PS204" DEFINITICNS:

a. Line Ream - The simultaneous reaming of an alignment of holes in multiple layers of material that results in near perfect alignment of the holes. b. Cold Work - In the case of this Process Specification, the process of forcing an oversize mandrel through a hole at room temperature that permanently expands the diameter of the hole, creating a zone of residual compressive stresses around the hole. c. Stackup - Multiple layers of material that are considered as a single unit. In the case of this Process Specification, the spar cap, and top and bottom splice blocks together are considered a"stackup". d. STDN - Standard Tool Diameter Number - The numbering system used to identify specific size tooling, including reamers, mandrels, and sleeves used in this Process Specification. e. Starting hole - A properly drilled and reamed hole just prior to the cold work operation. f. Gage finish reamer - A reamer that includes a non-cutting, nondetachable pilot, sized such that it will not enter a hole with a diameter less than the reauired Dost-cold worked diameter. Gc.NERAL : 

### This Process Speci=ication prOvides a set o: detailed i:

- lstructions for lir•e reaTing and coid WorKing tti'te winC 1Gwer spar sp=ice j01;1t Gn c1:r_=nft =odu`=2:P. ai_c=d*t. _.__S proceSs inciudes ii?1e 3'e:s:'iing o: the riinC _ ;oWer s^er caUS Cnd 5J1iCe b1oC7! hCles and Cold w;,.rk_nC ti?e two OutCOa=d ...^St hC! eS LS'_:1^ t.^•e sDl-t s_eeve cOld e::vansi c.^_ crocess. 'C= c.:ar'_=1Ca}=Jn, _^° S_''__.;e b10c'k ....^.! t .^_Q_ I - _ • sS cr8 :?i:..r:w^? ~ ?"'

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## ENGINEERI'VG REPORT ORDER # 204 

# R C- I
11/16/04 MODEL

= .^ e ''

~ -+ e?o w T'1_LX p~ 

### ocess Soeo_`;cezior: H.1 - f3tS'D

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061GPN.U. LSSi.°E DATE 

### ?/30/0 4 PAGE OF 

### 2 ?' :ioaels: 1

-

-.T-802, AT-802:: 

# _--- D gCO

Figure 1- Block Hole Numbering Scheme The lower wing spar cap and splice block holes will arrive at the wir+.g spar department machined 3/64" undersize final fastener diameter to allow the holes to be reamed or cold worked (as appropriate) to final diameter prior to spar assembly. The tooling used in this process consists of an alignment fixture clamped onto a vertical (CNC) mill table. The fixture holds the spar caps and splice blocks in near perfect alignment and allows precision reaming of the bolt holes in the cap/block stackup. The tooling is designed to allow all machiriing steps to be accomplished after a single set-up operation. The lower cap wing splice holes (#2 through #6) are line reamed only. These holes are first reamed to 1/64" undersize, and are then reamed a second time to final diameter. This 2-step ream process provides for excellent hole finish quality. The two outboard-most holes (#7 and #8 holes) in the lower cap wing splice will be line reamed to a"starting hole" size, cold worked using the Fatigue Technology, Inc. split sleeve cold expansion process, and then line reamed a second time to final hole size (nominal bolt size).


### PERSONNEL QUALIFICATION: Line reaming of the wing spar caps/splice block stackup and split sleeve cold expansion of bolt holes are both precision manufacturing tasks. The steps in this Process Specification shall only be performed by personnel who have attended an Air Tractor sponsored training course and 'nave r®ceived a certificate of completion for the Split Sleeve Cold Expansion process. This requirement may also be ful=illed bv attending a Fatigue Technology Inc. training session and receiving a Ce--t;ficate of Train.ina a-fter 

### the ccmaletion of that training.

## ENGINEERIN G "?8-R REN, 

# c REPORT 1 # 204 11/ 16/04 O RD ER MOD=L 65' CJt S'D X C p c. ? e 

### 1 0`0I ~ SNOW E?vGI3'vEERING CO. WICH7TA F.U1S, TEX.IS



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✓ ec? f_cG:-_on OR7G1N{L ISiLE DA7E P.IGE OF ?/30/0 ~ 

# 1 .5 - '1=ode_s: k"'-E02, AT-302- 

### EQ:i I:M E N i
P/N IDESCRIPTION



### CASR-60-1 Startinc Reamer CAG-60 Combination Gace CP.MG-60 Mandrel Gaoe CAS-60-36F Flared Sleeve (2 ea. per aircraft) CA.M-60-2-60-V2 Mandrel MEN-26B-1201F Nosecap Assembl CP.R-60-1-.3750 Gage Finish Reamer Table 1- Cold Work 'I'oo1 Klt List -#8 Holes (STDN = 60)

P/N DESCRIPTION CASR-70-1 Starting Reamer CAG-70 Combination Gage CAMG-70 Mandrel Gage CAS-70-90F Flared Sleeve (2 ea. per aircraft) CAM-70-2-60-V2 Mandrel MEN-26B-1901F Nosecap Assembly CAR-70-1-.4375 Gage Finish Reamer Table 2- Cold Work '1'oo1 Kit List -#7 Holes (STDN = 70) P/N DESCRIPTION MB-30 Medium Brute Puller Unit FT-20 Power Pak

120 micron surface finish comparator plate or profilometer 38A M Mounted Stone Deburring Wheel Table 3- Cold Work Tool Kit List - General Tools AT-802 Reamer Size Selection Tabte Hole Ream Step Reamer Size / Part 

### Number Acceptable Alternate



### Reamer Size # No Ream - b:7344 

### 2"° Reaiii #3 ls` Ream 0.6094 -

2°tl Ream 0.6250 (5/8) -
#5 1'` Ream 0.4844 -

2'` Ream 0.5000 (112) - 

# ^ D Ream

~ 

### 2n d : Re

~ 

### m' ;`OSOOQ (112)

_ I ?7 Pre

- C:: Re an CASR-70-1 1 .4100 

### j Post-Cx :.ea- CAR-70-1-.4375 .4375

,r ; . - 

### e
- 

### ..o r.ea.,. CASR-60=I , _,.. .. ... . 

### _,._.. 3490

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~ .. CAR-60-1-3750 3750 -M..- ~ '-. - ...r-.. ~ ..- . ~ l - ..

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## ENGINEERING `TINisex REi" 

# ~

Sti'OW ENGINEERING CO. C wictirr.+ F.{Lts, TEa.as REPORT # 204 11; 16; 0-t 

### O RDE R MUDEL 73nf BS' CFi&'D i.• ~. P c~ ~=~ : tl 

## rrocess aDec-cG:.-on M_:ce i,noues Jf:
ORIGI:iAL LSC'E D.4TE PAGE OF 

### 1/ 30/04 4 1 

### xMove_s: U-232, r3-8C2r General Notes on Line Reaming and Cold Working Holes:
3. eill rea

~ il;lg Operations are to be aCCCTDIished tising a vertical

(CNL) mill machine. Water soluble cutting flu;d should be used for all rea:r,ing steps. 

### 2. Seiect reamers carefully to avoid misreaming holes. Reference

Tabie 4 for proper rearners used during the Line P,eam process.

~ 

### . The stackup shall be securely clamped to obtain faying surface

contact during line reaming, starting hole preparation, cold working, and final sixing. 4. A surface upset is created during the cold working process at

each hole face. This surface upset is normal. 5. Sleeves may be stacked to obtain suf_`icient length. Total sleeve

length shall be at least 1/32" greater than the material stackup. 6. Sleeves are meant to be used only cnce. Sleeves must be

discarded after use. 7. Urient sleeve so that the split is pointing along the spar cap

centerline facing inboard and the flared end is toward the puller nosecap. S. If axial slippage of the sleeve occurs in the hole during cold

working, such that the end of the sleeve opposite the puller enters the hole, it is required that the hole be re-cold worked.
PROCEDURE: 

### 1. Install lower splice block (21082-2), lower caps (21083-1 and -2) and upper splice block (21082-1) onto TSK544 tooling fixture. 1.1. Place lower splice block (21082-2) into toolirtg fixture. Align lower block #1 holes with bolt holes in fixture. Splice blocks are steel stamped on one end with a release nurnber (XXXX-X), and on the other end with a part number (21082-1-L for the upper, 21082-2-L for the lower). The blocks must be placed in the fixture with the part numbered end on the side marked "LEFT WING". 1.2. Carefully slide spar caps into fixture and align at #1 hole locations in lower block. Left spar caps (21083-1) must be placed on the side of the fixture marked "LEFT P7ING" and right spar cans (21083-2) must be placed on the side of the fixture marked "RIGHT WING". 

### 1.3. P'_ace upper splice block (21082-1) into fixtu=e. Align upper block rl holes with 4 .1 holes in spar cans. 1.4. C'_amp caps and blocks at the T, itole locati or.s usi ng a.'480- 

### .74.90 ^?a. hardened a.^.d Qround ^ollow locating pin runn_^.g _'rcr.; ts:e tob 1 ccatina block _rto the bottom =ixture ola_e. _:?sta__ a 3/8 ::olt tl:roLlc:1 the CeT?Ler o: L.'le p1:?, ai:d scre'rl _:iz.. n °.?z C^ th: ,^ott:L" o_ the _'ixtt:rE ( _or7ue to 1 - 5

- 25 f _- 

### _:.$) . --n a: the =$ ::•cles us

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## P=cc

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## ss `___,_on 

## ENGINEERING REPORT P 

## ORDER s, - cstx M' ka R3?OG'1°S `.t; dRIG1tiAL tSSt'E DATE 

### =/3C/04 `:C'NS1EF[ F:FV 

## C # 204 11/16/0-4

~ fUDEL
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### liold caps agaanst =ixture back t:sing "ack screils or pr:eumazic p'usners ir:sta;led on fi-xture. 

### 2. Perform first line ream steo on r2 t:,ru jn' holes: 2.1. Select reamers carefully to avo?d m'sreaming holes. Re±erence Table 4 for proper reamers. 2.2. Starting with the 42 holes on both left and right wings, ream both t2 holes in the lower cap using the 1 5C reamer size. 2.3. Use compressed air to remove all cutting £luid residue and metal shavings from the holes. 2.4. Repeat ream steps for holes 43 thru #6 one hole location at a time, moving outboard. Example, ream #3 lower cap holes next, then continue with 7 1 14 holes, etc. 3. Perform second line ream step (to final size) on #2 thru #6 holes: 3.1. Select reamers carefully to avoid misreaming holes. Reference Table 4 for proper reamers. 3.2. Starting with the #?_ holes on both left and right wings, ream botYi #2 holes in the lower cap using the 2 °d (final) reamer size. 3.3. Repeat ream steps for holes #3 thru #6 one hole location at a time, moving outboard. Exarnple, ream #3 lower cap holes next, ttien continue with #4 holes, etc. 

### 3.4. Use compressed air to remove all cutting fluid residue and metal shavings from the holes. 3.5. Inspect holes #2 through #6 to ensure diameters and hole sur£ace finishes meet the requirements of Table 5. Holes may be inspected using a ball gauge and micrometer, or air gauge with the proper calibrated hole standards. Measure hole finish using surface finish comparator plates or a pro£ilometer. AT-802 #2 Hole thru #6 Hole Finish Ins ection Criteria Tabie Finish Diameter Tolerance Minimum Hole Finish # 3 Hol e 0.6250 (5/8) +.002 /-.000 120 micron

.4.5625 +:OU2:l,

~ 

### OOQ:` ' 12d'micron #5 Hole 0.5000 (1/2) +.002 /-.000 μ 120 micron 12.O:rimicron::.< =- Tab1e 5. - inspection Critzr_a 4. Clamp stackup at r 6 holes using com.*r

~ erci al bolts (gri p length 2 7/8 

### =hes, shank diameter .4985-.4995) and corn.merc-:al grade vras'r:ers and 1/2" _ine tteaC _n.l:ts ;tcrCFle to .

~ ,0

- 4'J :t-;bs) . Remoi%e 117 :10!e cia;tlp

~ Clts. Per=orM, Dre

- COlQ work (pre-Cx) _aam cn t ne 'r 7 hol-es: J._. L.iI'i£: Keam 4 -7 i`1o_eS '_?i the _.^,i•I?r caD/biCci: S=aci:

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### ,•rEa.As REPORT t# 204 11/16!04 ORDER JODEL 17zs aa c
~ isn * cGCY

~ c L ~ JjM1 

### E;rocess Mi=:e r,'hcdes iu SEP.LIL aRrciNAL

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### .3. Check =7 s`art:ng zc;e diarQLe_. Starting nale diareter :ustbe .409 -.412. C`aeck the starting ::cle using the CAG-70 GoNO so CCmb1i'ia`io.n. Gage, or a ball cage aP. d m:..^. 

### rometer . l!il;en 1.2s'_ ng t:le Go

- i`lo Co Co>ilbinaLioP. Gage, a C.

~ aQe that can CP.Iy t:e 

### inserted to the first machined "step" identifies a properly reamed hole. The starting hole should be checked for ovality by inserting the gage a second time, rotated 90°. See Figure 3. 6. General set up instructions for Cold Work tooling: 6.1. Thread proper mandrel onto puller unit (hand tight only). 6.2. Thread nosecap onto puller unit (hand tight only). 6.3. Make up pneurnatic (2) and hydraulic (1) connections between puller unit and PowerPak. 6.4. Connect shop air to PowerPak. 6.5. Refer to FTI process manuals for detailed instructions on proper use and care of the Cold Work tooling. 7. Cold work the lower cap/block stack-up at the #7 hole locations:7.1. Select the CAM-70-2-60-V2 mandrel and inspect using the CAMG70 Go-No Go gage or a micrometer. The mandrel major diameter shall be .4005 -.4015. The mandrel shall be checked at the 

### beginning of each aircraft job because the mandrel diameter is critical for proper cold expansion of the hole. An excessively worn mandrel will pass through the CAMG-70 Go-No Go gage and shall be replaced. See Figure 4. 7.2. Cold Er.pand hole (See Figure 5) 7.2.1. Select the CAS-70-40F split sleeve and slide it

over the mandrel. Orient sleeve so that the split is pointing along the spar cap centerline facing inboard and the flared end is toward the Puller nosecap. 7.2.2. Insert the mandrel and sleeve into the starting

hole. Ensure sleeve orientation is correct. 7.2.3. Place nosecap firmly against and perpendicular to

the upper surface of the splice block. 7.2.4. Activate puller. Continue holding the trigger

until mandrel is through the entire lower spar cap/block stackup. Release trigger when the mandrel is clear of the structure. 7.2.5. Remove sleeve from the cold worked ho_e and

d=scard. Sleeves ere used only once. 7.3. Check t^e coid ex Da:IC1ed hoie 

### d_a:meter using the CAG-70 Go-No GC Co!ribinati on gage. "_'he gage wi:il into 

### a prope rly e}:GcP.d'

cd hole . i 47e co_d iJo?'ke, '". :1o:e sholl=d :!!eaS'.3=e . L? 70 as a m].n].ffiuII 

### be=ore the I=:liSh rec':?T.l DrocesS. Note th :t a G::'_'=aCe i:pset is c=e3=ed dL:ri.Tl y ^ tZe c

~ Dl 

### d c,ork'_ng prOces5 aL eac.i nGic =a

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## ENGINEERING r`LMDEA RF:L' SIVOW EtiGI\`EERI\'G CO. C a'iCFCrrAF,a,1s,TES.As REPORT # 204 11/16/04 ORDER M°DE'" TrrLG er j`e Belc::

C~ CCeSS cDc^C
~ `? C^t-oP. j ✓ ,:ke F~ hodes jF; =ERIAL ORiGf\ALISLI:E DdT'E PAGE OF 

### i/30/04 ; 11

, h?odels : F'"-202, A _-802A



### 8.1. Line Ream =8 holes in the lo°..er cap/block stack-up to starting .^.ole s_Ze i:l prepa=ation for colci working. Reaar, the #8 Hole 

### using the CASR-60-1 starting reamer (see Table 4 for reamer selection and acceptable alterr.ate reamers). See Figure 2. 8.2. Use comaressed air to Yemove all cutting fluid residue and meta'_ shavings `rom the holes. 8.3. Check #8 starting hole diameter. Starting hole diameter mustbe .348 -.351. Check the starting hole using the CAG-60 GoNo Go Combination Gaae, or a ball gage and micrometer. When using the Go-No Go Combination Gage, a gage that can only be inserted to the first machined "step" identifies a properly reamed hole. The starting hole should be checked for ovality by inserting the gage a second time, rotated 90 ° . See Figure 

### 3. 9. Cold work the lower cap/block stack-up at the #8 hole locations.9.1. Select the CAM-60-2-60-V2 mandrel and inspect using the CP3MG60 Go-No Go gage or a mir_rometer. The mandrel major diameter shall be .3428 -.3438. The mandrel shall be checked at the beginning of each aircraft job because the mandrel diameter is critical for proper cold expansion of the hole. An excessively worn mandrel will pass through the CAMG-60 Go-No Go gage and shall be replaced. See Figure 4. 9.2. Cold Expand hole (See Figure 5) 9.2.1. Select the CAS-60-36F split sleeve and slide it over

the mandrel. Orient sleeve so that the split is pointing along the spar cap centerline facing inboard and the flared end is toward the puller nosecap. 9.2.2. Insert the mandrel and sleeve into the starting hole.

Ensure sleeve orientation is correct. 9.2.3. Place nosecap firmly against and perpendicular to the

upper surface of the splice block. 9.2.4. Activate puller. Continue holding the trigger until

mandrel is through the entire lower spar cap/block stackup. Release trigger when the mandrel is clear of the structure. 9.2.5. Remove sleeve from the cold workzd hole and discard.

Sleeves are used only once. 9.3. Check the cold expanded hole diameter using the CAG-60 Go-No Go Combination gage. The gage will _*`iz into a prooerly expanded hoie. The cold worked hole shoulc measure .3530 as a minimwn be:ore the finish =eam process. Note that a surfacc 

### upset ls created ^uring the cold work_r.Q proc=ss at each hcle Zace. This Sur-aCe upset ?S norfial. Gee _?gli:v '' 6. Note: __ Cold wo=}:ed ,'3o1e ±a11S tPe 

### .._am=ter CheC}: li: th_S Step, th? ?:c:e c3P. be :olC.: wCrted c seC.:,P.d =i'^e, tLsii1C new cleavag. 

### Ger:er

- ___y, a`:cle that 't--s _::e post-co-c t•:er' .: dia:°;ete- c's._ck

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..SNOR% ENGINEERING CO. WICFi1TA f A:..LS, TFK.,s

PrLcCsC So?clTiI.a:.iGi

## ENGINEERING REPORT ~ 

## ORDER sr ais L< - :•c R`:Gd2s yr OR1GItiAL l.SSUE IIA1E 

### ? /30/04 RFV 

## C # 204 11/16/04 !.SODEL Ow

OF 

### '*;aae

- is: r?`:-802, AT-802A

, i °0 

### rigure 5

o 

# ~ 'o

0

~ ^ o

0

Combination Gage

I t\



# ~

~ 0 0 Go-No-Go Gage 

# oo

0 Gage Finish Reamer 

### Gage Finish Reamer

— 

# \ ~ or ( Hole has been cold expanded.

f\\;


### ~~ lll Or Hote has not been

!

~ -- ~ i 

### cold expanded.



### \~~;



## F=iaure 6

## ENGINEERI'vG \LMBf:R REV S:tiOA' ENGINEERING CO. C WlC}3tTA F.&LIS, 

### TF-x+s REPORT n # 204 Il j]G;'o4 

### ORDER 

## ~"~ MODEL 

### " S=_ ?e;ew P-rCc

- ess SpeC:'1Cwr'_C:? 

### I,ike =^cdes iH OP.IG1tiAL ISSL;H DA7E

1/30/v4 `Mocie.:s: A;-802, .._-002:



## ~ ~ ~Y • 0



## Finish Reamer
Figure 7c 0

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