Expendable Tooling - Split Sleeve

Split Sleeve Expendable Tooling

Sleeves

split-sleeve-expendableSleeves are used, along with a mandrel, to coldwork a hole. Made from full hard stainless steel with a baked, dry-film lubricant on the inside surface, they prevent the mandrel from sticking to the hole being coldworked and can only be used once.

 

Flared sleeves are used when only one sleeve is necessary to coldwork the holefor example, using a 16F sleeve to coldwork a Ā½" stackup. Straight sleeves are used when a deep stack is to be coldworked. As many as necessary are put onto the mandrel after the flared sleeve to build up the equivalent of one long sleeve. The maximum length of flared sleeves is three inches.

split-sleeve-expendable

  • Close tolerances result in consistent gap width
  • Class I sleeves are used for high-interference coldworking, CB, CR, and CA processes
  • Class II sleeves are for low-interference work commonly found on older aircraft (CW process)
  • Total sleeve length must be at least 1/32" longer than the total stackup thickness
  • Special order sizes are available

split-sleeve-expendable

CBS-18-0-N-16F CB Process, nominal 9/16" hole, 1" long, flared
CAS-A70-20S CA Process, nominal 7/16" hole, 11/4", straight
CRS-R30-16F CR Process, 3/16" final hole diameter, 1" long, flared
CWS-B1267-20F CW, low interference, 1/8" nominal bolt or open hole, 11/4" long, flared

Mandrels

The mandrel, fitted with a sleeve, is used to coldwork the hole. West Coast Industries mandrels are made from highest quality vacuum-melted tool steel which has been double tempered and precision ground. Their useful life is related to the type and yield strength of the material to be coldworked, the amount of interference between the mandrel and the hole, wear due to a coldworking of the mandrel itself, and a slight abrasiveness of the lubricant on the inside of the sleeve.

split-sleeve-expendable

  • Mandrels are manufactured to be interchangeable with other manufacturer's coldworking equipment
  • Available in both high interference (Class I) suitable for highly stressed areas, and low interference (Class II), used in moderately stressed conditions.
  • Available in a number of lengths, based upon the stackup to be pulled. In addition, they are available in lengths to be used with flush nosecaps as well as extension nosecaps. The length designation of the mandrel is the total stackup length of the material to be coldworked, plus if applicable, the length of a nosecap extension
  • Special sizes are available

split-sleeve-expendable

WCI-CBM-36-2-N-5-20 CB, 1 1/8" nominal, 7/8" attachment, 2" stackup
WCI-CAM-A20-1-30 CA, 1/8" nominal, 7/16" attachment, 3" stackup
WCI-CRM-R40-1-10 CR, 1/4" final hole size, 7/16" attachment, 1" stackup
WCI-CWM-B9874-5-10 CW, 63/64" nominal, bolt or open hole, 7/8" attachment, 1" stackup

Nosecaps

Flush Nosecaps

The flush nosecap retains the jaw assembly, which keeps the sleeve in the hole during coldworking. The nosecap consists of three partsthe end cap, the jaw retainer, and the jaw assembly.

Std. Flush Nosecap
1700 /1800/1900 Pullers

split-sleeve-expendable

 

1800-HO Nosecap

split-sleeve-expendable

 

1800-OA Nosecap

split-sleeve-expendable

 

split-sleeve-expendable

WCI-1800N-18F 1800 puller nosecap, 9/16" hole size for use with flared sleeves
WCI-1800OAN-28S 1800 Offset Adapter nosecap, 7/8" hole, straight sleeve
WCI-1800HN-24F 1800 HO nosecap, 3/4" hole, flared sleeve
WCI-1700N-12F 1700 puller nosecap, 3/8" hole, flared sleeve

Extension Nosecaps

The extension nosecap enables coldworking in restricted access areas, such as next to a J-stringer, by providing a comparatively narrow diameter extension to the nosecap. The extension includes integral jaws. The nosecap may be ordered in a variety of lengths (L). Diameter (D) is dependent upon the mandrel size. An extension mandrel must be ordered with the extension nosecap.

split-sleeve-expendable

 

Mandrel Size D Dia
1700
Series
1800
Series
4-0-N - 8-3-N 0.45  
10-0-N - 10-2-N 0.57
10-3-N - 12-3-N 0.57
14-0-N - 14-3-N 0.69 0.69
16-0-N - 16-3-N 0.73
18-0-N - 20-1-N   0.82
20-2-N - 20-3-N 0.90
22-0-N - 22-1-N 1.00
22-2-N - 22-3-N 1.03
24-0-N - 26-3-N 1.07
28-1-N - 30-3-N 1.19

 

split-sleeve-expendable

split-sleeve-expendable

 

WCI-1700NE-1401-20F CB, 2" extension for a 1700 puller, covering 7/16" and 29/64" hole sizes
WCI-1700-ONE-A4041-30F CA, 3" extension for 1700 Offset Adapter, for 1/4" and 17/64" holes
WCI-1700HNE-R30-20F CR, 2" extension for 1700HO, for a 3/16" hole
WCI-1800NE-32-2-40F CW, 4" extension for 1800 puller, used for a 1" (B10030) hole

Jaw Assemblies

Flush Nosecaps

A jaw assembly is a set of three hardened steel ring segments that are held tightly to the mandrel minor diameter by O-rings. The jaws prevent the sleeve from coming out of the hole during coldworking. Jaw sets change as the mandrel size and sleeve type (flared or straight) change.

Standard Flush Jaw Set

split-sleeve-expendable

1700-OA Flush Jaw Set
1600/1700/1750 HO

split-sleeve-expendable

split-sleeve-expendable

WCI-1700J-04F 1700 puller jawset, used with a 1/8" hole and flared sleeves
WCI-1700OAJ-1201F 1700OA jawset for a 3/8" hole and flared sleeve

Starting Drills

Starting drills create a hole ready for reaming to the pre-coldwork size.

  • Manufactured from high speed steel or cobalt
  • Used to create holes in new production work
  • All drills under 1/2" have straight shank, larger sizes have a stepped-down shank to accept standard chucks.

    split-sleeve-expendable

split-sleeve-expendable

WCI-SD-22-2-N CB Process, 23/32" nominal hole size
WCI-SD-A42 CA Process, 9/32" nominal hole size
WCI-SD-R52 CR Process, 11/32" final hole size
WCI-SD-B3771 CW Process, bolt or open hole, 3/8" nominal hole size

Reamers

Start Hole Size

Start hole reamers bring the hole to its pre-coldwork size. The non-cutting pilot helps guide the reamer into the pre-drilled pilot hole. Cobalt reamers are available in many sizes.

split-sleeve-expendable

split-sleeve-expendable

 

WCI-SR-28-1-N CB Process, start reamer for 57/64" hole size
WCI-SR-A100 CA Process, for 5/8" nominal hole size
WCI-SR-R50 CR Process for 5/16" final fastener size
WCI-SR-R3170 CW Process for rivet, 5/16" nominal

Final Size Reamers

The final size reamer cleans up the ridge left by the sleeve and leaves a smooth, round hole ready for countersinking or fastener installation. The non-cutting pilot is used both as a guide and to verify the hole has been coldworked.

split-sleeve-expendable

split-sleeve-expendable

 

WCI-FR-24-0-N-7460 CB Process, 3/4" nominal, reaming to .7460"
WCI-FR-A30-2040 CA Process, 3/16" nominal hole size, reamed to .2040"
WCI-FR-R42-277 CR Process, 9/32" final hole size, reamed to .277" (CR reamer specified to thousandths)
WCI-FR-R2530-2570 CW Process, rivet, 1/4" nominal, reamed to .2570"

Go-No Go Gages

Go-No-Go gages can be purchased from West Coast Industries for on-line inspection of drilled start holes, reamed start holes, and final reamed holes.


Start Hole Gage

The start hole gage is used to verify the proper starting hole diameter. It features a stepped go-no go pin, or a two sided gage with the minimum and maximum start hole pin on either side, for easy inspection.

split-sleeve-expendable

WCI-SHG-12-0-N CB Process, to check a 3/8" nominal hole
WCI-SHG-A53 CA Process, checks a 23/64" nominal hole
WCI-SHG-R50 CR Process, checks the start size for a 5/16" nominal hole
WCI-SHG-B2676 CW Process, checks start size for a 17/64" nominal hole

Combination Gage

The combination gage is used to check the reamed, pre-coldworked start hole, with a go-no go end, while the other end verifies the hole has been coldworked.

split-sleeve-expendable

split-sleeve-expendable

WCI-CBG-12-0-N CB Process, to check a 3/8" nominal hole
WCI-CBG-A53 CA Process, checks a 23/64" nominal hole
WCI-CBG-R50 CR Process, checks the starting hole diameter for a 5/16" final hole diameter
WCI-CBG-B2676 CW Process, checks a 17/64" nominal hole

Final Hole Gage

A final hole gage verifies that coldworked holes are reamed to proper tolerances.

split-sleeve-expendable

WCI-FHG-3110-3140 All ProcessesGo diameter of .3110, with a No-Go diameter of .3140

Mandrel Wear Gages

Mandrel wear gages are available for every mandrel size. If the mandrel major diameter passes through the No Go gage, the mandrel is worn beyond its limit.

split-sleeve-expendable

split-sleeve-expendable

WCIS-WG-12-0-N CB Process, checks a 12-0-N mandrel
WCIS-WG-A32 CA Process, checks an A32 mandrel
WCIS-WG-R32 CR Process, checks an R-32 mandrel
WCIS-WG-H4340 CW Process, checks low interference, hex drive mandrel

Backup Blocks

Backup blocks are used to increase the stackup thickness, preventing material buckle in thin material. These blocks are commonly required for the coldworking of thin stackups and are used when the material stackup is less than one hole diameter in thickness. Made of aluminum, they are discarded after use.

split-sleeve-expendable

split-sleeve-expendable

WCI-BB-18-0-N CB Process for an 18-0-N mandrel, (9/16" nominal)
WCI-BB-A93 CA Process for an A93 mandrel, (39/64" nominal)
WCI-BB-R42 CR Process for an R42 mandrel (9/32" final hole size)
WCI-BB-R3780 CW Process for an R3780, class II mandrel for rivets, 3/8" nominal