Cold Working of Holes

BAPS 188-002

2018.06.18

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 Why Cold Work Holes?

Split sleeve cold working is performed on holes in highly stressed areas to

increase the fatigue life of structural members. Cold working expands the hole
diameter, thereby creating a radial plastic flow of material which produces high
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residual compressive stresses around the hole. The residual compressive
zone, depending upon variables such as material and applied expansion
levels, will usually extend out from approximately one radius to one diameter
from the hole.

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Polarized photo of compressive
residual stress pattern formed
by cold working process
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 Cold Work Benefits

Cold expansion counteracts the fatigue-prone characteristics of a hole by creating a

compressive residual stress field around the hole, effectively shielding the hole from
the cyclic tensile stress loads that cause cracks to form and grow. Design engineers
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use cold expansion to reduce the stress concentration factor associated with a hole,
thereby improving fatigue and damage tolerance of a structure and allowing for
weight savings by designing to a higher working stress level.

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 Split Sleeve Cold Working

The expansion process is accomplished by inserting a tapered mandrel into

a hole lined with a longitudinally split, disposable, stainless steel sleeve. The
sleeve has a coating of dry film lubricant on the internal surface to lower the
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applied load (pull-force) required to draw the mandrel through the hole. As
the mandrel is pulled back through the sleeve, the hole is expanded.

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 Overview of Cold Work Procedure

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 Overview of Cold Work Procedure

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 VIDEO - Cold Work Animation

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 Cold Work - Critical Points
• The process of cold working holes is tooling critical and requires the
use and verification of proper tooling. Use of non-conforming or worn
tooling will reduce fatigue life improvement.
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• Parts shall be securely clamped to obtain proper contact during drilling
and sizing of the starting hole, cold working and final hole sizing.
• For Type I cold working, inspection gauges, mandrels and sleeves shall
be visually examined before use to ensure there are no nicks, scratches
or other damage which may create defects in the cold worked holes.
• Prior to cold working, holes shall be free of machining coolant, paint,
sealant, anodic coatings, metal particles or any other contaminants.
• Holes into which fasteners are to be installed shall be perpendicular to
within 2 degrees (total) to the surface against which the fastener head
will seat.

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 Starting Hole Diameters
The starting hole diameters shall be verified using a Go/No-Go inspection
gauge. The inspection gauge tolerances shall be +0.0000/-0.0002 inch on all
Go-gauge diameters and +0.0002/-0.0000 inch on all No-Go gauge diameters.
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Combination Gage — The combination gage combines two gages into one
unit - the Start Hole Gage and the Verification Gage. One end of the gage
checks the pre-cold worked start hole while the other end verifies that the
hole has been cold worked.

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 Starting Ream
The start reamer is used to properly size the pilot hole prior to the cold
working operation.

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 Split Sleeve
Prior to cold working, ensure that the inside of the split sleeve is coated with a
solid film lubricant. This film is an integral part of the process and shall not be
removed.
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Also, ensure that there are no nicks or burrs along the edges of the split
sleeves prior to cold working.

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 Tool Inspection

Mandrel Wear Gage - The mandrel wear gage is used to check the mandrel
major diameter for excessive wear prior to the cold working operation. Failure
to check the mandrel could result in holes not being cold worked to the
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correct expansion level.

No-Go Go

Acceptable Unacceptable

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 Material Stackup Thickness
To prevent buckling of thin materials during cold working, back-up blocks shall be
used to increase the material stack-up thickness. The material stackup thickness
including the back-up block shall be greater or equal to the starting hole diameter.
Back-up
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alloy or temper condition as the part being cold worked.

Back-up blocks shall have a hole meeting the same dimensional and finish
requirements as the production part starting hole. After use, back-up blocks shall be
discarded; however, they may be re-used if reamed to the next starting hole size.

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 Final Ream
The final reamer is used to properly size the post-cold worked hole. The non-
cutting pilot of a final reamer is the same diameter as the verification gage. If
the hole has not been properly cold worked, the reamer pilot will not enter the
post cold worked hole.
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 Definitions
• Material Stackup - The combined thickness of a structure through which a
hole is located, or the total length of a bore. Material stackup is important when
determining the correct tooling required for a task, ie. Mandrel length, puller
unit
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10pt length, sleeve length, and nosecap length. A stackup of material
shall have complete faying surface contact during start hole preparation,
cold working, and final hole sizing operations.
• Puller Stroke - The total movement required to pull a mandrel, including the
tapered portion and major diameter, through a given material stackup.
• Edge Margin - Edge margin (e/D) is the ratio of the shortest distance between
the center of the hole and the edge of the part. Reworking of fastener holes
tends to reduce the edge margin. Fatigue testing has shown edge margins
of 1.75 or greater are preferred. Use of an interference fit fastener is
recommended for edge margins between 1.25 and 1.75.
e
Edge Margin =
D
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e D
e = distance from edge of part to center of hole
D = final hole diameter

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 Definitions
Major Mandrel Diameter - The largest mandrel diameter which, in conjunction
with the sleeve thickness, provides the proper amount of applied expansion to
cold work a hole. This dimension is critical to the process.
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Minor Mandrel Diameter - The mandrel dimension which, when combined with
the split sleeve thickness, allows insertion into the start hole.
Taper - Taper is the section of mandrel on either side of the major diameter which
enhances the cold work process. The taper on the front side of the major
diameter aides the installation of the split sleeve and insertion into the hole to be
cold worked. The taper on the backside of the major diameter controls the pull-
force required to cold work the hole.

Tool Code

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Mandrel
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 Definitions
Pull Force - The amount of force required to pull a mandrel through a particular
material is dependent upon the hole diameter, material stackup and material
properties.
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Start Hole Diameter - The measured size of the hole prior to cold working.
Important for ensuring the proper cold working of the hole. Hole must be
measured dimensionally throughout the hole bore and checked for concentricity
or roundness. Holes not meeting the dimensional specifications will not provide
the desired fatigue enhancement. Start holes must also be within 2º of normal to
the surface, and have a surface roughness of 125 rms or smoother.

Nominal Hole Diameter Approximate Puller Unit Pull Force

(inches) Requirements In Aluminum Alloys (lbs)
1/8 to 3/16 1,500
13/64 to 1/4 2,500
17/64 to 5/16 3,000
21/64 to 3/8 4,000
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25/64 to 3/4 10,000
49/64 to 1 14,000
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 Definitions
Existing Hole Diameter - The measured hole diameter determines which cold
working toolset is utilized for a hole. Proper examination of the hole is
important in order to ensure the maximum benefit from cold working. Important
factors to look for are fatigue indicators such as cracks, out of roundness, and
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a tapered bore. Holes slightly oval in shape or with a tapered bore, may be cold
worked if dimensions are within start hole tolerances.
Access Restriction - A term used to refer to areas which contain obstructions
that prevent the cold working of holes utilizing standard tooling. These
obstructions may be backside to the hole, frontside to the hole, or laterally to
the hole. For these types of restrictions, utilize either an Hydraulic Offset or
Puller Gun/Offset Adapter.

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 Definitions
Satellite Holes - A satellite hole is the smaller of two holes which has less
than 0.40 inch distance between the edges of the holes. The smaller holes
should be filled with a steel pin prior to cold working the larger hole.
The steel pin shall have a diameter less than the start hole diameter, but not
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greater than 0.002" under the start hole size. The purpose of these pins is to
prevent the collapse of these holes during the cold working of the larger hole.

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Material movement could
cause hole collapse

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 Definitions
Axial Ridge - An axial ridge on the bore of the hole is formed by plastic flow
of material into the longitudinal split of the sleeve during cold working. As an
indicator of cold working, it is normally removed by post-size reaming. After
cold
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10pt a small axial ridge will remain in the hole as shown below. The
ridge(s) shall be removed by reaming the hole to the final hole size. For
holes in which fasteners are not installed, such as drain holes, the small
axial ridge occurring along the length of the hole need not be removed.
Additionally, holes subject to low cycle fatigue may require that the sleeve
split be positioned away from the area of highest stress levels.

Axial Ridge
Shear discontinuity
Axial shear direction
Mandrel motion

Radial shear direction

Original Surface upset

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