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Author(s): Kai Buhr, Wolfgang Haydn, Manfred Bacher-Hoechst, Ulrich Wuttke and
Christina Berger
Source: SAE International Journal of Materials and Manufacturing , Vol. 2, No. 1 (2009), pp.
75-84
Published by: SAE International
Stable URL: https://www.jstor.org/stable/10.2307/26282736
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International Journal of Materials and Manufacturing
Finite-Element-Based Methods for the Fatigue Design of Bolts and Bolted Joints
ABSTRACT
FA working load
Due to the increase of computer performance, modern FSA additional bolt load
screw design is more and more based on finite element FM assembly preload FSA
analyses. Depending on the problem, different S elastic bolt resilience
possibilities of modelling bolted joints are reasonable. P elastic resilience of the
Traditionally, a nominal stress approach is used for the clamped parts
fatigue design of bolted joints. But, in modern lightweight
FAu=0
constructions it is more and more common to connect
threaded components directly without using a classic force F FAo=FA
bolted connection. In this case a local approach has to
FM
be used. In several investigations at the Fachgebiet und
S
Institut für Werkstoffkunde (Chair and Institute for
Materials Technology) in Darmstadt and the Robert
Bosch GmbH in Schwieberdingen different concepts for P
a local approach have been tested for the fatigue design
of threaded connections. As a result, an overview can be deformation f
given, which design concept and which model can be
properly used for calculations.
INTRODUCTION
− The resilience factor Φ includes the elastic LOCAL FATIGUE ASSESSMENT OF BOLTS
resilience S of the screw and P of the bolted AND BOLTED JOINTS
parts. Both are calculated by the help of simplified
approaches, which can be incorrect or inaccurate A fatigue assessment in principle is based on the
and seldom be used for real cross-sections. comparison of failure relevant stresses to the fatigue
− Predicting the fatigue limit of screws is very strength. The failure relevant stresses are either
conservative since it is based on uncertain calculated or measured. Depending on the used
operands (for example special values in /1/ like approach for the fatigue assessment the fatigue strength
the distance of the line of action of the axial load can be measured on the whole structure, single parts
from the axis of the symmetrical deformation body (nominal approach) or material specimens (local
a, the distance of the bolt axis from the axis of the approach). Two approaches basically exist for a local
symmetrical deformation body ssym or the fatigue assessment of bolts:
resilience factorΦ ).
− the local elastic stress approach
− Inhomogeneous stress distributions, which
normally occur in components with bolted joints, − the local strain approach.
can only be considered to a very limited extent. For the local elastic stress approach, stresses are
− Especially the evaluation of multi-bolted joints computed at the failure relevant local spot of crack
contains so many assumptions that it inevitably initiation with the adoption of a linear-elastic material
leads to a conservative design. behaviour. The calculated elastic stresses are evaluated
with the fatigue strength determinate from force/stress
− The nominal approach in the guideline implies that controlled cyclic tests. Contrary to that, a fatigue
the fracture occurs in the first load-bearing thread assessment according to the concept of local strain is
turn of the bolt. Other notched regions or a based on the (overall) elastic-plastic strain amplitude in
variable load distribution along the bolts a notch root for example. The evaluated overall strain
longitudinal axis can not be evaluated. amplitude comprises both: the linear-elastic and the
The limitation of the analytical calculation model for elastic-plastic ratio /5/. The computation of the local
bolted joints in the guideline can partially be avoided by stresses and strains is done in consideration of the
means of the finite element method, because stiffness material yield behaviour specified by a cyclic stress
and load transmission within complex shaped and strain curve. The use of this concept assumes the same
loaded components can be calculated precisely. crack initiation behaviour for the material in the notch
Therefore stresses within these components can be root and a simple material specimen under the same
determined easily, if the corresponding FEM model is strain load.
only detailed enough.
Unfortunately the fatigue strength of metallic materials is
The result of a detailed FEM model, a model including strongly influenced by variables, such as mean stress /6/
the thread of the bolt and the contact in all load carrying or supporting effect. Both influences have to be included
interfaces, are local stresses and strains which have to in a fatigue assessment if values of this material
Rm
− ( G + )
b G ⋅MPa
n = 1 + 4 χ * ⋅ mm ⋅ 10 , (3)
Table 1: Testing variants of bolts (B*) and bolted joints (BJ*) with corresponding results /12/
Table 3: Positions of failure of cyclical tested bolted joints (BJ*) and single bolts (B*) /12/.
testing variants according Bolted Joints Bolts
to /12/ BJ1 BJ2 BJ3 BJ4 BJ5 BJ6 B1 B2 B3 B4
head/shaft --- 11 1 3 --- 2 --- --- --- ---
shaft/thread 9 5 8 3 4 4 14 12 4 3
first bearing thread 4 1 3 4 10 5 --- 3 9 10
1,2
head/shaft shaft/thread first bearing thread
(hatched columns indicate position with most failures in the test)
1,0
(PSWT/nσ)/(PSWT,ref/nσ,ref)
0,8
0,6
0,4
0,2
0,0
BJ1 BJ2 BJ3 BJ4 BJ5 BJ6 B1 B2 B3 B4
Figure 4: Calculated damage parameters PSWT with corresponding supporting factor n at local hot spots in the screws of
cyclic tested bolted joints (BJ1-6) and bolts (B1-4)
Figure 5: Means, maxima and minima for calculated damage parameters PSWT with corresponding supporting numbers
n at local hot spots in the screws of cyclic tested bolted joints (BJ1-6), bolts (B1-4) and specimens (R-V/A)
In this case two different FEM models for the bolt are
used for the calculation:
Generally bolts will be highly prestressed. Because of PSWT = ( K tN ⋅ S SNa + K tM ⋅ S SMa ) ⋅ RF , (7)
the high notch factor the stresses will exceed the elastic
limit in the thread. If an elastic- ideal plastic material
(index N: relating to axial force; index M: relating to
behaviour is assumed the upper stress of a cyclic load is
bending moment). The elastic limit RF can be defined as:
defined as high as the elastic limit. In case of a bolt load
6
which leads to cycles in a range of N = 2 10 (endurance
Re + Rm (8)
limit as described in /1/) the local cyclic stress range can RF =
be idealised as linear. So the local cyclic stress 2
amplitude σa can be calculated with the elastic notch
factor Kt and the nominal stress amplitude SSa. Including (in /16/ stress defined for he calculation of the plastic
these two assumptions the damage parameter PSWT can collapse) with the elastic limit Re and the tensile strength
be simplified as follows /14, 15/: Rm.
Apart from the elastic limit only the nominal stresses and
PSWT = (σ a + σ m )ε a E (4)
the notch factors are needed for the calculation of PSWT.
Both values were evaluated separately for bending an
0
0 10 20 30 40
FB=3 x FA [kN] Figure 9: FEM model for the calculation of the notch
factor
MSA [Nm]
3.5 (the index TG indicates, that the values are calculated
Msa_Pret_neu
S1; beam model for the first load bearing thread). In the present case the
3.0 value of the endurance limit as a result of cyclic tests is
Msadetailed
S1; 3D model very low (nominal value for the dimension M6 in
comparison with the endurance limit following the VDI
2.5
guideline). For that reason the resulting value of PSWT,D of
PSWT,D/PSWT,ref = 0,85 is at the lower scatter band in
2.0 Figure 5.
0.5 The maximum value for PSWT results from the notch
effect of the different notched regions and the
distribution of the nominal stress. In the present case the
0.0
bending moment has an approximately linear distribution
0 10 20 30 40 along the bolt axis, with a maximum underneath the bolt-
FB=3 x FA [kN] head and a minimum near zero in the overlapping
threads. Contrary to this the maximum notch factor
Figure 8: Comparison of the additional bolt load (bolt exists in the first load-bearing thread turn of the bolt. The
S1 on the symmetric plane) with two different FEM conditions in this example lead to a maximum damage
models: detailed bolt model idealised bolt model (FB: parameter in the thread chamfer beneath the bolt head.
total working Load (see Fig. 6), FSA additional bolt load;
MSA additional bolt moment). Beside the material resistance and the resilience of the
different parts of the construction, the bolt preload is a
axial loading. The nominal stresses can be calculated very important parameter, which controls the opening of
with the beam model, the notch factor with a different the joint. In the case under consideration the preload will
detailed FEM-Model (see Figure 9). be applied torque-controlled. For that reason the
preload-values scatter over a much wider range. Beside
Normally the bolt fatigue strength is known in nominal the spread as a result of the tightening technique a
stresses and for a pure axial loading. With the simplified further reduction due to the embedding of the joint has to
equation for PSWT the endurable PSWT –factor is defined be taken into account. Because the joint has a very low
as: clamping length the amount of embedding is very
critical. In this example the minimum and maximum
1 preload FV is estimated by the VDI-Guideline 2230 /1/.
PSWT , D = K tN ,TG ⋅ S Sa , D ⋅ RF . (9)
The result in comparison with experimental values is
nσ ,TG
shown in the load-cycle diagram in Figure 10. Two main
conclusions can be drawn:
50
maximum working force FB[kN]
20
FV,max=13,0 kN; Pf = 99 %
2
experimental results 2
experimentally estimated F-N-curve 2
FEM based fatigue approach FV,min=5,0 kN; Pf = 1 % 3
10 3
4 5 6 7
10 10 10 10
number of cycles N
Figure 10: Comparison of the estimated life cycles based on the simplified local approach and experimental results (FV:
preload used in the calculation)
4 Fares, Y., Chaussumier, M., Daidie, A., Guillot, J., 13 Wuttke, U., Berger, C., Buhr, K., Bacher-Höchst,
Determining the Life Cycle of Bolts using a Local M., Haydn, W., Kreschel, H., Einsatzmöglichkeiten
Approach and the Dang Van Criterion, In: Fatigue der FEM zur Bewertung zyklisch beanspruchter
Fract Engn Mater Struct 29, 2006 Schraubenverbindungen, 8. Informations- und
Diskussionsveranstaltung Schraubenverbin-
5 Sonsino, C.M., Zur Bewertung des Schwing- dungen, Darmstadt, 2006
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(1993) 1, S.25-33 beanspruchter Schraubenverbindungen mit Hilfe
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Werkstoffkunde, TU Darmstadt, 1999 16 Issler, L., Ruoß, H., Häfele, P., Festigkeitslehre –
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