Bolted joint torque setting using numerical simulation and experiments

In vehicle design process, the torque setting for a bolted joint is mainly determined based on hardware tests. For a newly designed joint of a vehicle, making prototypes and performing tests is expensive and time consuming. Numerical simulation can help predict joint behavior and detect potential failure modes prior to hardware testing. This study developed a numerical simulation using the finite element method to set the installation torque for a joint based on torque-angle signature curves. A three-dimensional detailed model of the joint was constructed. Then, finite element dynamic simulation was used to simulate the installation process of the bolt by gradually applying a torque until the bolt failed. Using these simulations, the torque-angle curves were generated and were used to determine the installation torque of the joint. This was different from the majority of earlier approaches which mainly used hardware tests, two-dimensional or three-dimensional simplified models, and static analyses instead of dynamic analyses. Material nonlinearity and contact were used in the study to capture the joint failure and contact conditions. For comparison, experiments were conducted. The study showed that the finite element analysis accurately predicted the bolt behavior. These results show that numerical simulation can be used to determine torque settings analytically, and can be developed as a standard practice for determining joint torque when designing vehicles.

[1]  Sayed A. Nassar,et al.  The Effect of Coating and Tightening Speed on the Torque-Tension Relationship in Threaded Fasteners , 2006 .

[2]  Nabil Motosh,et al.  Development of Design Charts for Bolts Preloaded up to the Plastic Range , 1976 .

[3]  Chu-Hwa Lee,et al.  Finite element modeling of self-loosening of bolted joints , 2007 .

[4]  Toshimichi Fukuoka,et al.  Elastic plastic finite element analysis of bolted joint during tightening process , 2003 .

[5]  Radesh Vangipuram,et al.  Torque Angle Signature Analysis of Joints with Thread Rolling Screws and Unthreaded Weld Nuts , 2007 .

[6]  A. A. Pisano,et al.  Mechanically fastened joints in composite laminates: Evaluation of load bearing capacity , 2011 .

[7]  Peter Iványi,et al.  On the simulation of failure mechanisms in steel structures , 2009, Adv. Eng. Softw..

[8]  Tae-Won Park,et al.  An Experimental Study of Self-Loosening of Bolted Joints , 2004 .

[9]  Eann A. Patterson,et al.  Investigation into the Effect of the Nut Thread Run-Out on the Stress Distribution in a Bolt Using the Finite Element Method , 2003 .

[10]  Sayed A. Nassar,et al.  Handbook of bolts and bolted joints , 1998 .

[11]  H. Saunders,et al.  An Introduction to the Design and Behaviour of Bolted Joints , 1983 .

[12]  Chu-Hwa Lee,et al.  A Study of Early Stage Self-Loosening of Bolted Joints , 2001, Threaded and Riveted Connections, Design Issues, Reliability, Stress Analysis, and Failure Prevention.

[13]  P. Camanho,et al.  A design methodology for mechanically fastened joints in laminated composite materials , 2006 .

[14]  Mike Guo,et al.  Study on Simplified Finite Element Simulation Approaches of Fastened Joints , 2006 .

[15]  Atsushi Iwasaki,et al.  Three-dimensional Finite Element Analysis of Tightening and Loosening Mechanism of Threaded Fastener , 2005 .

[16]  S J Hardy,et al.  Experimental results and finite‐element predictions of the effect of nut geometry, washer and Teflon tape on the fatigue life of bolts , 2005 .