bolted joints presentation

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Bol ted Jo int Analys is BOLT.XLS

An Inside Look…..

By: Rick Palm

NAT; CAE Dept.

[email protected]

Author ized by: Oskar Rozalski



8/19/2014

Contents:

Why Perform Joint Analysis?

Torque – Tension.

K-Factor, and Friction Coefficients.

Slip Planes, and Joint Capacity.

Examples #1.

Additional Information.



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WHY ?

Increased GVW’s. Decreased content.

Increased wheel sizes.

H-rated tire. Nickel Anti-seize.

Increased corrosion requirements.

Eliminating hexavalent chrome. S426 & S427 finishes (self loosening).

Wax coated frames.



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Loose Joints !

1997 PN/UN Wheel Attachment Recall: $107M

1999 PN/UN Trailer Hitch Recall: $ 65M

2000 Transit Wheel Attachment Recall: $ 5M

F-350/450/550 DRW Wheel Attachment: $ ???M

U222 Wheel Nut Loosening.

U222 Ball Stud Loosening .

Steering Gear Attachments. And more are coming!



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Torque –

Tension



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w/o Friction:

Axial Load = P

P/2

P/2

P

P/2

P/2

A p p

l i e d T or q u e


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With Friction:

B e ar i n gF r i c t i o

n

T

h r e a d F r i c t i on

Axial Load = P

P/2

P/2

P

P/2

P/2

A p p

l i e d T or q u e

P = Torque / ( D x K )

D



Torque –Tension:

Tension = Torque / ( Diameter * K )

K = K(bearing) + K(threads) + K(pitch)

K is a function of: Geometry

Friction Coefficient (U)



K-Factors &

Friction Coefficients



K & Friction Coefficients:

K determined experimentally using 2,384 torque-tension tests.

Friction Coefficients correlated to K.

Friction Coefficients in BOLT.XLS look-up table.

New K factors calculated.

Calculated K accurate to within +-20%



BOLT.XLS Coefficient Table:Lookup Table for Friction Coeficients

I.D. Name Coeficient of friction

Prior Values

(reference only)

Current

Values variation27 S7 + Wax (Cadmium + Wax) - 0.10 6%

22 Thread Adhesive 0.10 0.10 6%

6 Anti-Sieze Compound 0.10 0.10 6%

7 Oil; Wax; Par-Coat 0.10 0.10 6%

8 S426/S427 0.11 0.11 6%

3 S (Steel with "dry-to-the-touch" trace of residual mfg oil) 0.21 0.12 6%

28 S7 (Cadmium ) - 0.13 6%

23 S2 & S4 (Phosphate + Oil) 0.13 0.13 6%

19 S43 (Zinc + Olive Drab Chromate) 0.14 0.14 6%

11 Paint or E-coat 0.15 0.14 6%

12 Rusted + oil 0.14 0.14 91%

26 Dry Phosphate - 0.14 6%

25 S301 (Dacromet) 0.13 0.15 6%

17 S13; S37; S45 (Chrome) 0.15 0.15 34%

9 S428 (don't use) 0.16 0.16 6%

1 S436 (Zinc Phosphate + Organic) 0.16 0.17 6%

24 S309 except w/o integral lubricant 0.12 0.17 6%

20 JS500 0.17 0.17 6%

2 S309 (Zinc+Di-Chromate) 0.21 0.17 6%

29 S8 (Zinc) - 0.18 6%

4 S301 except w/o integral lubricant 0.22 0.22 40%10 Rusted 0.26 0.26 100%

13 Aluminum 0.29 0.48 46%

21 Rough Machined Aluminum 0.60 0.60 40%

18 Clear-Coat 1.00 1.13 10%

999 User Defined Test Value - 0.150 6%

Today = 5/10/02 12:27

Correlated Friction variation = 6%



Slip Planes &Joint Capacity



Clevis Brackets:

F_shearF_shear

U1 = 1st Plane

U2 = 2nd

Plane

F_shear <= ( P – P bracket ) x ( U1 + U2 )

PP bracket

( 2 Slip Planes )



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Shear Plates:

F_shear

F_shear

U1 = 1st Plane

U2a = 2nd Plane

U2b = 2nd

Plane

P

(2 Slip Planes )

Bolt Bending& Fatigue

F_shear <= P x ( U1 + min(U2a, U2b) )




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Box Sections:

F_shear

U1 = 1st Plane

(1 Slip Plane )F_shear <= P x ( U1)

F_shear

P



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Torsion Joints:

F <= P x ( U1 + U2 )

M = 4 x F x r <= ( 4 x P x r ) x ( U1 + U2 )

8 Slip Planes with U1 & U2

F r

U1 = 1st Plane U2 = 2nd Plane

MM

F

F

F

P




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http://www.homepages.ford.com/truckcae/home

Bolt.xls is located on the V610 Department Homepage

>> Local Software

>> Bolt.xls



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Bolt.XLS Example #1

P221 Engine Mount to Frame Joint

By: Yong Sun

Chassis/Body/PTSE CAE [email protected]



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Clamp Load Lost to Deform the Clamping Brkt,

contact analysis:

Bracket

Spacer

P P

d



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Bolt.xls Input

Sheet



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Bolt.xls K Factor Calculation



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Slip

Plane

Input



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Bolt.xls : Joint Capacity



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Joint.xls: Joint Capacity (continued)



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Additional

Information



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T H I S I S O N L Y A P R E L I M I N A R Y E S T I M A T E ! Latest Update: 02/17/03 F I N A L P RO V E O U T M U S T B E B A S E D O N T E S T I N G !

Description:

Data Entered by: rpalm

Diameter 16.00 mm

Pitch 2.00 mm

Me tric Prope rty Cla ss of Bolt 10.9

Cone Angle 45

Nominal Cone Size 2 mm

OD = 20.8 mm

ID = 16.8 mm

Height = 2 mm

Sy = 210 MPa

Calculations:

Shear Capacity of each Cone:Projected Shear area = Do * height

Projected Shear area = 41.6 mm 2̂

Sy = 210 MPa

Fshear = Sy * A

Fshear = 8,736 N per cone K Factor

-3 sigma K_nom +3 sigma

Calculated 0.165 0.202 0.263

Force to Seat Cone:Projected seat area = pi (Do 2̂- Di^2) / 4

Projected seat area = 57.6 mm 2̂ Tension = (Torque-Torque Prevailing) / (K * Dia)

Sy = 210 MPa Tensile Load = 156,145 N

Yield Load = 140,530 N

Fseat = Sy * A Proof Load = 126,477 N

Fseat = 12,086 N Clamp Load (Newtons)

okTorque

N-m -3 sigma K Nominal K +3 sigma K

Min Fseat available = 55,652 N max 316 120,018 97,656 75,293

(at -3 sigma torque and +3 sigma K) nom 275 104,364 84,918 65,473

min 234 88,709 72,180 55,652

Bracket on HRLC Steel

BOLT_Shear_Cone.xls

Fshear Fshear

Fseat

Angle

OD

ID



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Today's Date:

Data Entered by:

Model Year:

Vehicle Model:

Component:

Comments:

2/18/03 9:28 AM

2002

rpalm

48.00

U222

Front LCA Strut Clevis; Ductile Cast Iron

Assumed: Load & Deflection at Bolt Centerline.

Bolt_Clevis.xls

Geometry parameters

72.00

13.00

48.70

13.00

15.00

72.00

15.00

b0

0

b1

1

Bolt Centerline

L1

b0 & t0

are at the base

of the clevis.

b1 & t1

are at the base

of the boltcenterline.

Geometry 1

Geometry 2



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Load Deflection; Non-Linear Material

31,353

23,831

82,545

31,748

0

10,000

20,000

30,000

40,00050,000

60,000

70,000

80,000

90,000

0.00 1.00 2.00 3.00

Deflection (mm)

F o r c e

( N e w t o n s )



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WHEEL.XLS:

Specialized Joint Analysis Joint

Analysis for Wheel Attachment.

Spike Stops & Rough Road.

Fatigue Life.



8/19/2014

Tapered Ball Stud Analysis:



8/19/2014

More to Consider:

bolted joints presentation

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