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Bol ted Jo int Analys is BOLT.XLS
An Inside Look…..
By: Rick Palm
NAT; CAE Dept.
Author ized by: Oskar Rozalski
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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
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Torque –Tension:
Tension = Torque / ( Diameter * K )
K = K(bearing) + K(threads) + K(pitch)
K is a function of: Geometry
Friction Coefficient (U)
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K-Factors &
Friction Coefficients
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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%
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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%
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Slip Planes &Joint Capacity
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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) )
Bolt Bending& Fatigue
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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
Bolt Bending& Fatigue
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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.
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Tapered Ball Stud Analysis:
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More to Consider: