2.72 Elements of Mechanical Design Lecture 07: Bolted Joints

2.
72
Elements of
Mechanical Design
Lecture 07: Bolted
joints
Bolted joint +’s and –’s
Good:
 Low cost?
 Able to be disassembled
 Strong
 Compatible with almost any material
Bad:
 Takes up a lot of space
 Micro-slip/hysteresis/damping problems
 Difficult to model and control
 Can require long fabrication and assembly time
© Martin Culpepper, All rights reserved 2

Bolted joints: Their purpose
Bolted joints = connectors, impact many parts:
Stiffness Vibration Damping Stability Load capacity
Bolted joints are semi-permanent!

 Max benefit obtained when it is highly preloaded, i.e. near the yield point
 Threads can plastically deform/work harden
 Some elements of bolted joints are not reusable
Bolted joints are used to create assemblies that resist:

(i) Tensile loads (ii) Moments (iii) Shear loads
Bolts are NOT meant to resist (i) – (iii)

Components
Anatomy of a bolted joint
l
 Grip
Ad
At
 Tensile stress area HBolt tw
Ad
ld t1
 Major diameter area l
L
t2
lt lt
 Threaded length in grip
HNut tw
LT
ld
 Unthreaded length in grip
At
d
 Major diameter (unthreaded)
Joint components: Clamped member
Things to consider with the clamped member:

2. Stone or lap the surface (increase
stiffness)
3. Remove burs (increase joint stiffness)
4. Be sure flange surfaces are flat so bolt
does not bend

Bolted joint components: Bolt
Rolled Threads NEVER in shear or bending
 Stress concentrations at the
Head root of the teeth
 Fatigue crack propagation!
 Exception: Shoulder bolts
Keep threads clean &

Shank
lubed to minimize losses
 ~50% power to bolt head
Cut Threads friction
 ~40% power to thread

friction
 ~10% power to deforming

Steel is most the bolt and flange
common
Bolted joint components: Washers
Purpose of Washers:
 Spacer
 Distribute load in clamped member
 Reduce head-member wear
 Lower coefficient of friction/losses
 Lock bolt into the joint (lock washer)
 Increase preload resolution (wave washer)

Bolted Joint Components: Nut
Threads do not distribute the load evenly: What can be done to distribute the load better
2. First thread has the shortest load path 2. Use a softer nut material
(stiffest)
3. Use a bolt and nut that have different pitch
3.Threads plastically
The pitch of the boltdeform
threads and nutBolts are values
used once forwith
to begin precision applications
threads change as they are loaded
4. Use a special nut that lengthens the load
path of the first thread
Stiffness
Preload
While preloading joint, are the flange & bolt “springs” in parallel or in series?
Series:
• Same Forces
• Different Displacements (stretches) Parallel:
• Same Displacements (stretches)
• Different Forces
Fpreload
= Flange Compression
Kflange
Fpreload
= Bolt Stretch
KBolt
Preloaded joint modeled as series spring
km kb
Need to find equivalent bolt and member stiffness

Bolt stiffness
Shoulder bolt/cap screw consists
of two different parts
 Threaded
Ad E
kd = Unthreaded
kd

ld
Each has different
At E
kt = * kt  Cross sectional area
lt  Axial stiffness
The load passes through both

The effective threaded grip  They act in series
 This is a series spring calculation
length, lt*, used in the
−1
stiffness calc is the sum of 1 1  kt k d
the threaded grip length kb =  +  =
plus three threads  kt k d  kt + k d
Member stiffness
dw Pressure cone exists in the member
z materials and bolt head
The clamping area at the member

interfaces depends upon
 Washer diameter, dw
 Half-apex angle, α
dh
α  Bore clearance, dh
25o-45o
Stiffness calculation by integration

P dz
dδ = through the depth of the member
E A(z )
 Ed tan   
km 
 dh    d w  d h  2t tan      d w  d h  
2 2
dw 
A z      z tan        ln  
  2  2    d w  d h  2t tan      d w  d h  
Loading
Tensile loads in bolted joints
Fi
 Preload
P
 External tensile load HBolt tw
Pb
ld t1
 Portion of P taken by bolt l
L
t2
Pm
lt
 Portion of P taken by members
HNut tw
LT
C
 Fraction of P carried by bolt
1-C
 Fraction of P carried by members

Forces in the bolt and the members
When loaded with a tensile force
 Most of the force is taken by the members
 Very little (<15%) of the force is taken by the bolt
 For most, this is counter intuitive….
P P
km kb
P P

Forces in the bolt and the members
So how much does each see? kb
Pb  PPC
 Pm = Portion of P taken by members k m  kb
 Pb = Portion of P taken by bolt
P = Pm + Pb Pm = P (1 − C )
km kb Pb Pm
δ= = Fb  Pb  Fi
kb k m
Fm  Pm  Fi
High preload = High load capacity
P,δ Fb  CP  Fi Fm = (1 − C ) P − Fi
What happens when joint separates?

Static load capacity
Typically the bolt fails first, why? CP Fi
σb = +
 It is the least expensive At At
 It is the most easily replaced
C n P Fi
+ = Sp
Proof load and stress At At
 Sp = proof stress = Limiting value of σb (~ 0.85 σy)
S p At − Fi
Load factor (like a factor of safety) n=
CP
 n > 1 ensures σb < Sp
How high should the pre-load be? P P

 Non-permanent: Some suggest 0.75 Fp
 Permanent: Some suggest 0.90 Fp P P

Shear resistance
When joint is in shear
 Friction between the members takes the load, not the bolt
 Coefficient of friction and preload are the important properties
 Dowel pins or shoulder bolts should be used to resist shear
P P P   s Fi
P P

Torque,
friction,
preload
Bolt torque and preload
How to measure
 Via stretch = but impractical
 Via strain = expensive built-in bolt sensor
 Via torque = not “ultra-repeatable” but easy and most often used
Relationship between Torque and Stretch?

ETorque = E friction + Estretch
How much do you torque the bolt when tightening?
 Too little = weak, compliant joint
 Too much = bolt may break or the joint may bulge
 Usually torque the bolt until Proof Load is reached
Continuous tightening is important: μs > μ k

Best practices
Best practices
Threads should be at
H >2D least 1.5 D deep for
bolt to reliably hold a
load

Applications: Gasket / roller bearings
Gasket Roller Bearings
Wave washers can reduce

tightening sensitivity to
achieve desired preload.
Exercise
Group exercise
The tool holder stiffness is critical to lathe accuracy.
Calculate the stiffness of the bolted joint between your

tool holder and cross slide bearing.
How does the relative stiffness of this compare with the

stiffness of other parts in the load path?
 Structure
 Bearings
 Rails
 Etc…

Preventing Bolts from Coming Loose
How do you prevent bolts from coming loose?
2. Use the joint in a low vibration environment
3. Use bolts with fine threads (small pitch)
4. Use a large preload
5. Use materials with high coefficients of friction
6. Use Loctite on the threads
7. Use an adhesive between the bolt head and flange
8. Use lock washers
N
F
F = μ s*N

Applications: Bearing Rails
Rails Carriage
Tighten bolts sequentially
1.5 L
L

Applications: Bearing Rails
Objectives:
Accuracy is maximized by
• Maximize stiffness overlapping strain cones.
Therefore, the thicker the rail,
• Decrease manufacturing cost
the few bolts are necessary.
• Maximize accuracy But the rail becomes less stiff.
Same stiffness
Beware of bulging
High manufacturing
cost
Bolt spacing should be about 4x the
bolt diameter

2.72 Elements of Mechanical Design Lecture 07: Bolted Joints

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2.

© Martin Culpepper, All rights reserved 2

Bolted joints are semi-permanent!

Bolted joints are used to create assemblies that resist:

Bolts are NOT meant to resist (i) – (iii)

© Martin Culpepper, All rights reserved 3

Things to consider with the clamped member:

© Martin Culpepper, All rights reserved 6

Keep threads clean &

 ~40% power to thread

 ~10% power to deforming

 Distribute load in clamped member

 Reduce head-member wear

 Lower coefficient of friction/losses

 Lock bolt into the joint (lock washer)

 Increase preload resolution (wave washer)

© Martin Culpepper, All rights reserved 8

Need to find equivalent bolt and member stiffness

© Martin Culpepper, All rights reserved 12

The load passes through both

The clamping area at the member

Stiffness calculation by integration

© Martin Culpepper, All rights reserved 16

© Martin Culpepper, All rights reserved 17

High preload = High load capacity

What happens when joint separates?

How high should the pre-load be? P P

© Martin Culpepper, All rights reserved 19

© Martin Culpepper, All rights reserved 20

Relationship between Torque and Stretch?

Continuous tightening is important: μs > μ k

© Martin Culpepper, All rights reserved 24

Wave washers can reduce

Calculate the stiffness of the bolted joint between your

How does the relative stiffness of this compare with the

© Martin Culpepper, All rights reserved 27

© Martin Culpepper, All rights reserved 28

Tighten bolts sequentially

© Martin Culpepper, All rights reserved 29

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