Laboratory Report on

FE MODELING AND STRESS ANALYSIS OF BOLTED JOINT

Submitted to

VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama, Belgaum
in partial fulfilment of the requirements
in Design Engineering Lab II (14MDE26) for the degree of
MASTER OF TECHNOLOGY
in
MACHINE DESIGN
Submitted by

Sharath B N
Thoufeeque Abdul Rahman Rafique

1BM14MMD13
1BM14MMD15

Under the guidance of

Dr. H. K. Rangavittal
Associate Professor

Mr. Shivashankar R. Srivatsa

Assistant Professor

Department of Mechanical Engineering

B. M. S. COLLEGE OF ENGINEERING
PB No. 1908, Bull Temple Road, Bangalore 560 019.
May 2015

Sl. No. Title

Page No.

Introduction

03

Theory

04

Modelling and simulation

06

3.1

Methodology

06

3.2

Linear analysis in SolidWorks

07

Problem statement

09

Geometric model and analysis in SolidWorks

10

5.1

Solid modelling

10

5.2

Analysis of the bolt and plates

11

Analysis in ANSYS

20

SOM calculations

23

Results

25

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INTRODUCTION
Bolts are one of the most commonly used fastening elements in the assembly of
mechanical parts. They are used in almost every engineering application. Structures with
bolted joints are usually subjected not only to various static loads but also to impact loads.
Because bolts provide localized connection, they lead to high stress concentration in the
joined plates. Considering that impact loads are much more damaging at notches, the region
around a bolts one of the most critical locations in the plates. Designing for safety requires
accurate determination of stress and strain states in the critical locations so that damage done
during a crash can be predicted.
A bolted joint by itself is a very complex part considering the complexity of its
geometry, the contact between teeth of the bolt and the nut, the pre-tension in the bolt shank,
contact surfaces between the nut and the washer, bolt head and the washer, washers and the
sheets, bolt shank and the holes of the sheets. Although very complex phenomena can be
simulated with todays computational capabilities and commercial finite element codes,
proper decisions need to be made regarding the constitutive model, the model of the material,
element type, mesh structure, step size, etc. to produce an accurate representation of a
physical event. Another difficulty is that given the complexity of a single bolted joint,
analysis of panels or beams fastened by many bolts is quite a demanding and time-consuming
task. If one tries to simulate the behaviour of such a structure with all its complexity, the
results cannot be obtained within a time short enough to be of use in a design process, which
requires trials of many configurations to find an effective design. For this reason, the
complex geometry should be simplified so as to reduce the computational burden without
compromising accuracy.

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Theory
Typically, a bolt is tensioned (preloaded) by the application of a torque to either the
bolt head or the nut. The preload developed in a bolt is due to the applied torque and is a
function of the bolt diameter, length, the geometry of the threads and the coefficients of
friction that exist in the threads and under the bolt head or nut.
The stiffness of the components clamped by the bolt has no relation to the preload that
is developed by the torque. The relative stiffness of the bolt and the clamped joint
components do, however, determine the fraction of the external tension load that the bolt will
carry and that in turn determines preload needed to prevent joint separation and by that
means to reduce the range of stress the bolt experiences as the tension load is repeatedly
applied. This determines the durability of the bolt when subjected to repeated tension loads.
Maintaining a sufficient joint preload also prevents relative slippage of the joint components
that would produce fretting wear that could result in a fatigue failure of those parts when
subjected to in-plane shearing forces.
The clamp load, also called preload, of a fastener is created when a torque is applied,
and so develops a tensile preload that is generally a substantial percentage of the
fastener's proof strength. A fastener is manufactured to various standards that define, among
other things, its strength and clamp load. Torque charts are available to identify the required
torque for a fastener based on its property class (fineness of manufacture and fit)
or grade (tensile strength).
When a fastener is torqued, a tension preload develops in the bolt and a compressive
preload develops in the parts being fastened. This can be modeled as a spring-like assembly
that has some assumed distribution of compressive strain in the clamped joint components.
When an external tension load is applied, it relieves the compressive strains induced by the
preload, hence the preload acting on the compressed joint components provides the external
tension load with a path other than through the bolt. As long as the forces acting on the
fastened parts do not exceed the preload, the fastener's tension load will not increase.

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This however, is a simplified model that is only valid when the fastened parts are
much stiffer than the fastener. In reality, the fastener carries a small fraction of the external
tension load even if that external load does not exceed the clamp load. When the fastened
parts are less stiff than the fastener (those that use soft, compressed gaskets for example), this
model breaks down and the fastener is subjected to a tension load that is the sum of the
tension preload and the external tension load.
In some applications, joints are designed so that the fastener eventually fails before
more expensive components. In this case, replacing an existing fastener with a higher
strength fastener can result in equipment damage. Thus, it is generally good practice to
replace old fasteners with new fasteners of the same grade.

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MODELING AND SIMULATION:

Methodology
SOLIDWORKS is a solid modeler, and utilizes a parametric feature-based approach to create
models and assemblies. The software is written on Parasolid-kernel.
Parameters refer to constraints whose values determine the shape or geometry of the model
or assembly. Parameters can be either numeric parameters, such as line lengths or circle
diameters, or geometric parameters, such as tangent, parallel, concentric, horizontal or
vertical, etc. Numeric parameters can be associated with each other through the use of
relations, which allows them to capture design intent.
Design intent is how the creator of the part wants it to respond to changes and updates. For
example, you would want the hole at the top of a beverage can to stay at the top surface,
regardless of the height or size of the can. SOLIDWORKS allows the user to specify that the
hole is a feature on the top surface, and will then honor their design intent no matter what
height they later assign to the can.
Features refer to the building blocks of the part. They are the shapes and operations that
construct the part. Shape-based features typically begin with a 2D or 3D sketch of shapes
such as bosses, holes, slots, etc. This shape is then extruded or cut to add or remove material
from the part. Operation-based features are not sketch-based, and include features such as
fillets, chamfers, shells, applying draft to the faces of a part, etc.
Building a model in SOLIDWORKS usually starts with a 2D sketch (although 3D sketches
are available for power users). The sketch consists of geometry such as points, lines, arcs,
conics (except the hyperbola), and splines. Dimensions are added to the sketch to define the
size and location of the geometry. Relations are used to define attributes such as tangency,
parallelism, perpendicularity, and concentricity. The parametric nature of SOLIDWORKS
means that the dimensions and relations drive the geometry, not the other way around. The
Page | 6

dimensions in the sketch can be controlled independently, or by relationships to other

parameters inside or outside of the sketch.
In an assembly, the analog to sketch relations are mates. Just as sketch relations define
conditions such as tangency, parallelism, and concentricity with respect to sketch
geometry, assembly mates define equivalent relations with respect to the individual parts or
components, allowing the easy construction of assemblies. SOLIDWORKS also includes
additional advanced mating features such as gear and cam follower mates, which allow
modeled gear assemblies to accurately reproduce the rotational movement of an actual gear
train.
Finally, drawings can be created either from parts or assemblies. Views are
automatically generated from the solid model, and notes, dimensions and tolerances can then
be easily added to the drawing as needed. The drawing module includes most paper sizes and
standards (ANSI, ISO, DIN, GOST, JIS, BSI and SAC).

Linear analysis in solidworks:

Linear stress analysis with SOLIDWORKS Simulation enables designers and
engineers to quickly and efficiently validate quality, performance, and safetyall while
creating their design.
Tightly integrated with SOLIDWORKS CAD, linear stress analysis using SOLIDWORKS
Simulation can be a regular part of your design process, reducing the need for costly
prototypes, eliminating rework and delays, and saving time and development costs.
Linear stress analysis calculates the stresses and deformations of geometry given three basic
assumptions:
1.

The part or assembly under load deforms with small rotations and displacements

2.

The product loading is static (ignores inertia) and constant over time

3.

The material has a constant stress strain relationship (Hookes law)

Page | 7

SOLIDWORKS Simulation uses finite element analysis (FEA) methods to discretize design
components into solid, shell, or beam elements and uses linear stress analysis to determine
the response of parts and assemblies due to the effect of:

Forces

Pressures

Accelerations

Temperatures

Contact between components

Loads can be imported from thermal, flow, and motion Simulation studies to perform
multiphysics analysis.
In order to carry out stress analysis, component material data must be known. The
standard SOLIDWORKS CAD material database is pre-populated with materials that can be
used by SOLIDWORKS Simulation, and the database is easily customizable to include your
particular material requirements.

Page | 8

PROBLEM STATEMENT
AIM:
Finite element modelling and failure analysis of bolted joints
To understand the material stress distribution that occurs in a bolted joint, FE
modelling and failure analysis has been done using CAE tool Solidworks and obtained results
are tabulated.

Page | 9

Geometric model and analysis in SolidWorks

Solid modelling
The solid model considered along with the loading and boundary conditions for the bolted
joint analysis is shown below. The middle plate is held rigidly at one end while a load of 5kN
each is applied on the opposite ends of the upper and lower plates. The three plates are held
together by an M10 bolt.

Page | 10

2-D drawing of the above assembly with the dimensions is as shown below.

Analysis of the bolt and plates

1.

Upper/lower plate

Material: Alloy steel - Properties

Page | 11

Solid model.

Halfmodel of

Since the model is symmetric, half of the model is built and symmetric boundary condition is
applied along the plane of symmetry.

Boundary conditions and loads

Page | 12

Fixed boundary
condition where the
bolt comes into

Applied

Symmetric
boundary
condition

Along with the symmetric boundary condition as mentioned before, a section of the hole
where the bolt makes contact with the plate is constrained, shown by Green arrows. The
angle of surface contact considered here is 800; the data was obtained from Hand Book of
Bolts and Bolted joints by John Bickford and Sayed Nassar. A load of 5000 N is applied at
the end of the plate, shown by Pink arrows.
Analysis - Von-Mises stress

Iso clipping of the Von-Mises stress

Page | 13

From the Iso clipping it is seen that the average Von-Mises stress over the plate obtained is
around 130 Mpa, considering the errors due to meshing and boundary conditions.
Deformation plot

Maximum deformation obtained is 6.0e-3 mm.

2. Middle-plate
Page | 14

Material: Alloy Steel - Properties

Solid model.

Halfmodel of

Since the model is symmetric, half of the model is built and symmetric boundary condition is
applied along the plane of symmetry.

Boundary conditions and loads

Page | 15

Fixed boundary
condition where the
bolt comes into
Applied

Symmetric
boundary
condition

A section of the hole where the bolt makes contact with the plate is loaded with a force equal
to 10000 N shown by Pink arrows, which is a sum of the loads applied to the upper and lower
plates. In the middle plate, the bolt comes into contact with the plate hole on the opposite
surface in comparison with the upper and lower plates. The end surface is given fixed
boundary condition, which is represented by Green arrows.
Stress - Von-Mises

-Iso clipping of Von-Mises Stress

Page | 16

From the Iso clipping it is seen that the average Von-Mises stress over the plate obtained is
around 220 Mpa.
Deformation plot

Maximum deformation obtained is 1.5e-2 mm.

3. Bolt
Page | 17

Material: Ti-8Al-1Mo-1V Annealed - Properties

Solid Model

Surface area
in contact
with upper
Surface area
in contact
with lower

Surface area
in contact
with middle

A bolt of 10mm diameter is considered. The surface area of the bolt which comes into contact
with the plate is also modelled into the bolt, as shown.

Boundary conditions and loads

Page | 18

Applied

Fixed boundary
condition where the
Applied
bolt comes into

The surface area which comes into contact with the middle plate is constrained, represented
by Green arrows and a load of 5000 N is applied on each of the two surfaces which comes
into contact with the upper and lower plates. This load is represented by Pink arrows.
Stress - Von-Mises

Iso clipping of Von-Mises Stress

Page | 19

From the Iso clipping it is seen that the average Von-Mises stress over the bolt obtained is
around 300 Mpa.

Analysis in Ansys
Page | 20

1. Upper/lower plate
Von Mises Stress

Average Von Mises stress obtained = 123 MPa

Total deformation

2. Middle plate
Page | 21

Von Mises Stress

Average Von Mises stress obtained = 233 MPa

Total deformation

Page | 22

3. Bolt
Von Mises Stress

Average Von Mises stress obtained = 307 MPa

Deformation

Page | 23

SOM calculations
The bolt and plate are subjected to various stresses upon loading. But in the Strength of
Materials approach, the boundary and loading conditions are simplified to a great extent by
considering various assumptions. The stresses considered for the plates and the bolt is given
below.
In our bolt and plate configuration, the bolt is subjected stresses due to double shear about the
cross section because of the two plates and is also subjected to crushing stress along the
cylindrical face where the surfaces of the plate and bolt are in contact. The plate is subjected
Tearing stress.
Stress due to double shear
Type of bolt used is Metric bolts Data taken from Bolt grade marking and strength chart
Bolt properties:
Class 10.9 Alloy steel, quenched and tempered
Yield strength, y = 940 MPa
According to maximum shear stress theory

y =

y
2

y =

940
2

y = 470 MPa
The bolt is subjected to double shear as shown in the figure

Page | 24

The shear stress on the bolt is given by the formula

= F/2Ab
= (10*103)/(2*102/4)
= 63.66 MPa
Factor of safety for the bolt is given by
FOS = y/
FOS =

470
63.66

FOS = 7.38
Generally bolts are designed to maintain a factor of safety in the range of 5-10.
But in the Finite Element model, the analysis is conducted by considering the load on the
cylindrical surface of the bolt. But in the above analytical approach, the shear load is
assumed to be acting on the cross-section of the bolt as shown in the figure. Hence a
correlation between the Von-Mises stress on the bolt obtained by FEA and the
crushing/bearing stress from SOM approach is more appropriate.
Crushing stress,

F1

= dt

+2X

F2
dt

Where d: diameter of the bolt, t: thickness of the section of the bolt which is in contact with
the plates, considered for each plate individually.
F1: force acting on centre of the bolt, F2: force acting on top/bottom of the bolt

10000

= 1010

+ 2X

5000
1010

= 200 Mpa
Page | 25

Factor of safety is given by,

FOS =

y
v

FOS =

940
200

FOS = 4.7
But the Von-Mises stress obtained from FEA is 300 Mpa. This difference is due to the
difference in boundary conditions between the two approaches.

Results
Yield stress

Von-Mises stress

Analysis method
Plate - Alloy
steel

Bolt Titanium
alloy

Plate

Bolt

220 Mpa

300 MPa

233 Mpa

307 MPa

SolidWorks

ANSYS Workbench

620.42 MPa

930.79 MPa

The results obtained from the analysis of the bolted joints have been presented in the table
above. It is seen that the Von-Mises stress values are lower than the stress at yielding point,
and hence the design is safe.

Page | 26