Bolt Preload Theory and Application

BoltPreloadTheoryandApplication

withFemap andNXNastran

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 BoltPreloadTheoryandApplication

TableofContents

1. Introduction 3
2. SettinguptheModel 4
3. BoltRegions 5
4. DefiningaBoltPreload 6
5. ContactRegions 7
6
6. Classic Example of Bolt Preload
ClassicExampleofBoltPreload. 8
7. IdealizationofBoltPreloads... 10
8. BoltPreloadswithPlateModels.. 12
9. BoltPreloadsinSolidModels. 13
10. Summary.. 14

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 BoltPreloadTheoryandApplication

Introduction
Whatisboltpreload?
Boltpreloadisusedtoclamptogethertwoplatesortwostructuresandcreateafrictionallockbetweenthemembersandreduce
p p g p
theeffectsofcyclingloadingonthebolt.Withrespecttothelatter(i.e.,boltfatigue),boltpreloadcanmakeallthedifference
betweenasafe,longlastingstructureorcatastrophicfailure.

Wheretouseboltpreload?
Boltpreloadisnotafreelunch.ToeffectivelyuseboltpreloadonFEAconnectionsrequiresmanyadditionalstepsanditconverts
alinearrunintoanonlinearrunthatrequirestwosequentialnonlinearanalysiswhere(i)theboltpreloadisappliedandthen
l l h l l l h () h b l l d l d d h (ii) ( )
theexternalstructureloadisapplied.

Whatiscoveredinthiswhitepaper?
Thiswhitepaperwillcoverathebasicsofsettingupyoumodelforboltpreload,theoreticalfoundation,examplesofitsuseanda
bolt fatigue primer
boltfatigueprimer.

EngineeringComment:
Boltpreloadaddsquiteabitofcomplexitytoanymodelsincetheanalysisprocedureisnonlinear(geometricallynonlinear)and
thattwosequentialnonlinearrunsarerequiredtoarriveatthefinalboltpreloadsolution.Theutilityofthisapproachliesinits
abilitytoquantitativelycalculatetheboltaxialandshearforcesforanytypeofboltedconnection.Additionally,ifboltfatigueis
important,thenaboltpreloadapproachisinvaluable.

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 BoltPreloadTheoryandApplication

SettinguptheModelforBoltPreloading

Acommonapplicationofboltpreloadingistheconnectionofflangegeometries.Intheexamplebelow,asymmetricflangeis
boltedtogetherwithfourbolts.Theboltsaremodeledusingbeamelementsandtheirendnodesareconnectedtothesolidmesh
modelusingrigidlinks.Thisidealizationisquitecommon.Allmodelsassociatedwiththiswhitepapercanbedownloadedfrom
thePredictiveEngineeringwebsite.

Contactisenforcedbetweenthetwopartsandaboltpreloadisappliedtothebeamelements.Ifthereaderisunfamiliarwiththis
typeofmodeling,theyshouldtakealookatthePredictiveEngineeringwebsiteunderSeminarsandreviewourseminaron
ContactModeling.

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 BoltPreloadTheoryandApplication

BoltRegions

BoltRegionsareuser definedregionsthatcanbedefinedusingeitherbarorbeamelements.DefiningBoltRegionsbeforeusing
theboltpreloadcommandisslower,butallowsyoutomoreeasilyname/labeleachregion,allowingyoutokeepyourmodel
moreorganized.CreatingBoltRegionsisalsousedforthespecialcaseswheneachofyourboltsaremadeupofmultiplebeam or
barelementsinseries.

DefiningaBoltRegion

TobegindefiningaBoltRegion,usetheBoltRegion command,foundeitherontheModelTreeunderConnections>Regions>
BoltRegion orunderthefilemenuConnect>BoltRegion.ThiscommandbringsuptheBoltRegiondialoguebox.Sincewewillbe
defining the Bolt Regions using FE mesh rather than geometry select the Element radio button under Defined By box If the bolt
definingtheBoltRegionsusingFEmeshratherthangeometry,selecttheElementradiobuttonunderDefinedBybox.Ifthebolt
consistsofonlyoneelement,youcanselectthedesiredelementandclickOK.Iftheboltconsistsofmorethanoneelement, click
theMultiple button;thisbringsupthestandardselectdialoguebox.Pickalloftheelementsthatareapartofthebolttobe
includedintheBoltRegionandclickOK.Remember,eachBoltRegionshouldconsistofonlyonebolt.Repeatforeverydesired
BoltRegion.

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 BoltPreloadTheoryandApplication

DefiningaBoltPreload

Itisnotneccessary tocreateaBoltRegionpriortoBoltPreloadapplication,butitisrecommendedformodelorganization.The
boltpreloadcommandcanbeaccessedbygoingtoModel>Load>Bolt Preload,orbyusingtheModelTree.Thisbringsupthe
CreateBoltPreloaddialoguebox.Note:thevalueofthepreloadistheloadperbolt,notthetotalload.Iftherearepreviously
definedBoltRegions,bothoptionswillbeavailableintheApplyTo box,ifBoltRegionshavenotbeendefined,onlytheElement(s)
option will be available
optionwillbeavailable.

IftheBoltRegion(s)radiobuttonisselectedintheApplyTo box,theEntitySelection SelectRegion(s) dialogueboxwillappear.

PickeachoftheBoltRegionstheboltpreloadistobeappliedtodirectlyorusethemenutoselecttheregions.ClickOKwhen
done.

IftheElement(s)optionisselected,theSelectElementsdialogueboxwillappear.Handpickeachofthebarorbeamelementsthe
boltpreloadistobeappliedto.ClickOKwhendone.Foreachelementselected,acorrespondingBoltRegionwillbeautomatically
created.

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 BoltPreloadTheoryandApplication

ContactRegions

Forboltpreloadtowork,linearcontactmustbeenabled.Foradetailedexplanationofhowtodothis,seeourwebinarandwhite
paperonLinearContactAnalysis.

Shownbelowishowlinearcontactwassetupforthisexample.

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 BoltPreloadTheoryandApplication

ClassicBoltPreloadExample:Tension

Shownbelowarecontactpressureandboltaxialforceresultsfromthecurrentexampleundertensileloadingof100,000lbfwith a
boltpreloadof50,000lbfperbolt.Thecontactpressureshowsthattheboltsarepullingtheflangestogethersincethetensileload
ispullingthecenterofthestructureapart.Theboltsaxialforcesrangefrom62,827to62,837lbf orapproximately62,800lbf.If
theboltpreloadis50,000lbf,isitcorrecttosaythatthisanalysisisaccurate?Beforeweanswerthisquestion,letslook atanother
load case using this model
loadcaseusingthismodel.

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 BoltPreloadTheoryandApplication

ClassicBoltPreloadExample:Bending

Abendingloadisappliedtothemodelandonesideofthecontactfaceisundercompressionwhiletheopposingsideseparates.
Thesameboltpreloadof50,000lbfperboltwasapplied.Undertheseconditions,theboltaxialforceis50,113lbfontheside
undercompressionand84,410lbfonthesideundertension.Arethesereasonableresults?Theonlywaytoknowwhetherornot
thesearelogicalresultsistounderstandabitofthetheoryunderlyingboltpreloadanalysis.

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 BoltPreloadTheoryandApplication

IdealizationofBoltPreloads

Boltpreloadcanbeidealizedas:(MechanicalEngineeringDesign,Shigley,3rd Ed,1977)
kb * P
Fb = + Fi
kb + k s
Fb = totall axial
i l force
f b l Fi = bolt
on bolt b l preload
l d
P = externally applied load kb = bolt stiffness k s = structure stiffness

Thisidealizationisonedimensionalandassumesuniformloadapplicationof
bolt preload (Fi) and the applied load (P) The bolt stiffness is kb and the
boltpreload(Fi)andtheappliedload(P).Theboltstiffnessiskbandthe
stiffnessoftheconnectedmembersisks.Toillustratethisequation,asimple
brickmodelwascreatedwithunitdimensions.Aboltwascreatedatthe
centerwitha1unitcrosssectionalarea.Thematerialwasaluminumwithan
E=1e7psi.Rigidlinksattheendsofthebeamkeepthetopandbottom
surfacesflat.Thismodelingidealizationwherethetopandbottomsurfaces
movetogetherwiththebeamends,satisfiesthedisplacementcontinuityas
requiredbytheaboveequation(seeShigley fordetails).

Giventhissimpleidealization,theboltstiffness(kb)isequaltoA*E/Lor
1*1e7/2=5e6andthestructurestiffness(ks)isequalto1*1e7/2=5e6.Witha
b lt l d (Fi) 1 000 lbf andanexternallyappliedload(P)of500lbf,the
boltpreload(Fi)=1,000lbf d t ll li d l d (P) f 500 lbf th
equationwouldpredictatotalaxialforceonbolt(Fb)=*500+1,000=1,250
lbf.Asshownontheright,thetotalaxialforceontheboltis1,250lbf.

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 BoltPreloadTheoryandApplication

IdealizationofBoltPreloads

Thepriorequationisvalidaslongascompressionexistsbetweenthepreloadedparts.Iftheexternalloadcausesthepreloaded
partstoseparate,thenthetotalexternalloadiscarriedonlybythebolt.Thistippingpointcanbecalculatedusingthefollowing
equationfromShigley:
ks * P
Fs = Fi Fs = force between preloaded parts
kb + k s
Iftheboltpreload(Fi)is1,000lbf,thentheclampedpartswouldseparatewhenFs=0.0.Theaboveequationcanthenbe
rearrangedandtheexternalloadtonegatethepreloadwouldbe:
kb + k s
P = Fi P = 1,000 2 = 2,000
ks

Ingeneralterms,ifyourboltpreloadisequalorgreaterthanthe
externallyappliedload,thenthepreloadedpartswillstayclampedand
facilitatethejointstayinglocked.
j y g

Fromafatigueviewpoint,theimportanceofapreloadedjointcannot
beoverstatedduetoloweralternatingstressesintheboltandthatthe
jointstayslocked.Afatiguediscussionisgivenattheendofthiswhite
paper.

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 BoltPreloadTheoryandApplication

BoltPreloadswithPlatemodels

Plateelementshavenothroughthicknessstiffness.Assuch,kmdoesnotexistandtheappliedloadhasnoeffectuptothebolt
preload.

Intheexampleshownbelow,ahalfsymmetricaltubeispreloadedthroughaboltatitscenter.Theboltismodeledwithabeam
element and two rigid links The bolt is given a preload of 1 000 lbf An external tensile load is given to our structure at 50 100
elementandtworigidlinks.Theboltisgivenapreloadof1,000lbf.Anexternaltensileloadisgiventoourstructureat50,100,
and150%oftheboltpreload.Theboltsaxialforceisthen1,000,1,000and1,500lbf,respectively.Theseresultsarecorrect
althoughonanengineeringbasis,areillogicalsinceweknowthatallstructureshavesomestiffness.

Akeypointofthisanalysisisthatwhenusingboltpreloadonplatestructures,thefinalboltloadwillalwaysbeunderestimated
ornonconservative.

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 BoltPreloadTheoryandApplication

BoltPreloadsinSolidModels

A3Dmodelwasconstructedusingbrickelements.Inthisexample,alltherelevantboltloadphysicsarecaptured.

Thesameexampleformatisfollowedwiththeexternallyappliedloadat50,100and150%oftheboltpreload.

Thekeypoint,isthattheboltaxialstiffnesswillalwaysbeabitmorethanyourpreload,anditshouldscaleinareasonable
The key point is that the bolt axial stiffness will always be a bit more than your preload and it should scale in a reasonable
manner. Inthiscase,theboltsaxialforceis1,038,1,285and1,542lbf.Withoutadirectcalculationofkbandks,areasonable
mannerisopentointerpretation.Thisiswheregoodengineeringjudgmentmustbeapplied.

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 BoltPreloadTheoryandApplication

SummaryofBoltPreloadTheory,ApplicationandFatigue

Boltpreloadtheorystates:
kb * P
Fb = + Fi
kb + k s
Andassumesthattheboltpreloadandtheexternalloadactonthesamesectionofsolidmaterial.Thefinalaxialforceona
preloadedbolt(Fb)willbetheboltpreloadandthensomefractionoftheexternallyappliedload.

In plate models ks isinfinite(itreallydoesn

Inplatemodelsk is infinite (it really doesnttexistsinceitisaplate).Hence,theappliedloaddoesnotincreasetheboltload
exist since it is a plate). Hence, the applied load does not increase the bolt load
(Fb)untilPexceedsFi.Thisunderpredictstheactualboltloadsinceallboltedstructureshavesomeboltedjointstiffness(km).

Inasolidmodel,boltpreloadfunctionsasonewouldexpectandthetotalboltaxialforcefollowsbolttheoryingeneralterms.
However,careshouldbetakeninhowtheboltheadandnutaremodeledwithrigidlinkssincetheboltpreloadmechanism
requiresthatthestructuralmembersbecompressedunderneaththeboltheadornutforboltpreloadtofunctionasdesired.

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 BoltPreloadTheoryandApplication

SummaryofBoltPreloadTheory,ApplicationandFatigue

Oneofthemainreasonsforapplyingboltpreloadistoavoidfatigueofthebolt.Thismaynotseemimmediatelyobviousafter
thepriordiscussionsinceitwasshownthatthefinalboltloadisalwayshigherthantheinitialboltpreload.Thatis,the bolt
stressisalinearcombinationoftheboltpreloadandsomefractionoftheexternallyappliedload.But,theboltsalternating
stressisgreatlyreduced.Thisisthedominantadvantageofboltpreload.

LetsconsidertwofatiguecasesandevaluateboltlifeusingtheSoderberg equationforsimplicitywhere:
a m
+ =1
Se Sy
a = Alternative Stress m = Mean Stress
Inthisexample,wellassumethatanyexternalloadincreasestheboltpreloadby20%(seetheorysection).
Herearetheparameters:
BoltArea=1sqin
BoltPreload=80,000lbf
AlternatingStress(ExternallyAppliedLoad=100,000lbf thatcyclesfrom0.0).
BoltStressEndurance(Se)=70,000psi
BoltYieldStress(Sy)=140,000psi

Thequestionthatisposedisdoesboltpreloadhelporhurt?
NoBoltPreload:
50 , 000 50 , 000
+ = 1 . 07 > 1 . 0 Fails
F il
70 , 000 140 , 000

WithBoltPreload: F b = 0 . 2 * 100 , 000 + 80 , 000 F b = 100 , 000

10 , 000 90 , 000
+ = 0 . 79 < 1 . 0 Passes
70 , 000 140 , 000

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