Mawe.201900143 Nord Lock

Materialwiss. Werkstofftech. 2020, 51, 267–283 DOI 10.1002/mawe.
201900143 267
1
2
Calculation of lockbolt joints in mechanical
3 engineering
4
5
6
Bemessung von Verbindungen mit Schließringbolzen im
7 Maschinenbau
8
9
10 M. Schwarz1, R. Glienke2, F. Wegener1, C. Blunk1, K.-M. Henkel3
11
12 Lockbolts become increasingly important for modern mechanical engineering. The
13 advantageous notch effect in consequence of a softer groove geometry, the larger
14 stress cross section for the same nominal diameter and a lower scattering of pre-
15 load results in the potential for increasing the load capacity of lockbolt systems in
16 mechanical joints in comparison to conventional bolted joints. Consequently costs
17 can be reduced with structural adjustments in mechanical engineering. These in-
18 clude the reduction of the required nominal diameter and consequently the reduc-
19 tion of component dimensions. Furthermore savings in manufacturing and assem-
20 bly as well as cost reduction for maintenance are possible. For the calculation of
21 lockbolt systems in mechanical joints the Technical Bulletin DVS-EFB 3435–2 is
22
available now for design and calculation engineers. The Technical Bulletin allows
to calculate joints with lockbolt systems according to VDI 2230 – Part 1 [1, 2]. This
23
paper presents joints with lockbolts in mechanical engineering. At first, the lockbolt
24
technology and the assembly preload of the lockbolts will be introduced. After that
25
the structural behavior of joints with lockbolts under static and alternating load will
26
be presented. Finally, the modified calculation steps according to the VDI 2230 –
27 Part 1 will be demonstrated [2].
28
29 Keywords: Lockbolts / mechanical joints / lockbolt joints / lockbolt assembly process /
30 assembly preload / load bearing behavior
31
32 Schließringbolzen gewinnen immer mehr an Bedeutung im modernen Maschinen-
33 bau. Aufgrund der günstigeren Kerbwirkung durch eine entsprechende Schließril-
34 lengeometrie, des größeren Spannungsquerschnitts bei gleichem Nenndurchmes-
35 ser und geringeren Streuungen der Montagevorspannkraft besteht beim Einsatz in
36 mechanischen Fügeverbindungen das Potential der Tragfähigkeitssteigerung im
37 Vergleich zu klassischen Schraubenverbindungen. Damit verbunden sind Kosten-
38 einsparungen durch konstruktive Anpassungen im Maschinenbau. Dazu zählen
39
eine Verringerung der erforderlichen Nenndurchmesser und die damit einherge-
40
hende Reduzierung der Bauteilabmessungen. Darüber hinaus sind Einsparungen
in der Fertigung und Montage sowie Kostenreduzierungen für Wartung und Unter-
41
42
1 Fraunhofer-Institute für Großstrukturen in der Pro- 3 Universität Rostock – Fakultät für Maschinenbau
43
duktionstechnik IGP, Albert-Einstein-Straße 30, und Schiffstechnik, Lehrstuhl Fügetechnik, Albert-
44
18059 ROSTOCK, GERMANY Einstein-Straße 30, 18059 ROSTOCK, GERMANY
45 2 Hochschule Wismar – Fakultät für Ingenieurwissen-
46 schaften Bereich Maschinenbau / Verfahrens- und Corresponding author: M. Schwarz, Fraunhofer-Insti-
47 Umwelttechnik, Philipp-Müller-Straße 14, 23966 tute für Großstrukturen in der Produktionstechnik IGP,
48 WISMAR, GERMANY Albert-Einstein-Straße 30, 18059 ROSTOCK, GER-
49 MANY,
50 E-Mail: mathias.schwarz@igp.fraunhofer.de
© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

268 M. Schwarz et al. Materialwiss. Werkstofftech. 2020, 51, 267–283
1 haltung von Konstruktionen möglich. Für die Berechnung von Verbindungen mit
2 Schließringbolzen im Maschinenbau steht das DVS-EFB Merkblatt 3435-2 den
3 Konstruktions- und Berechnungsingenieuren zur Verfügung. Die Rechenschritte
4
erfolgen in Anlehnung an die VDI 2230 – Blatt 1 [1, 2]. Der vorliegende Beitrag
5
stellt Verbindungen mit Schließringbolzen im Maschinenbau vor. Dabei wird zu-
nächst auf die Schließringbolzentechnologie und die Montagevorspannkraft bei
6
Schließringbolzenverbindungen eingegangen. Weiterführend wird das Tragverhal-
7
ten von Schließringbolzenverbindungen bei zügiger und schwingender Beanspru-
8
chung betrachtet. Abschließend werden die modifizierten Rechenschritte in Analo-
9
gie zur Berechnung von Schraubenverbindungen nach VDI 2230 – Blatt 1
10 dargestellt [2].
11
12
Schlüsselwörter: Schließringbolzen / mechanische Fügeverbindungen /
13
Verbindungen mit Schließringbolzen / Montageprozess mit Schließringbolzen /
14 Montagevorspannkraft mit Schließringbolzen / Tragfähigkeit
15
16
17
18 1 Problem and approach preloaded bolted joint will be applied by the pre-
19 loaded components into the joint. The bolt is only
20 In Germany 68 % of all detachable joints in the stressed with an axial load by its preload and by an
21 field of mechanical and vehicle engineering are di- additional load (FSA), if FA exists. The axial load
22 mensioned by the calculations according to VDI (FA > 0, tensile load) causes a loss of the assembly
23 2230 – Part 1 [2, 3]. For 40 years, VDI 2230 has preload by the proportion of the relieving load from
24 been regarded worldwide as the standard guideline the clamped parts FPA [7]. Furthermore, it is re-
25 in calculations of bolted joints. It shows the general quired that for the sealing function (FKP), for pre-
26 theoretical relations between loads, torques and de- venting the one-sided opening at the interface (FKA)
27 formations and derives the relevant equations. The or for transmitting a transverse load by friction grip
28 stipulations of this standard apply to steel bolts (FKQ), a minimum residual clamp load FKR in the
29 with the dimensions from M4 to M39 with the bolted joint has to be available. The required mini-
30 strength grades of bolts of DIN EN ISO 898-1 in mum clamp load FKerf results from the following
31 high-stressed and high-strength bolt joints [4, 5]. So equation:
32 far there are no appropriate fundamental equations
33 for joints with lockbolts. In accordance with the F Kerf � maxðF KQ ; F KP þ F KA Þ (1)
34 characteristic of load bearing behavior and the di-
35 mensions of bolts in mechanical engineering the When determining the friction conditions and
36 gap for the assessment of the joints with lockbolts selecting the tightening processes, the maximum
37 under the influence of a concentric axial load FA assembly preload FMmax increased by the tightening
38 and / or a transverse load FQ should be closed. factor αA is obtained by using the main dimension-
39 A bolted joint in mechanical and rail vehicle en- ing formula of the standard VDI 2230 – Part 1:
40 gineering is defined as follows: “A bolted joint has
41 the task of joining components in such a way, that F Mmax ¼ aA � F Mmin ¼
42 the appearance of slippage or widening the gap are � � (2)
43 prevented” [6]. As a calculation model for bolted aA � F Kerf þ ð1 FÞ � F A þ F Z þ DF Vth
44 joints the single-bolted joint and the joint diagram
45 from will be used, Figure 1 [2]. Based on the pre- Because of the suitability for high strength pre-
46 viously known load conditions a loss of preload FZ loading, the mode of action of lockbolts is quite
47 as a result of embedding during operation and a similar to bolts in mechanical engineering. Accord-
48 temperature difference from room temperature ing to this circumstance the lockbolt technology
49 ΔFVth is taken into account. The operating transvers shows a pleasant potential as an alternative fastener
50 loads (FQ) or in direction of the bolt axis (FA) of the for mechanical joining due to its advantageous

Materialwiss. Werkstofftech. 2020, 51, 267–283 Calculation of lockbolt joints 269
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Figure 1. Main dimensions in the joint diagram (without thermal additional load ΔFVth) according to VDI 2230 – Part 1 [2].
19
Bild 1. Hauptdimensionsgrößen im Verspannungsdiagramm (ohne thermische Zusatzkraft ΔFVth) in Anlehnung an VDI 2230
20 – Blatt 1 [2].
21
22
23 characteristics compared to bolts. In course of sev- lockbolts have plane-parallel or helical locking-
24 eral completed public research activities at the grooves. The material of the collar is plastically
25 Fraunhofer Research Institute for Large Structures formed into the grooves of the lockbolt by an in-
26 in Production Engineering IGP the input variables stallation tool during the assembly process. After
27 for the calculation of concentric loaded joints with the mounting procedure it results in a form and
28 lockbolts have been developed and prepared for the force fitting manner, high strength preloaded me-
29 calculation steps by the Technical Bulletin DVS- chanical bolted joint with a high preload level [10].
30 EFB 3435-2 [1, 8, 9].
31
32 2.1 Embodiments and fields of application
33 2 The lockbolt technology
34 Lockbolt systems are divided and available in two
35 Lockbolt systems are two-piece joining elements, different embodiments and also in different temper-
36 which require an access to the joint from both sides ing conditions, Figure 2.
37 [10]. They consist of a lockbolt and a collar. The
38
39
40
41
42
43
44
45
46
47
48
Figure 2. Lockbolt systems with breaking groove and pintail (left side), without pintail (right side) [1].
49
50 Bild 2. Schließringbolzensystem mit Sollbruchstelle und Abrissteil (links), ohne Abrissteil (rechts) [1].

1 According to the Technical Bulletin DVS-EFB steps. The following procedure is an example with
2 3435-2 the following embodiments are dealt with: a lockbolt system without a pintail, Figure 4.
3 Type A: Lockbolt systems (FK 8.8 and 10.9) 1. The lockbolt gets inserted from one side into the
4 with plane-parallel locking-groove geometry hole of the component. On the opposite side the
5 Type B: Lockbolt systems (FK 10.9) with heli- collar gets plugged or screwed on the lockbolt.
6 cal locking-groove geometry and with or without a 2. The installation tool which implements the ten-
7 breaking groove sile load pneumatically or hydraulically depend-
8 Type C: Lockbolt systems (FK 10.9) with heli- ing on the diameter of the lockbolt is applied on
9 cal locking-groove geometry without a breaking the side of the collar. When the installation tool
10 groove and with reduced pintail is triggered, the assembly process starts in which
11 Lockbolts made of steel are available in the the clamping jaws of the installation tool graps
12 strength grades 5.8, 8.8 and 10.9 according to DIN the pintail of the lockbolt and create a tensile
13 EN ISO 898-1 [5]. Additionally, lockbolts and the load on the lockbolt. During this step the nose
14 related collar can also be offered as aluminum and assembly (load section with clamping jaws)
15 corrosion resistant material. Currently lockbolts are moves with the deformation sleeve over the col-
16 available in metric and imperial dimensions. The lar. As the tensile load increases, the compo-
17 nominal diameters range from 4.8 mm up to nents are pulled together and the lockbolt is pre-
18 36 mm. stretched by tightening the lockbolt pintail and
19 The manufacturing of lockbolts and collars can counter-supporting on the collar.
20 be realized by machining as well as by hot or cold 3. In the further forming process the deformation
21 forming. Subsequent heat treatment provides with sleeve continues moving in the direction of the
22 the required strengths of lockbolt systems. In the fi- collar flange and effects the final elongation of
23 nal production step the coatings and a wax film the lockbolt with simultaneous forming of the
24 which serve on the one hand to protect against cor- collar material into the lockbolt grooves. The
25 rosion and on the other hand to ensure a defined collar is installed in a form and force fitting
26 friction during assembly were applied. In the con- manner on the grooved lockbolt and the preload
27 text of this article the manufacturing processes will is applied. By forming the collar into the lock-
28 not be discussed in more detail. bolt grooves, recovery losses are scarcely ob-
29 A lockbolt system has several advantages in its served, as they occur, for example, in pulling
30 application. The plastic deformation of the collar preloaded processes for bolted joints. The as-
31 into the locking-grooves of the lockbolt creates a sembly process is completely free of torsion.
32 form fitting bolted joint that prevents the collar 4. The removal of the installation tool marks the
33 from automatically loosening. Another further ad- completion of the assembly process. Simulta-
34 vantage is the high stability of the assembly process neously, the lockbolt system offers the oppor-
35 in comparison to the torque-controlled bolt assem- tunity to inspect the successful assembly process
36 bly process. In general, the scatter is less than 5 % (e. g. visual or gauge inspection).
37 during the application of assembly preload [11]. A The interaction between the individual parts
38 disadvantage in joints with lockbolt systems is that (lockbolt, collar and installation tool) is significant.
39 currently only a few system manufacturers for For the quality of the joint the influence of the ge-
40 strength grades of 8.8 and 10.9 (Arconic Fastening ometry part of the installation tool (called nose as-
41 Systems and Rings Ltd., Avdel Deutschland sembly) is elementary. The nose assembly forms
42 GmbH, Gebr. Titgemeyer GmbH & Co. KG) are the collar during the installation process and thus
43 represented on the market, Figure 3. ensures the material-flow of the collar into the
44 grooves of the lockbolt. The individual parts like
45 lockbolt, collar and nose assembly influence each
46 2.2 Lockbolt assembly process other. For this reason it is important to coordinate
47 these parts for the installation of a perfect joint ac-
48 Joining with lockbolts is to be assigned to join by cording to the quality aspects [12].
49 forming. The assembly process is divided in four
50

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29 Figure 3. Current fields of application for lockbolt systems in mechanical engineering.
30 Bild 3. Aktuelle Anwendungsgebiete von Schließringbolzensystemen im Maschinenbau.
31
32
33 2.3 Securing effect with transverse loading
34
35 In frictionally engaged load-transmitting bolted
36 joints, the maintenance of the clamp load FKerf is of
37 decisive importance for the required load-bearing
38 effect. One of the causes of the loss of preload in
39 alternating transverse loaded joints is the automatic
40 loosening effect. This is the subject of numerous
41 scientific investigations [13–16]. Based on these
42 Figure 4. Assembly process of lockbolts without breaking observations, a vibration test bench was developed
43 groove [22]. with which the automatic loosening of bolted joints
44 Bild 4. Montagevorgang mit Schließringbolzen ohne Soll- under alternating transverse load can be inves-
45
bruchstelle [22]. tigated, Figure 5 [13].
46 The vibration test bench and the test sequence
47 are specified in the standard DIN 65151 [17]. The
48 securing behavior of a joint is carried out appropri-
49 ately on the basis of the preload referred to. In or-
50 der to demonstrate and compare the securing effect

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Figure 5. Comparison of the securing effect of joints with lockbolts and bolts, section vibration test bench (downright) [16,
17 22].
18 Bild 5. Vergleich der Sicherungswirkung von Schließringbolzen und Schraubenverbindungen, Ausschnitt Vibrationsprüf-
19 stand (unten rechts) [16, 22].
20
21
22 of bolts and lockbolts, there is an example of ex- due to the elimination of acquisition costs and in-
23 perimentally determined relationships between the stallation times for separate securing elements, Fig-
24 preload and the number of load cycles for the nom- ure 5.
25 inal diameter d = 16 mm of respective fasteners,
26 Figure 5. The curves show the loosening behavior
27 of an unsecured mechanical engineering bolt ISO 3 Assembly preload for lockbolts
28 4017-M16-8.8 with nut ISO 4032-M16 and washer
29 ISO 7089, a mechanical engineering bolt joint se- The lockbolt assembly process is basically different
30 cured with wedge-lock washers and a lockbolt sys- to the assembly process of classical mechanical en-
31 tem under comparable boundary conditions on the gineering bolts. It is defined as a volume-con-
32 vibration test bench [18–20]. The tested bolts were trolled, forming and torsion-free joining process,
33 degreased at the head bearing area and in the thread also operator-independent and it is not going to be
34 and then defined lubricated with Microgleit DF977. influenced by the installation procedure or the local
35 The evaluation of the experimental determined cor- friction conditions in the thread and in the head
36 relations between the related preload and the num- bearing area like for bolts. For bolts in mechanical
37 ber of load cycles was carried out after 2.000 load engineering a tightening factor αA is determined ac-
38 cycles had been achieved in accordance with the cording to the standard VDI 2230 – Part 1 depend-
39 standard EN DIN 25201-4 applied in rail vehicle ing on tightening procedures and local friction con-
40 construction, because the main loss of preload of ditions [2]. The scattering for the assembly preload
41 the unsecured bolt joint occurs within this number occurs from � 5 % to 60 %. The lockbolt shows a
42 of load cycles [21]. much smaller scattering of the assembly preload in
43 There is a significant advantage of the lockbolt comparison to bolts. The range is � 5 % [22]. Out
44 in direct comparison to the bolted joint. The effect of this a tightening factor of αA = 1.05 has been de-
45 of automatic unsecuring is not effective with lock- fined in the Technical Bulletin DVS-EFB 3435-2
46 bolts. A lockbolt is a vibration proofed fastener. [1]. The preload is reached by lockbolts and collars
47 Accordingly, the lockbolt system does not require with strength grades of 8.8 and 10.9.
48 an additional unscrewing safety device. A facili- During tightening the bolt with the tightening
49 tation is given with regard to feasibility. This is ac- moment MA the bolt is stressed by a tensile load,
50 companied by an increase in economic efficiency which means it gets stretched by the value fSM. Si-

1
2
3
4
5
6
7
8
9
10
11
12
13
14 Figure 6. Joint diagram for the assembly states of lockbolts (left side), characterization (description) of the tightening pro-
15 cess of lockbolts and bolts (right side) [23].
16 Bild 6. Verspannungsschaubild für den Montagezustand bei SRB (links), Charakterisierung des Anziehvorgangs bei SRB
17 und Schraube (rechts) [23].
18
19
20 multaneously, the components get compressed by
21 the value fPM. The result is the assembly preload
22 FM. The principle of equality of load applies. This
23 relationship can be transferred to lockbolt joints.
24 The joint diagram shows the load-deformation-ratio
25 for the assembly state. The tightening process for
26 lockbolt systems is presented by the assembly pre-
27 load-time-diagram, Figure 6.
28 The assembly process of lockbolts can be de-
29 scribed by the following steps:
30 1. The assembly process begins with the arrange-
31 ment of the parts by inserting the lockbolt in the Figure 7. Preload-time-curve during the assembly process
32 clearance hole. The collar gets plugged or of a lockbolt system.
33 screwed on the lockbolt on the opposite side. Bild 7. Vorspannkraft-Zeit-Verhalten bei der Schließringbol-
34 2. The preloading starts with the release of the as- zenmontage.
35 sembly process by the installation tool.
36 3. The assembly preload increases till reaching the
37 maximum value Fmax. This value marks the 4 Load bearing behavior of lockbolt joints
38 forming of the collar material into the lockbolt
39 grooves. The following section deals with the axial loaded
40 4. The load after the removal of the installation lockbolt joints. In this context the structural behav-
41 tool is called the initiated lockbolt assembly pre- ior under static and alternating (dynamic) axial load
42 load FM,SRB. will be presented. The aim of this illustration is the
43 In addition to the assembly process of the lock- explanation of the general design principle of lock-
44 bolt, a torque controlled tightening process can also bolt systems.
45 be compared with a bolt, Figure 6. If, for example,
46 ten preload-time-curves are compared to lockbolt
47 systems with a nominal diameter of d = 16 mm, the 4.1 Load bearing behavior under static load
48 extremly low scatter for the achieved assembly pre-
49 tensioning load can be seen, Figure 7. The calculation of mechanical engineering bolts un-
50 der static axial load is based on the general design

1 principle of bolts. During a static overload the me- off the collar. The load-stroke-diagram during a
2 chanical engineering bolt fails in the free loaded static concentric axial load of a lockbolt system
3 thread [7]. The conditions for this kind of failure with a bolt diameter of d = 20 mm in stroke con-
4 are an effective length of thread engagement or trolled mode of the testing machine can be charac-
5 rather a normal nut height ( = 1.0 d) as well as a terize. In the first part of the diagram the test load
6 matched strength of bolt and nut. Bolts have a high increases linear. By reaching the maximum load it
7 deformation capacity because of their sufficient comes to an audible failure (stripping off the collar)
8 material toughness. After reaching the 0.2 % proof and thereby to a sudden loss of load capacity with-
9 stress RP0,2 of the bolt there is a typical high elastic out an announcement, Figure 8.
10 plastic elongation till reaching the elongation at After reaching the maximum load the test load
11 break and the failure of the bolt. The static bolt fail- decreases rapidly. Afterwards the test load in-
12 ure appears with an announcement e. g. due to nois- creases again. The remaining collar grooves are
13 es generated by loosened components under alter- then sheared off above the lockbolt grooves until
14 nating (dynamic) load [7]. the collar is completely stripped off. The stripping
15 The lockbolt behaves completely different under off the collar is the general design principle of
16 static tensile load. The failure mode for axial load- lockbolt systems. The reason for stripping off the
17 ed lockbolt systems is characterized by stripping collar material is its lower strength compared to the
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Figure 8. Load-stroke-diagram and failure mode of lockbolt systems after static concentric (left side) and eccentric axial
32
load (right side) [23, 28].
33
Bild 8. Kraft-Weg-Verlauf und Versagensbild von Schließringbolzensystemen bei zügiger Längszugbelastung zentrisch
34
(links), exzentrisch (rechts) [23,28].
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Figure 9. Fatigue resistance of lockbolts with nominal-Ø � 20 mm (left side), nominal-Ø > 20 mm (right side).
49
50 Bild 9. Schwingfestigkeit Schließringbolzen Nenn-Ø � 20 mm (links), Nenn-Ø > 20 mm (rechts).

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Figure 10. Notch factor curve of a bolt-nut joint and a lockbolt joint [7].
19
Bild 10. Kerbfaktorverlauf an einer Schraube-Mutter-Verbindung und an einer Schließringbolzen-Verbindung [7].
20
21
22
23 lockbolt. The permitted axial substitution load FA,zul the influence of size of the bolt based on the nomi-
24 is related with reaching the 0.2 % proof stress of nal stress concept is necessary. Influence factors on
25 the stress cross section ASRB according to [22, 23]. the stress amplitude of the endurance limit σA like
26 Due to the fact that the stripping off the collar hap- the way of manufacturing the groove (bolts rolled
27 pens without an announcement an additional reduc- before heat treatment or bolts rolled after heat treat-
28 tion of the load capacity about 10 % (safety margin ment), the type of the groove (metric standard
29 SF = 1.1) is applied in the Technical Bulletin DVS- thread or fine thread) as well as the type of corro-
30 EFB 3435-2 [1]. sion protection (e. g. hot-dip galvanized) are con-
31 The comparison of the structural behavior of sidered in the guideline VDI 2230 – Part 1 [2]. In
32 lockbolt joints during concentric and eccentric stat- alternating (dynamic) loaded lockbolt joints the
33 ic axial load shows that the load-stroke-diagrams verification must be carried out in accordance with
34 are quite similar. Even in the tensile test on eccen- the guideline VDI 2230 – Part 1 with the stress am-
35 tric loaded lockbolt systems the collar stripes also plitude of the endurance limit of σA = 33.5 N/mm2
36 off while reaching the maximum load. Afterwards (nominal-Ø � 20 mm) and σA = 31.5 N/mm2 (nomi-
37 this leads to a sudden loss of the test load. How- nal-Ø > 20 mm) [1, 2]. The determination of the
38 ever, the maximum load and thus the static load ca- endurance limit was carried out in accordance with
39 pacity for eccentric axial loaded lockbolt systems is the standard DIN 969 : 1997-12 [24]. Basically this
40 almost about half less than the concentric loaded standard defines the conditions for the procedure of
41 lockbolt systems, which can be explained by the fatigue tests under axial load on threaded fasteners.
42 additional bending stress. In addition requirements are also defined for the
43 test setup as well as the testing procedure. These
44 standardized tests are tests under continuous alter-
45 4.2 Load bearing behavior under alternating nating load on fasteners providing that the type of
46 (dynamic) load preloading of the fasteners causes the axial, sinus-
47 oidal operating load FA generated by the testing
48 In alternating (dynamic) loaded bolt joints in me- machine to act completely on the fastener [7]. The
49 chanical engineering the verification of fatigue tests were only carried out in accordance to DIN
50 strength or endurance limit for the bolt considering 969 : 1997-12 to determine the endurance limit of

1 bearing groove or until the number of alternating

2 cycles during continuous loading ND = 2 · 106 ( =
3 run out) is reached. Selected results of fatigue tests
4 on lockbolts type C for the nominal diameter of
5 d = 12 mm; 20 mm; 25.4 mm and 36 mm are pre-
6 sented, Figure 9.
7 The fracture in the first load-bearing groove can
8 be uniformly determined as the typical failure type.
9 The slope of m = 3 for the fatigue strength ranges
10 is proved to be suitable.
11 The stress distribution at a bolt-nut-joint and a
12 lockbolt-joint can be compared. Due to their func-
13 tion-related design with the head, the shank and the
14 thread, bolts have critical notches which result in
15 high notch stresses σmax. The notch factor curve
16 shows that the highest notch stress occurs in the
17 first load-bearing thread, resulting in the highest
18 notch factor αK at a bolt-nut joint, Figure 10 [7].
19 The notch factor αK is the ratio of notch stress σmax
20 and nominal stress σNenn and describes local stress
21 concentrations. Measures are listed to improve the
22 endurance limit of bolts in [7]. With the aid of
23 these measures, the fatigue limit at the critical
24 notches mentioned above has to be increased. With
25 its corresponding groove geometry and the smaller
26 transition radius from the head to the shank, the
27 lockbolt fulfils these measures to increase the fa-
28 tigue limit in its design. The advantageous groove
29 geometry minimizes the local stress peaks which is
30 advantageous for lockbolt joints compared to bolt-
31 nut joints. This is reflected in the notch factor
32 curve, Figure 10.
33
34 Figure 11. Possible load types of lockbolt joints according
to Technical Bulletin DVS-EFB 3435–2 according to
35 DIN 25201–2 and VDI 2230 - Part 1 [1–2, 6].
5 Calculation of lockbolt joints
36
Bild 11. Mögliche Beanspruchungen von Schließringbol-
37 zenverbindungen nach DVS-EFB Merkblatt 3435–2 in An- The design and calculation of joints with lockbolt
38 lehnung an DIN 25201–2 und VDI 2230 – Blatt 1 [1–2, 6]. systems depends on the respective field of applica-
39 tion. The Technical Bulletin DVS-EFB 3435-2 pro-
40 vides design basics for mechanical engineering as
41 the lockbolts [24]. The test procedure was devel- well as for steel constructions in accordance with
42 oped and enables a fatigue test for lockbolt systems the series of standards EN 1993 (Eurocode 3) [1].
43 without preload [25]. To determine the fatigue The Technical Bulletin DVS-EFB 3435-2 is de-
44 strength the respective lockbolts were mounted into veloped within the scope of the DVS-EFB working
45 the test inserts with additional spacer plates in the group “Mechanical joining AGMF3/V10.3 Blind
46 tensile device of the test machine. In the course of a rivets and lockbolts“ and is taken into account a
47 static preload above the gap, the spacer plates can large number of research projects between 2008
48 be removed and the lockbolts can be tested free of and 2015 [8–9, 26–27]. In mechanical engineering,
49 preload with a constant mean load according to the especially in vehicle and rail construction, the de-
50 preload level FV,SRB until fracture in the first load- sign rules are based on the standard VDI 2230 –

1 Part 1 for the systematic calculation of highly

2 stressed bolted joints under concentric clamped and
3 concentric axial load [2]. Examples of calculations
4 for the design and calculation engineers are pro-
5 vided in the appendix of the Technical Bulletin [2].
6
7
8 5.1 Specification for the application of the
9 regulations according to VDI 2230 – Part 1
10
11 For joints with mechanical engineering bolts, a
12 general distinction between single-bolt joints sub-
13 jected to axial and / or transverse load is made. Figure 12. Division of a lockbolt into individual cylindrical
14 This is transferable to joints with lockbolts. Lock- bodies according to VDI 2230 Part 1 [1].
15 bolt joints can be calculated for different load types Bild 12. Aufteilung eines Schließringbolzens in zylindrische
16 according to DIN 25201-2 and VDI 2230 – Part 1, Körper in Anlehnung an VDI 2230 Blatt 1 [1].
17 Figure 11 [1, 2, 6].
18 The rules for the design of joints with lockbolts
19 in mechanical engineering apply basically for high tic plate resilience δP. To describe the axial resil-
20 stressed cylindrical single bolt joints according to ience of a lockbolt it is assumed that the lockbolt is
21 VDI 2230 – Part 1 [2]. The applicability of the de- composed of individual elements characterized by
22 sign rules requires a realistic transmission of static cylindrical bodies, Figure 12.
23 and alternating operating loads (axial and trans- The elastic linear deformation fi of the separate
24 verse loads) and is valid for high-strength pre- elements under an impacting concentric axial load
25 loaded lockbolts made of steel with nominal diame- FA results as follows:
26 ters of d = 5 mm to d = 36 mm or rather of d = 3/
27 16“ to d = 1“ in combination with the strength li � F
fi ¼ (3)
28 grades 8.8 and 10.9. The corresponding minimum ESRB � Ai
29 values for 0.2 % proof stress Rp0,2 and the tensile
30 strength Rm can be summarized, Table 1. The elastic resilience δi of the cylindrical sepa-
31 Joints with lockbolts must be converted into pre- rate elements of a lockbolt results further to:
32 dictable mechanical models. The loads and de-
33 formations have to be described by simple mechan- fi li
di ¼ ¼ (4)
34 ical spring models according to VDI 2230 – Part 1 F ESRB � Ai
35 [2]. The lockbolt is regarded as a tension spring
36 with the elastic resilience δSRB and the clamped If it is assumed that the separate elements like
37 components as a compressing spring with the elas- the head, shank, free loaded grooves as well as
38
39
40 Table 1. Nominal values of the yield strength, tensile strength, shear strength ratio for lockbolts in dependence of the
41
strength grade [1].
42 Tabelle 1. Nennwerte der Streckgrenze, Zugfestigkeit, Scherfestigkeitsverhältnis des SRB in Abhängigkeit von der
Festigkeitsklasse [1].
43
44 Strength grade 5.8 8.8 10.9 A2-50 A4-50
45 Rp0.2 [N/mm2] 400 640 900 190 190
46 Rm [N/mm2] 500 800 1000 500 500
Utilization factor ν of the yield point stress during tightening [–] –1) 0.7752) 0.6882) –1) –1)
47
Shearing strength ratio tB =Rm [–] 0.55 0.55 0.55 0.50 0.50
48
1) 2)
49 not suitable for preloading; a higher degree of utilization factor shall be demonstrated by experimental
50 investigations

1 Table 2. Dimensioning of lockbolts in mechanical engineering – summary of calculation steps [1].

2 Tabelle 2. Schließringbolzenauslegung im Maschinenbau – Zusammenfassung der Rechenschritte [1].
3
Requirements
4
Calculation Determination of Symbol
5 step
6
R0 Minimum clamp load FKerf
7
(considering the following requirement)
8 Frictional locking for transmission of a transverse load FQ:
9
F Qmax �SG
10 F KQ ¼ qF �mTmin
11
12 Sealing against a medium:
13
F KP ¼ AD � pi;max
14
15 Claim:
16
17 F Kerf � maxðF KQ ; F KP Þ
18
R1 Tightening factor αA = 1,05
19
20 R2 Selection of the bolt diameter (preliminary sizing) AS,erf,
21 Maximum assembly preload: d,
� � AS,vorh
22
F Mmax ¼ aA � F Mmin ¼ aA � F Kerf þ ð1 FÞ � F A þ F Z þ DF Vth
23
24 Minimum assembly preload:
25
26 F Mmin ¼ AS;vorh � n � RP0:2
27
Necessary preloadable stress cross section:
28
29 AS;erf ¼ aA �
F Kerf þð1 FÞ�F A þF Z þDF Vth
n�Rp0:2
30
31 Appreciated load factor F ¼ 0:2; loss of preload by FZ and thermal stress ΔFVth will be ap-
32 preciated at first
33
34
35
Joint diagram
36 R3 Distribution of working load/load factor n = 1,
37 Load factor during concentric preload and load: δSRB, δP,
38 FSA, FPA,
dP
Fn ¼ n � dSRB þdP Fn
39
F
40 Load factor as quotient of additional lockbolt load and axial working load:
41
F SA
42 F ¼ FA
43
44 Additional plate load:
45
F PA ¼ ð1 FÞ � F A
46
47 For the determination of F the elastic resilience of the lockbolt δSRB as well as the elastic
48 resilience of the preloaded components δP are necessary.
49
50

1 Table 2. continued
2
Requirements
3 Calculation Determination of Symbol
4 step
5
R4 Preload changes FZ, ΔFVth
6 Loss of preload as a result of embedding:
7
fZ
8 FZ ¼ ðdSRB þdP Þ
9
10 Loss of preload by different coefficients of thermal expansion:
11 lK �ðaS �DT S aP �DT P Þ
DF Vth ¼ E
dSRB ESRT
E
þdP EPRT
12 ST PT
13
14 R5 Minimum assembly preload FMmin
15 F Mmin ¼ F Kerf þ ð1 Fn Þ � F Amax þ F Z þ DF Vth
16
R6 Maximum assembly preload FMmax
17 Claim:
18
19 F Mzul � F Mmax
20 with F Mzul ¼ AS;vorh � n � Rp0:2
21
22
Stress cases & strength verifications
23
(Stress and Resilience)
24
25 R7 Examination of the selected preload FMzul
26
(assembly stress)
27 R8 Working stress σzmax,
28 Maximum load of lockbolt in working stress: SF
29
30 F Smax ¼ F Mzul þ Fn � F Amax DF Vth
31
Maximum working load in the stress cross section of bolt AS:
32
33 F Smax 1
s zmax ¼ As ¼ As � ðF Mzul þ F SAmax DF Vth Þ
34
35 Verification against the failure “slipping off the collar”:
36 Rp0;2
s zmax < 1:1
37
38 Safety margin against “slipping off the collar”:
39
Rp0;2
40 SF ¼ 1:1�s zmax � 1:0
41
42 The safety has to be defined by the design and calculation engineers.
43 R9 Alternating stress σa,
44 Alternating stress as alternating tension for concentric stress: σA, σAZ
45 SD
F SA;a F SAo F SAu F Smax F Smin
46 sa ¼ As ¼ 2�As ¼ 2�As
47
Stress amplitude of the endurance limit:
48
49 N
s A ¼ 31:5 mm2 (nominal ;� 36 mm); type B
50

2
Requirements
4 step
5
6 For the numbers of alternating cycles during continuous loading ND � 2·106
7 Verification of the dynamic strength within the fatigue strength range (NZ > 104) and slope of
8 the fatigue strength curve m = 3 [1]:
9 r�
ffiffiffiffiffiffiffiffi�ffiffi
3 ND
10 s AZ ¼ s A � NZ
11
Verification of the dynamic strength:
12
13
sa � sA
14
15 Safety margin against fatigue failure:
16
SD �s a
17 sA � 1; 0 with SD ¼ 1:2
18
19 R10 Surface pressure pMmax,
20 Surface pressure in assembled state: pBmax,
21 pG,
F Anz
22 pMmax ¼ Apmin with F Anz ¼ 0:95 � RP0:2 � As SP
23
Surface pressure in working state:
24
ðF Vmax þF SAmax DF Vth Þ
25 pBmax ¼ Apmin
26
27 Verification against exceeding of the limiting surface pressure pG (Tab. A9[2]):
28
pMmax � pG and pBmax � pG
29
30
31 R11 Slipping FKRmin,
32 Minimum residual clamp load: FKQerf,
33
μTmin,
F Mzul
F KRmin ¼ aA ð1 Fn Þ � F Amax FZ DF Vth SG
34
FQzulS,
35 Required clamp load: S A,
36 FQzulL,
F Qmax
37 F KQerf ¼ qF �mTmin SL,
38 τa,
Verification against slipping: τ A,
39
τAZ,
40
F KRmin > F KQerf SD
41
42 Safety margin against slipping:
43
F KRmin
44 SG ¼ F KQerf > 1:0 with
45
SG ¼ 1:20 ðstatic loadÞ
46
47 SG ¼ 1:80 ðalternating loadÞ
48
49 Shearing
50

2
Requirements
4 step
5 Permissible shearing capacity of the lockbolt:
6
� �
7 tB p
F QzulS ¼ tB � At ¼ Rm � Rm � 4 � d2t
8
9 Safety margin against shearing off the lockbolt:
10
F QzulS
11 SA ¼ F Qmax > 1:25
12
Permissible bolt bearing capacity of the component:
13
14 h�dt �Rp0:2P
F QzulL ¼ SL
15
16 Safety margin against bearing pressure of the bolt:
17 F QzulL
SL ¼ F Qmax > 1:0
18
19
Increased permissible bearing capacity of the bolt for components made of steel
20 and aluminum:
21
k1 �ab �h�dt �RmP
22 F QzulL ¼ SL with SL ¼ 1:25
23
Alternating stress as an alternating shearing stress;
24
25 ta ¼
F Qmax F Qmin
2�At
26
27 Stress amplitude of the endurance limit (ND � 108) under shear stress:
28
N
29 tA ¼ 23 mm2
30
Verification of dynamic strength within the fatigue strength range and slope of fatigue
31 strength curve
32 m = 5:
33 r�
ffiffiffiffiffiffiffiffi�ffiffi
34 5 ND
tAZ ¼ tA � NZ
35
36 Verification of the dynamic strength:
37
38 ta � tA
39
Safety margin against fatigue failure:
40
41 SD �ta
tA � 1:0 with SD ¼ 1:2
42
43
44
45
dSRB ¼ dSK þ dSch þ dRil þ dSR (5)
46 formed-in groove- and collar areas are arranged in
47 series the total resilience of the lockbolt can be
48 added up:
49
50

1 5.2 Calculation steps according to VDI 2230 – how the load bearing behavior of lockbolts can be
2 Part 1 described under static and alternating load under
3 the influence of an eccentric operating load FA and
4 The proof of the assembly and working stress of the associated additional bending load. The authors
5 high strength preloaded lockbolt joints in mechan- already investigated this question in the AiF public
6 ical engineering must be carried out using the cal- research project (AiF 17824BR) in order to in-
7 culation steps (R0 to R11). In regard to the charac- corporate the findings gained here into the Techni-
8 teristics of lockbolts the calculation steps existing cal Bulletin DVS-EFB 3435-2 [1, 28]. In addition,
9 for bolt joints had to be modified. For example, the recommendations for the detection of multiple bolt
10 tightening behavior (preload FV,SRB and tightening connections using the Finite Element Method are
11 factor αA), the load capacity and the load capacity generally planned for VDI 2230 – Blatt 2 [29].
12 during alternating stress are considered, Table 2.
13
14 Acknowledgement
15 6 Conclusion
16 The authors would like to express their gratitude to
17 The mode of action and applicability of the lock- the “Europäische Forschungsgesellschaft für Blech-
18 bolt is comparable to that of mechanical engineer- verarbeitung e.V.” for the fact that with the help of
19 ing bolts. Due to its strength properties, the lock- several completed public research projects the cal-
20 bolt is suitable for high-strength preloading and culation of lockbolt joints in mechanical engineer-
21 therefore exhibits closely related load-bearing be- ing in form of the Technical Bulletin DVS-EFB
22 havior with bolted joints. It is obvious in general to 3435-2 is currently possible for the design and cal-
23 apply the model for single-bolt joints for mechan- culation engineers [1, 8, 9]. In this context, the im-
24 ical engineering bolts also to the model of single- portance of joint industrial research within the
25 bolt joints for lockbolts in association with the joint framework of the AiF is pointed out. Furthermore,
26 diagram in the assembled and working states for the chairman and the members of the DVS-EFB
27 the calculation algorithm according to VDI 2230 – working group “Mechanical Joining AGMF3/V10.3
28 Part 1 and the calculation steps connected. Here, Blind rivets und lockbolts“, in particular the repre-
29 advantageous properties of the lockbolt technology sentatives of the companies Arconic Fastening Sys-
30 come into effect [2]. In this context, the operator- tems and Rings Ltd., Bombardier Transportation
31 independent, torque free assembly process with low GmbH and Titgemeyer GmbH & Co. KG will be
32 scatterings in the assembly preload (tightening fac- thanked for the active participation, discussions and
33 tor αA = 1.05) and the alternating stress resistance critical remarks which have contributed to the crea-
34 (σA = 33.5 N/mm2 for nominal diameter of tion of this Technical Bulletin.
35 � 20 mm und σA = 31.5 N/mm2 for nominal diame-
36 ter of > 20 mm) should be mentioned. In addition
37 to the advantages, the disadvantages of the lockbolt 7 References
38 technology must also be pointed out. The purchase
39 of special assembly tools is costly and un- [1] Technical Bulletin DVS-EFB 3435–2, Düssel-
40 economical, especially for small-sized companies. dorf, DVS Media GmbH, 2017.
41 However, the biggest disadvantage for the di- [2] VDI 2230 - Part 1: 2015–11, Berlin, Beuth
42 mensioning of lockbolt joints in mechanical en- Verlag GmbH, 2015.
43 gineering could be solved with the publication of [3] W. Lori, Seminarunterlagen des VDI, Düssel-
44 the Technical Bulletin DVS-EFB 3435-2 [1]. The dorf, VDI Wissensforum GmbH, 2015.
45 modified calculation steps for the design of joints [4] http://www.vdi.de/presse/artikel/neuauflage-
46 with lockbolts in mechanical engineering are pre-
des-anerkannten-vdi-regelwerks-zur-schrau-
47 sented in this article.
benberechnung/, [Online] 2017.
48 Since the calculation steps have been limited to
49 concentric clamped and loaded joints with lock-
50 bolts, the author is confronted with the question

1 [5] DIN EN ISO 898–1: 2013–05, [Hrsg.] [19] DIN EN ISO 4032: 2013–04, Deutsches In-
2 Deutsches Institut für Normung e.V., Berlin, stitut für Normung e.V., Berlin, Beuth Verlag
3 Beuth Verlag GmbH, 2013. GmbH, 2013.
4 [6] DIN 25201–2: 2015–12, [Hrsg.] Deutsches [20] DIN EN ISO 7089: 2000–11, Deutsches In-
5 Institut für Normung e.V., Berlin, Beuth Ver- stitut für Normung e.V., Berlin, Beuth Verlag
6 lag GmbH, 2015. GmbH, 2000.
7 [7] K.-H. Kloos, W. Thomala, Schrau- [21] DIN 25201–4: 2004–06, Deutsches Institut für
8 benverbindungen - Grundlagen, Berechnun- Normung e.V., Berlin, Beuth Verlag GmbH,
9 gen, Eigenschaften, Handhabung, Berlin, Hei- 2010.
10 delberg, Springer Verlag GmbH, 2007. [22] R. Glienke, C. Blunk, C. Denkert, M.-C.
11 [8] R. Glienke, M.-C. Wanner, EFB-For- Wanner, Bemessung und Ausführung von Ver-
12 schungsbericht Nr. 324, Hannover, Euro- bindungen mit Schließringbolzen im Stahlbau,
13
päische Forschungsgesellschaft für Blechver- Berlin, Ernst & Sohn Verlag für Architektur
14
arbeitung e.V. (EFB), 2011. und technische Wissenschaften GmbH & Co.
15
[9] R. Glienke, M.-C. Wanner, EFB-For- KG, 2015, 84.
16
schungsbericht Nr. 355, Hannover, Euro- [23] R. Glienke, Dissertation, Fakultät für Maschi-
17
päische Forschungsgesellschaft für Blechver- nenbau und Schiffstechnik der Universität Ro-
18
arbeitung e.V. (EFB), 2012. stock, 2013.
19
[10] DVS-EFB Merkblatt 3435–1: 2008–11, Düs- [24] DIN 969: 1997–12, Deutsches Institut für
20
21
seldorf, DVS Media GmbH, 2008. Normung e.V., Berlin, Beuth Verlag GmbH,
22
[11] H.-A. Städler, Dissertation, Fakultät Maschi- 1997.
23
nenwesen der Technischen Universität Dres- [25] W. Schneider, VDI-Berichte 478, Darmstadt,
24 den, 2012. 1983.
25 [12] C. Bye, vorgestellt auf der 14. Paderborner [26] C. Blunk, R. Glienke, M.-C. Wanner, EFB-
26 Symposium Fügetechnik, Paderborn, 2006. Forschungsbericht Nr. 410, Hannover, Euro-
27 [13] G. Junker, International Automotive En- päische Forschungsgesellschaft für Blechver-
28 gineering Congress and Exposition, Detroit, arbeitung e.V. (EFB), 2015.
29 Society of Automotive Engineers, 1969. [27] A. Ebert, R. Glienke, M.-C. Wanner, EFB-
30 [14] D. Koch, Dissertation, Siegen, Shaker Verlag Forschungsbericht Nr. 406, Hannover, Euro-
31 GmbH, 2012. päische Forschungsgesellschaft für Blechver-
32 [15] G. Dinger, Dissertation, Siegen, Shaker Ver- arbeitung e.V. (EFB), 2015.
33 lag GmbH, 2013. [28] M. Schwarz, R. Glienke, F. Wegener, W.
34 [16] E.-G. Paland, Dissertation, Technische Hoch- Flügge, EFB-Forschungsbericht Nr. 480,
35 schule Hannover, 1966. Hannover, Europäische For-
36 [17] DIN 65151: 2002–08, Deutsches Institut für schungsgesellschaft für Blechverarbeitung e.
37 Normung e.V., Berlin, Beuth Verlag GmbH, V. (EFB), 2018.
38 2002. [29] VDI 2230 - Blatt 2: 2014–12, Berlin, Beuth
39 [18] DIN EN ISO 4017: 2015–05, Deutsches In- Verlag GmbH, 2014.
40 stitut für Normung e.V., Berlin, Beuth Verlag
41 GmbH, 2015. Received in final form: September 16th 2019
42
43
44
45
46
47
48
49
50

Mawe.201900143 Nord Lock

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Mawe.201900143 Nord Lock

Hochgeladen von

Copyright:

Verfügbare Formate

Materialwiss. Werkstofftech. 2020, 51, 267–283 DOI 10.1002/mawe.

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

1 bearing groove or until the number of alternating

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

1 Part 1 for the systematic calculation of highly

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

1 Table 2. Dimensioning of lockbolts in mechanical engineering – summary of calculation steps [1].

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

© 2020 WILEY-VCH Verlag GmbH & CO. KGaA, Weinheim www.wiley-vch.de/home/muw

Das könnte Ihnen auch gefallen