Analysis of Stress Concentration in Bolt-Nut Connectors

1. INTRODUCTION

Nuts and bolts have been used in a wide range of engineering structures over
hundreds of years. Fastening and joining is the method of bringing together,
connecting and uniting to become one unit. There are many types of fasteners such as
bolts and nuts, adhesive bonds, welds, rivets etc. Nuts and boltsare mainly the type of
mechanical fasteners widely used. They are used in assemblies for their strength, re-
usability and easy disassembly.

Bolt-nut connectors play an important role in the safety and reliability of structural
systems. The number of bolt-nut connectors used in some complex structures are
`more. For example, on an average, 2.4 million different fasteners are used to
assemble a Boeing 747 aircraft. Out of this, 22% are Bolt-nut connectors . So, the
importance of study of failures of bolt and nut are always emphasized. One of the
main reason of failure of bolts and nuts is the stress concentration. The load
distribution in bolt-nut connector is very unequal due the presence of variable cross-
section along the length. Results in high stress concentration at the thread roots
because of less area of cross-section. Several researchers have studied the stress
distribution in bolt-nut connectors using experimental methods like photoelasticity to
study the stress distribution in bolt-nut joints. With advances in computational
methods of stress analysis, it has become much easier to study the stress distribution
in bolt-nut joints. The photoelasticity method is time consuming and expensive, and
can have lower resolution than do computational methods such as finite element
analysis FEA.

In the last decade the finite element method (FEM) or finite element analysis
(FEA) has become prevalent technique used for analyzing physical phenomena. FEM
has very wide applications for the solutions of problems in the field of engineering
such as mechanical design, mechanical vibrations, aeronautical engineering, heat
transfer, fluid mechanics, soil and rock mechanics, bio-engineering etc. With aid of
FEM, we can reduce the computational time and valuable expenses.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

The comparative study among the various proposed or existing models can be
effectively studied. The objective of the study is to show a quantitative comparison of
various design modifications and to provide design guidelines on the most efficient
ways to modify the design of bolt-nut connectors to minimize the stress concentration.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

2. LITERATURE REVIEW

 In the past, several researchers have studied the stress distribution in bolt-nut
connectors using computational and experimental methods.
 Fukuoka T.et al. has investigated how the maximum stress occurred in the bolted
joint could be reduced. A modified nut with a curved bevel is also treated, and it is
concluded that the modified nuts are significantly effective for bolts with larger
nominal diameter and fine pitch.
 Hobbs J. W., Burguete R. L., Patterson E. A.et al. have used two dimensional
models of bolt for stress distribution study using FEM. A number of models
representing different positions were created to obtain more data for the stress
distribution.
 Kim Jeong , Yoon Joo-Cheol, Kang Beom-Soo et al. have introduced a modeling
technique of the structure with bolted joints. Four kinds of finite element models are
introduced; a solid bolt model, a coupled bolt model, a spider bolt model, and a no-
bolt model.
 Mackerle Jaroslav et al.has given a bibliographical review of finite element
methods applied for the analysis of fastening and joining. The bibliography at the
end of the paper contains 726 references to papers and conference proceedings.
These are classified in the following categories: pin joints, thread connections,
bolted joints, screws, nuts, rivets, fittings, tubular joints and other types of fastening.
 Venkatesan Sriman et al. has studied the stress distribution in the bolt-nut
connectors using an axisymmetric finite element model. Various geometric designs
proposed in the literature were studied to determine the extent to which they reduce
stress concentrations.
 The current seminar work have modelled the nut and bolt using finite element
software (Ansys Workbench). Different design modifications were studied to
minimize the stress concentration.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

3. THE FINITE ELEMENT MODEL

The basic model of bolt-nut connector used is M20×2.5 bolt. That is 20mm
diameter bolt and 2.5mm pitch with plain hexagonal nut.The screw threads are metric
type for both internal and external threads.The root radius for the threads is taken as
H/6 where H is the thread height. This form is followed for all the models.The basic
shape of threads is as shown in Fig. 1.

Fig. 1 Basic Metric Threads for M20×2.5

 The basic dimensions are

Major diameter (Do) = 20mm
Minor diameter (Di) = 16mm
Pitch (p) = 2.5mm
Angle = 600
 The material for the bolt and nut is structural steel having Young’s modulus E =
200GPa and Poisson’s ratio µ = 0.3.

Here contact between the bolt and nut is analyzed using the finite element software
ANSYS Workbench 14.5.Elements used are auto generated in default mesh generator
in ANSYS.A pressure is applied to the elemental edge at the head.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

 Fig. 2 shows the basic model of bolt and nut used for the study. It also shows the
load and boundary conditions used for the given model.
 Each bolt-nut combinations is modeled using the axisymmetryin two-dimensional
with displacement constraints applied to the geometric edges. The axis of symmetry
of the bolt is constrained in the radial direction.
 Such a model as being axisymmetry, which enables a three-dimensional object to be
represented in two-dimensional. This is obviously a simplification as certain aspects
of the three-dimensional geometry are neglected, most notably the helix angle.
 A surface pressure of P =0.1MPa was applied to the top surface of the bolt.
 The upper surface of the nut is also constraint in the vertical direction while the
lower surface is free.
 Helix angle has been ignored in the study. The helix angle is very small (less than
40) on most of the bolts so the three dimensional effect will be very small.
 For each model the stress concentration factor is calculated as the ratio of maximum
stress in the nut-bolt system to the nominal stress in the shank of the bolt.

Fig. 2 Load and boundary conditions for the base model (Model A)

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 Analysis of Stress Concentration in Bolt-Nut Connectors

Material Properties :-

 The material used in the analysis for both bolt and nut is structural steel.
 Properties of structural steel – Young’s modulus E = 200GPa and Poisson’s
Ratio µ = 0.3

Constraints :-

 The axis of symmetry of the bolt is constrained in the radial direction.

 The upper surface of the nut is also constraint in the vertical direction while
the lower surface is free.

Loading Conditions :-

 Load is acting on the bolt at the top surface in the form of surface pressure.
 No direct load is acting on the nut.
 A surface pressure of P = 0.1 MPa was applied to the top surface of the bolt
 Fig. 2 shows the surface pressure acting on the top in positive Y-direction.

The maximum principal stress is obtained from the finite element analysis. The
highest stress is found to occur at the first thread in bolt and decreases at subsequent
threads .Fig. 3 shows the finite element mesh for both nut and bolt in contact and
stress distribution at the contacting threads.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

Fig. 3 Finite element mesh and stress distribution at the contacting threads

After the solving the model, results of the maximum stresses in the bolt and nut are
obtained as shown in the Fig. 3. Red colored section near the root of the last thread
denotes the maximum stress in the bolt. Green colored section denotes less stress. The
stress concentration factor is found out to be 7.63 for the base model.

Validation of the FEA results :-

Finite element Analysis is an approximate solution technique. Hence, results

obtained from it must be valid and must be compared with experimental techniques.
Patterson and Kenny have experimentally studied the effect of some design
modifications of bolt-nut connectors on stress concentration . Patterson and Kenny
used photo elastic analysis. Maruyama produced finite element models that were two
dimensional and axis symmetric. He found good correlation between the results from
his finite element model and from photo elastic analysis of Patterson and Kenny.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

Effect of Friction :-

When the coefficient of friction at the thread interface is increased, the stress
concentration factor decreases as shown in Table 1.The zero friction case gives the
highest stress concentration factor, and hence, it is the worst case from a design stand
point. In this study ,the coefficient of friction is taken to be zero to consider the worst
case scenario helping in safety point of view. Table 1 shows the effect of coefficient of
friction between threads (µ) on stress concentration factor (K) for base model.

Table 1 Effect of coefficient of friction between threads on stress

concentration factor for base model

Coefficient of friction between the threads (µ) K

0 7.63
0.15 7.02
0.30 6.97

4. DESIGN MODIFICATIONS :-
The base model (Fig. 2) represents a plain bolt-nut connectors and
corresponding load and boundary conditions. The stress concentration factor is
found out to be 7.63 for the base model. In order to reduce the stress concentration
factor, various modifications are made in either bolt or nut or in both. The bolt-nut
connector model shown in Fig. 2 is the base model for the study. The base model
is designated as Model A (Fig. 2).Various modifications were done in the design of
Model A and are named from Model B to Model E. Model B to model E
incorporates the different modifications in model A which are stated in further.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

Effect of Reduction of Shank Diameter of the Bolt :-

When the shank diameter of the bolt is reduced for the base model, the stress
concentration factor is found to decrease significantly.For the bolt having shank
diameter equal to major diameter, the stress flow lines are prone to deviate from
their path . Hence produces more stress concentration at the deviation point as
shown Fig. 4.For the bolt having shank diameter equal to minor diameter, the stress
flow lines goes straight without deviating from their path. Hence having less stress
concentration, as shown in Fig. 5.Hence in the study for all models including base
model, shank diameter is kept equal to minor diameter.

Fig. 4 Bolt of shank diameter = major Fig. 5 Bolt of shank diameter = minor
diameter diameter

5. MODEL B :-
In this design modification, a groove is added to the face of the nut which is closer
to the head of the bolt.The depth of the groove is limited to half the height of nut (H)
so as to ensure enough material to support the wrench when nut is tightened.In all
cases, the location of the maximum principal stress is at the root of the first thread of
the bolt in contact with the nut.
The different modified dimensions for model B are taken as,
a= H/2, b=h=W/4, r= [w-(b+h)]/2.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

Fig. 6 Model B – Groove in the nut

This design results in the stress concentration factor of 5.81, which is reduction of
24% compared to the base model.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

6. MODEL C

In model C, a step is added to the nut, and there are no grooves in the bolt.Modified
dimensions of the nut for model C are taken as [5]
h= H/2, b= W/2, r= W/4.
The corresponding model shown in the Fig. 7.

Fig. 7 Model C – Step on the Nut

This design results in the stress concentration factor of 5.40, which is reduction of
29% compared to the base model.The location of the maximum principal stress is
the same as the base model that is at the root of the first thread of the bolt in contact
with the nut.It was found that a design that incorporated a step on the nut in addition
to a groove on the lower end of the bolt (which is next model, model D) gives much
lower stress concentration factor.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

7. MODEL D

In this design, there is a step on the nut (as in the model C), in addition to which
there is a groove on the lower end of the bolt.Modified dimensions of the nut for
model D are taken as [5]
h= H/2, b= W/2, r= W/4,
Whereas for the bolt are as
hb= 0.5T, rb= Di/4.
The corresponding model shown in the Fig. 8.

Fig. 8 Model D – Step on nut and groove on bolt

This design results in the stress concentration factor of 4.61, which is reduction of
40% compared to the base model.The location of the maximum principal stress is
the same as the base model that is at the root of the first thread of the bolt in contact
with the nut.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

8. MODELE :-

Now, among all the above modifications from model B to model D, model D is
found to give the lowest value of stress concentration factor.The reduction in the
shank diameter of the bolt results in a significant decrease in stress concentration
factor. A new model is therefore investigated, which combines the effect of a
reduction of a shank diameter with the features of previous model, model D.Hence,
the model E has a step on the nut, a groove on the lower end of the bolt and the shank
diameter is reduced.
The various dimension of the nut for the model E are [5]
h= H/2, b= W/2, r= W/4.
Whereas for the bolt are as
d=0.8Di, hb= 0.5T, rb= Di/4.
Refer Fig. 9 for the model E.

Fig. 9 Model E – Step on the nut, groove on the bolt and reduced shank diameter of
the bolt
The stress concentration factor for model E comes out as 3.54 which is
lowest of all the models. The stress concentration factors reduces when the shank
diameter decreases.When the shank diameter is less than or equal to 0.5Di, the stress
concentration factordepends solely on the shank diameter and is independent of the
geometry at the threaded portion.
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 Analysis of Stress Concentration in Bolt-Nut Connectors

Table 2 Different design modifications

Design Description Modified Design Stress

concentration
factor
Model A 7.63
This is a base model
consisting a bolt of
M20×2.5 and corresponding
nut.
Model B 5.81
A groove is added to the nut.

Model C 5.40
A step is added to the nut
with no grooves on the bolt.

Model D 4.61
A step is added to the nut
and a groove is added lower
end of the bolt.

Model E 3.54
A step is added to the nut
and a groove is added lower
end of the bolt. The shank
diameter of the bolt is
reduced.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

9. SUMMARY

 The study shows that the most significant reduction in stress concentration can
be achieved by reducing the shank diameter. However, if the system is based on
the shank diameter size then reducing the shank diameter may not be the best
option.
 It is possible to reduce the stress concentration factor by incorporating the steps
and grooves on the nuts and bolts even without the reduction of the shank
diameter. For example, the model D having a step on the nut and a groove on the
lower end of the bolt gives a stress concentration factor reduction up to 40% of
the model A.
 Model E featuring a groove on the lower end of the bolt, a step to the nut and a
reduction of the shank diameter gives the maximum reduction in stress
concentration.
 All the modifications in the nuts and bolts remove material, results in a better
material utilization and cost point of view.

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 Analysis of Stress Concentration in Bolt-Nut Connectors

10. REFERENCES

Research Papers

[1] Fukuoka T., “Evaluation of the Method for Lowering Stress Concentration at
the Thread Root of Bolted Joints With Modifications of Nut Shape”, ASME, J.
Pressure Vessel Technology, Feb 1997, 119(1), pp. 1-9.
[2] Hobbs J. W., Burguete R. L., Patterson E. A., “Investigation into the Effect of
the Nut Thread Run-Out on the Stress Distribution in a Bolt Using the Finite
Element Method,” ASME, Journal of Mechanical Design, September 2003,
Vol. 125/527.
[3] Kim Jeong , Yoon Joo-Cheol, Kang Beom-Soo, “Finite Element Analysis and
Modeling of Structure with Bolted Joints”, Elsevier, Applied Mathematical
Modelling, 2007, 31, pp. 895 – 911.
[4] Mackerle Jaroslav, “Finite Element Analysis of Fastening and Joining: A
Bibliography (1990–2002)”, Elsevier, International Journal of Pressure
Vessels and Piping 2003, 80, pp. 253-271.
[5] Venkatesan Sriman, “Reduction of Stress Concentration in Bolt-Nut
Connectors”, ASME, Journal of Mechanical Design, November 2006, Vol.
128/1337.

Research Books

[6] Bhandari V. B., “Design of Machine Elements”, Third edition, McGraw-Hill,

2010, pp.141 – 181, 219 – 230.
[7] Shigley J. E., “Mechanical Engineering Design”, Eighth edition, McGraw-
Hill, 2008, pp.398 – 460.

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