Method for Determining the Stress in a Bolted Joint Important Note This summary of the VDI 2230 Standard is intended to provide a basic understanding of the method. Readers who wish to put the standard to use are urged to refer to the complete standard that contains all information, figures, etc. Definitions • Covers high-duty bolted joints with constant or alternating loads • Bolted joints are separable joints between two or more components using one or more bolts • Joint must fulfill its function and withstand working load Aim of Calculation Determine bolt dimension allowing for: • Strength grade of the bolt • Reduction of preload by working load • Reduction of preload by embedding • Scatter of preload during tightening • Fatigue strength under an alternating load • Compressive stress on clamped parts 1. Range of Validity • Steel Bolts • M4 to M39 • Room Temperature 2. Choice of Calculation Approach • Dependent upon geometry – Cylindrical single bolted joint – Beam connection – Circular plate – Rotation of flanges – Flanged joint with plane bearing face Cylindrical Single Bolted Joint • Axial force, FA • Transverse force, FQ • Bending moment, MB Beam Geometry, Ex. 1 • Axial force, FA • Transverse force, FQ • Moment of the plane of the beam, MZ Beam Geometry, Ex. 2 • Axial force, FA • Transverse force, FQ • Moment of the plane of the beam, MZ Rotation of Flanges • Axial force, FA (pipe force) • Bending moment, MB • Internal pressure, p Flanged Joint with Plane Bearing Face, Ex. 1 • Axial force, FA (pipe force) • Torsional moment, MT • Moment, MB Flanged Joint with Plane Bearing Face, Ex. 2 • Axial force, FA (pipe force) • Transverse force, FQ • Torsional moment, MT • Moment, MB Flanged Joint with Plane Bearing Face, Ex. 3 • Axial force, FA (pipe force) • Transverse force, FQ • Torsional moment, MT • Moment, MB 3. Analysis of Force and Deformation • Optimized by means of thorough and exact consideration of forces and deformations including: – Elastic resilience of bolt and parts – Load and deformation ratio for parts in assembled state and operating state 4. Calculation Steps • Begins with external working load, FB • Working load and elastic deformations may cause: – Axial force, FA – Transverse force, FQ – Bending Moment, MB – Torque moment, MT Determining Bolt Dimensions • Once working load conditions are known allow for: – Loss of preload to embedding – Assembly preload reduced by proportion of axial bolt force – Necessary minimum clamp load in the joint – Preload scatter due to assembly method Calculation Step R1 • Estimation of bolt diameter, d • Estimation of clamping length ratio, lK/d • Estimation of mean surface pressure under bolt head or nut area, pG • If pG is exceeded, joint must be modified and lK/d re-determined Calculation Step R2 • Determination of tightening factor, A, allowing for: – Assembly method – State of lubrication – Surface condition Calculation Step R3 • Determination of required average clamping load, Fkerf, as either: – Clamping force on the opening edge with eccentrically acting axial force, FA Or – Clamping force to absorb moment MT or transverse force component, FQ Calculation Step R4 • Determination of load factor, including: – Determination of elastic resilience of bolt, S – Evaluation of the position of load introduction, n*lK – Determination of elastic resilience of clamped parts, P – Calculation of required substitutional cross- section, Aers Calculation Step R5 • Determination of loss of preload, FZ, due to embedding • Determination of total embedding Calculation Step R6 • Determination of bolt size and grade – For tightening within the elastic range, select bolt for which initial clamping load is equal to or greater than maximum initial clamping load due to scatter in assembly process – For tightening to yield, select bolt for which 90% of initial clamping load is equal to or greater than minimum initial clamping load due to scatter in assembly process Calculation Step R7 • If changes in bolt or clamping length ratio, lK/d, are necessary, repeat Steps R4 through R6 Calculation Step R8 • Check that maximum permissible bolt force is not exceeded Calculation Step R9 • Determine alternating stress endurance of bolt • Allow for bending stress in eccentric load applications • Obtain approximate value for permissible stress deviation from tables • If not satisfactory, use bolt with larger diameter or greater endurance limit • Consider bending stress for eccentric loading Calculation Step R10 • Check surface pressure under bolt head and nut bearing area • Allow for chamfering of hole in determining bearing area • Tables provide recommendations for maximum allowable surface pressure • If using tightening to or beyond yield, modify calculation 5. Influencing Factors • Allow for factors depending upon: – Material and surface design of clamped parts – Shape of selected bolts and nuts – Assembly conditions Strength of the Bolt • Stress caused by: – Torsional and axial stresses during tightening – Working load • Should not exceed yield load Minimum Thread Engagement • Depends upon: – Thread form, pitch, tolerance, and diameter – Form of the nut (wrenching width) – Bolt hole – Strength and ductility of bolt and nut materials – Type of stress (tensile, torsional, bending) – Friction coefficients – Number of tightenings Thread Shear Strength • Bolt-Nut Strength Matching • Number for strength grade of nut is equivalent to first number of strength grade of bolt Calculation of Required Nut Height • Allows for geometry and mechanical properties of joint elements • Predicts type of failure caused by overloading • Considers: – Dimensional values (tensile cross-section of bolt thread, thread engagement length, etc.) – Thread form & nut form – Bolt clearance hole Bolt Head Height • Ensures that failure will occur in free loaded thread section or in the shank • Highest tensile stress in thread < Highest tensile stress in bolt head Surface Pressure at Bolt Head & Nut Bearing Areas • Calculation determines surface pressure capable of causing creep resulting in loss of preload • Surface pressure due to maximum load should not exceed compressive yield point of clamped material Tightening Factor, Alpha A • Allowance must be made for torsional stress caused by pitch and thread friction, and axial tensile stress • Scatter in friction coefficients and errors in method of controlling preload create uncertainty in level of tensile and torsional stress • Tightening factor, A, reflects amount of required “over-design” Fatigue Strength • Design modifications to improve endurance limit of joint – Increase preload – Reduce pitch of screw thread – Reduction of modulus of nut material elasticity – Increase thread engagement Fatigue Strength -Continued • Design modifications to improve endurance limit of joint – Change form of nut – Reduce strength of nut material – Increase elastic resilience of bolt, lower elastic resilience of parts – Shift introduction of load toward interface Embedding • Caused by flattening of surface irregularities • Affects forces in joint • Reduces elastic deformation and preload Self-Loosening and Prevention • Preload drops due to: – Relaxation as a result of embedment or creep – Rotational loosening due to relative movements between mating surfaces 6. Calculation Examples • Ex. 1, Concentric Clamping and Concentric Loading • Ex. 2, Transverse Shearing Force • Ex. 3, Torsional Shearing Load • Ex. 4, Eccentric Clamping and Eccentric Loading • Ex. 5, Eccentric Clamping and Loading