Fatigue and Fretting of Self-Piercing Riveted Joints

Manufacturing ◽  
2002 ◽  
Author(s):  
K. Iyer ◽  
F. L. Brittman ◽  
S. J. Hu ◽  
P. C. Wang ◽  
D. B. Hayden ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Crack Initiation ◽  
Fatigue Cracks ◽  
Three Dimensional ◽  
Lap Joints ◽  
Experimental Program ◽  
Thick Sheet ◽  
Element Analysis ◽  
Tension Tests ◽  
Three Dimensional Finite Element

The fatigue life and fretting characteristics of aluminum alloy 5754-O self-piercing riveted lap joints have been investigated experimentally and analytically. The experimental program involves a set of 27 cyclic tension tests on three different joints consisting of either 1 mm, 2 mm or 3 mm-thick sheet specimens. In most cases (85%), fatigue cracks are found to initiate on the faying surface of the upper sheet, adjacent to the hole, and at an angular location that lies on the sheet loading axis towards the loading end. Three-dimensional finite element analysis of the three joints has also been performed. Computed distributions of local stresses and rivet-sheet slips are interpreted in terms of experimental observations of fatigue life, crack initiation location and fretting damage observations. Significantly, the calculations provide a rationale for the surprising crack initiation location.

Influence of Interference and Clamping on Fretting Fatigue in Single Rivet-Row Lap Joints

2000 ◽  
Vol 123 (4) ◽  
pp. 686-698 ◽  
Author(s):  
K. Iyer ◽  
C. A. Rubin ◽  
G. T. Hahn
Keyword(s):  
Crack Initiation ◽  
Three Dimensional ◽  
Fretting Fatigue ◽  
Cyclic Stress ◽  
Lap Joints ◽  
Element Analysis ◽  
Out Of Plane ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Fretting Damage

Primary fretting fatigue variables such as contact pressure, slip amplitude and bulk cyclic stresses, at and near the contact interface between the rivet shank and panel hole in a single rivet-row, 7075-T6 aluminum alloy lap joint are presented. Three-dimensional finite element analysis is applied to evaluate these and the effects of interference and clamping stresses on the values of the primary variables and other overall measures of fretting damage. Two rivet geometries, non-countersunk and countersunk, are considered. Comparison with previous evaluations of the fretting conditions in similar but two-dimensional connections indicates that out-of-plane movements and attending effects can have a significant impact on the fatigue life of riveted connections. Variations of the cyclic stress range and other proponents of crack initiation are found to peak at distinct locations along the hole-shank interface, making it possible to predict crack initiation locations and design for extended life.

Progressive fatigue behavior of single-lap bolted laminates under different tightening torque magnitudes

2020 ◽  
Vol 234 (10) ◽  
pp. 1303-1312
Author(s):  
M Feyzi ◽  
S Hassanifard ◽  
A Varvani-Farahani
Keyword(s):  
Finite Element ◽  
Fatigue Life ◽  
Fatigue Behavior ◽  
Damage Model ◽  
Three Dimensional ◽  
Bolted Joints ◽  
Element Analysis ◽  
Damage And Failure ◽  
Experienced Fatigue ◽  
Three Dimensional Finite Element

The present paper studies fatigue damage and life of single-lap bolted joints tightened with different torque magnitudes subjected to uniaxial load cycles. The adherends were constructed from E-glass/epoxy layers using a hand layup technique and assembled by 1.5, 3, and 8 N m of applied torques. Increasing the torque magnitude benefitted the final fatigue life of the joints so that the high-cycle fatigue life of the joint sample tightened with 8 N m was as high as 10 times that of the joint tightened with 1.5 N m. In the numerical section of this study, a three-dimensional finite element analysis was employed, and the impacts of applied torques were included in the progressive damage model to assess damage and failure in the bolted joints. For the joints tightened with higher torque levels, numerical results revealed higher fatigue lives but at the cost of more delamination at the vicinity of the hole. Laminate fracture surface was investigated through scanning electron microscopy and more cracking/damage progress was evidenced in matrix, fiber, and matrix–fiber interface as composite joints experienced fatigue cycles. Experimental life data of tested joints agreed with those anticipated through the use of finite element analyses indicating the developed model as an appropriate tool in evaluating the effects of applied torques on the fatigue fracture behavior of bolted laminates.

Fatigue Life Evaluation of Vehicle Wheel Bolts under Random Loading

2005 ◽  
Vol 297-300 ◽  
pp. 1770-1775 ◽  
Author(s):  
Young Woo Choi ◽  
Byeong Wook Noh ◽  
Kyung Chun Ham ◽  
Sung In Bae
Keyword(s):  
Fatigue Life ◽  
Residual Life ◽  
Three Dimensional ◽  
Real Life ◽  
Local Stress ◽  
Tensile Tests ◽  
Fatigue Tests ◽  
Random Loading ◽  
Element Analysis ◽  
Three Dimensional Finite Element

The fatigue life of hexagon head and socket head bolts, attached to vehicle a wheel, is assessed and the estimation of the residual life of existing bolts in vehicle wheel is investigated. Field- measured load histories were applied in this test. Tensile tests and fatigue tests were performed to evaluate the effect of tightening torque and to obtain the basic experimental data. A three-dimensional finite element analysis was also performed to evaluate the local stress fields. Miner’s rule was used to predict the fatigue life of bolts. The results indicate the prediction of fatigue life of the bolts was in good agreement with the real life of vehicle wheel bolts in this test.

Three-Dimensional Analysis of Double Rivet-Row Lap Joints: Part I — Non-Countersunk Rivets

2001 ◽  
Author(s):  
K. Iyer ◽  
C. A. Rubin ◽  
G. T. Hahn
Keyword(s):  
Finite Element Analysis ◽  
Three Dimensional ◽  
Lap Joints ◽  
Lap Joint ◽  
Double Row ◽  
Element Analysis ◽  
Single Row ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Contact Pressures

Abstract Three-dimensional finite element analysis of an elastic, double rivet-row, aluminum alloy lap joint with non-countersunk aluminum rivets, is presented. The compliance of the connection, rivet tilt, peak contact pressures and slip amplitudes, in the absence of interference and clamp-up, are described. Rivet-panel slips in the double-row assembly are between 50–60% of those calculated for the single-row case. Contrary to the expectation that the second row of rivets might reduce the stress concentration factor by half, the additional row of rivets provides a reduction of only 28%.

Fatigue Crack Initiation and Propagation in SuperCMV Hollow Shafts with Transverse Holes

2011 ◽  
Vol 70 ◽  
pp. 141-146 ◽  
Author(s):  
Ran Li ◽  
W. Sun ◽  
Thomas H. Hyde ◽  
Edward J. Williams ◽  
Xing Guo Wang
Keyword(s):  
Fatigue Crack ◽  
Crack Initiation ◽  
Crack Growth ◽  
Fatigue Cracks ◽  
Fatigue Crack Initiation ◽  
Three Dimensional ◽  
Axial Loading ◽  
Maximum Principal Stress ◽  
Experimental Results ◽  
Three Dimensional Finite Element

A fatigue crack growth test program has been carried out on hollow, SuperCMV shaft specimens, with transverse holes, under combined torsional and axial loading. The experimental results show that fatigue cracks always initiated in the stress concentration areas, i.e., in the transverse holes. Up to four cracks were observed to be initiated at different positions near the holes in the shafts. The fatigue crack propagation was initially found to occur under Mode I conditions, followed by a period of mixed Mode II/III crack growth. Three dimensional, finite element, elastic-plastic analyses have also been conducted, in an attempt to predict the crack-initiation locations and lives. The predicted crack-initiation sites agree with the experimental observations, for a range of loading conditions. The initiation sites were found to be approximately on the planes of maximum principal stress. The predicted, torque-dominated, fatigue lives of the shafts, obtained by use of a stress-life (S-N) approach, correlate reasonably well with the experimental results.

Analytical Modeling of Cylinder Head Distortion to Eliminate Intake Valve Burning

2001 ◽  
Author(s):  
Cherng-Chi Chang ◽  
William Wistehuff
Keyword(s):  
Finite Element ◽  
Cylinder Head ◽  
Three Dimensional ◽  
Engine Performance ◽  
Element Model ◽  
Experimental Program ◽  
Development Phase ◽  
Intake Valve ◽  
Element Analysis ◽  
Three Dimensional Finite Element

Abstract Intake valve seat recession and subsequent valve leakage were experienced during the late development phase of a new DOHC aluminum engine. This type of failure was not observed in the earlier development phase during engine break-in. To resolve this valve burning issue, a three-dimensional finite element model was used to study the thermal/mechanical behavior of this engine. A parallel experimental program was conducted to evaluate the effect of the hardware changes between the early and late engine development phases on engine performance. The experimental effort also provided engine temperature and measured distortion data for validating the analytical model. The finite element analysis was able to identify the root cause of this condition and to propose structural modifications to remedy this problem rapidly by predicting the distortion and stress distribution within the cylinder head.

Three-Dimensional Analysis of Double Rivet-Row Lap Joints: Part II — Countersunk Rivets

2001 ◽  
Author(s):  
K. Iyer ◽  
C. A. Rubin ◽  
G. T. Hahn
Keyword(s):  
Three Dimensional ◽  
Peak Stress ◽  
Companion Paper ◽  
Lap Joints ◽  
Lap Joint ◽  
Stress Concentrations ◽  
Element Analysis ◽  
Dimensional Finite Element ◽  
Stress Concentration Factors ◽  
Three Dimensional Finite Element

Abstract Three-dimensional finite element analysis of an elastic, double rivet-row, aluminum alloy lap joint with countersunk, aluminum and steel rivets, is presented. Relations between the connection compliance, rivet deformation, peak contact pressures and slip amplitudes, in the absence of interference and clamp-up, are described. Analysis of a connection with non-countersunk rivets is presented in a companion paper. The trends seen in the results are similar to those obtained with non-countersunk rivets, although the peak stress concentrations in the present case are much higher. A superposition approach for estimating stress concentration factors in the panels of multi-row riveted connections with standard or countersunk rivets is presented.

Sign in / Sign up

Export Citation Format

Share Document