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Bulk Head Bolt

Problem:
The figure illustrates the connection of a cylinder head to a pressure vessel using 10 bolts and a confined-gasket seal. The effective sealing diameter is 150 mm. Other dimensions are A = 100, B = 200, C = 300, D = 20, and E = 25, all in millimeters. The cylinder head is used to store gas at a static pressure of 6 Mpa. ISO class 8.8 bolts with a diameter of 12 mm have been selected. This provides an acceptable bolt spacing. Find the stress in the bolts after the pretension load is applied and then again after the external load is applied. In the model use At as the diameter of the bolts across the entire length of the bolt.

Joseph Shigley and Charles Mischke. Mechanical Engineering Design 5th ed. New York: McGraw Hill, May 2002.

Bulk Head Bolt


Overview

Anticipated time to complete this tutorial: 1 hour

Tutorial Overview
This tutorial is divided into six parts: 1) Tutorial Basics 2) Problem Planning 3) Preprocessing 4) Solution 5) Post-Processing 6) Hand Calculations

Audience
This tutorial assumes an intermediate knowledge of ANSYS 8.0; therefore, it goes into moderate detail to explain each step. A problem planning section has been added to help set up the problem. More advanced ANSYS 8.0 users should be able to complete this tutorial fairly quickly.

Prerequisites
1) ANSYS 8.0 in house Structural Tutorial 2) Completion of three or more Basic Machine Design Tutorials

Objectives
1) Use a pretension mesh in ANSYS to apply the bolt preload 2) Solve for the preload stress in the bolt 3) Apply external loads to the bolt joint 4) Solve for the final stress in the bolt

Outcomes
1) Learn how to set up the problem before starting Ansys 2) Increase familiarity with the graphical user interface (GUI) 3) Learn how to create and mesh more complex geometries 4) Increase familiarity with post processing tools

Bulk Head Bolt


Tutorial Basics
In this tutorial: Instructions appear on the left. Visual aids corresponding to the text appear on the right. All commands on the toolbars are labeled. However, only operations applicable to the tutorial are explained. The instructions should be used as follows: Bold > Text in bold are buttons, options, or selections that the user needs to click on > Preprocessor > Element Type > Add/Edit/DeleteFile would mean to follow the options as shown to the right to get you to the Element Types window Text in italics are hints and notes Click on the left mouse button Click on the middle mouse button Click on the right mouse button

Example:

Italics

MB1 MB2 MB3

Some basic ANSYS functions are: To rotate the models use Ctrl and MB3. To zoom use Ctrl and MB2 and move the mouse up and down. To translate the models use Ctrl and MB1.

Bulk Head Bolt


Problem Planning
Take a few minutes to plan out your solution to this problem. Your plan should include some of the following items: 1) Obtain all necessary known informa- 4) Plan appropriate loads and constraints. tion. The bolt preload will be applied External Load per Bolt, P: using the pretension feature in ANSYS. If At: you model only half of the bolt section, you can apply symmetrical boundary conRt (based on At): straints to the model. If you model only Rbolt head: half of the bolt section, you also need to Material 1 apply only half of the preload force and Youngs Modulus: half of the external load (since the area is Poisson's Ratio: half of what it normally would be). Thickness: Keypoints at the bottom of the bolt can be Material 2 fixed to prevent rigid body displacement. Youngs Modulus: Poisson's Ratio: 5) Identify which results will be analyzed. Thickness: Preload Force, Fi: You are asked to find the pretension stress in the bolt and to find the final stress 2) Plan a simple, representative geometry. in the bolt after the external load is applied. To do this, you can select the nodes in the The entire bulk head does not need center of the bolt and then make a list of the to be modeled. One of the 10 bolts will suf- stresses in those nodes. This can also be fice. The Create Cylinder by Dimensions repeated after the external load is applied. volume modeling tool is a good tool to create the volumes used in this problem. You might create half of the bolt section so that you can see the stresses in the bolt. After the volumes are created, they can be glued together to prevent separation during the analysis. 3) Contemplate an appropriate element for the mesh. Since you are creating a solid model from a volume, use an element listed under the Solid category (possibly use Solid92).

Bulk Head Bolt


Preprocessing
1) Change the working directory and jobname. 2) Set Preferences to Structural. 3) Add a Solid92 element. 4) Create the Material Models. Material 1 E: 207e9 PRXY: .292 Material 2 E: 113e9 PRXY: .211 5) Set a scalar parameter for Rt. > Parameters > Scalar Parameters R=.00518 6) Create the volumes representing the bolt shaft, bolt head, nut, and material layers. > Preprocessing > Modeling > Create > Volumes > Cylinder > By Dimensions Volume 1: Nut Outer Radius: Inner Radius: Z1: Z2: Starting angle: Ending angle: Volume 2: Bolt Head Outer Radius: Inner Radius: Z1: Z2: Starting angle: Ending angle:

3*R 0 -.0108 0 0 180

3*R 0 .045 .0558 0 180

Bulk Head Bolt


Preprocessing
Volume 3: Bolt Shaft Outer Radius: Inner Radius: Z1: Z2: Starting angle: Ending angle: R 0 0 .045 0 180

Volume 4: Bottom Material Layer Outer Radius: .03 Inner Radius: .0065 Z1: 0 Z2: .025 Starting angle: 0 Ending angle: 180 Volume 5: Top Material Layer Outer Radius: .03 Inner Radius: .0065 Z1: .025 Z2: .045 Starting angle: 0 Ending angle: 180 Your model should appear similar to the one shown to the right. 7) Glue all the volumes together. > Preprocessor > Modeling > Operate > Booleans > Glue > Volumes > Pick All 8) Compress the model numbering. The NUMCMP command compresses out unused item numbers by renumbering all the items, beginning with one and continuing throughout the model. > Main Menu> Preprocessor > Numbering Ctrls > Compress Numbers > All Replot the volumes if necessary.

Bulk Head Bolt


Preprocessing
9) Mesh the volumes using the mesh tool. Make sure that smart sizing is turned off. Under Element Attributes, choose Global and click Set. Set the Material number to 1 and click OK. Click Mesh. Select the bolt shaft, bolt head, nut, and top material layer volumes to be meshed. In the MeshTool dialog box, choose Global and click Set under Element Attributes. Set the Material number to 2 and click OK. Click Mesh. Select the bottom material layer to be meshed. Plot Elements. Your model should appear similar to the one shown to the right. 10) Apply the pretension. Select: > Main Menu > Preprocessor > Sections > Pretension > Pretensn Mesh > With Options > Divide at Valu > Elements in Volu Pick the bolt shaft volume and click OK in the picker. Enter the following information in the dialog box and click OK: NAME: Pretension KCN: Global Cartesian KDIR: Z-axis VALUE: 0.0225 ECOMP: elems

Bulk Head Bolt


Preprocessing
11) View the pretension section. Select: > Utility Menu > Select > Comp/Assembly > Create Component Enter Line for the Component name. Choose Lines for the Entity and click OK. Select: > Utility Menu > Plot > Components > Selected Components Your model should look similar to the one shown to the right.

Bulk Head Bolt


Solution
12) Change the Solution Controls for this problem. Select: > Main Menu > Solution > Analysis Types > Sol'n Controls Click on the Sol'n Options tab. Choose Precondition CG under Equation Solvers and click OK. 13) Apply symmetric boundary conditions on areas. > Utility Menu > Select > Entities Choose Areas, By Location, and Y-coordinates and click OK. Select > Main Menu > Solution > Define Loads > Apply > Structural > Displacement > Symmetry B.C. > On Areas. Click Pick All. Select > Utility Menu > Select > Entities Make sure Areas are still selected and click Sele All. Click OK. 14) Apply a UX displacement constraint on the middle keypoint at the top of the bolt (i.e. the top of the bolt head). Apply both UX and UZ displacement constraints on the middle keypoint at the bottom of the bolt (i.e. the middle keypoint at the bottom of the nut).

Bulk Head Bolt


Solution/Post Processing
15) Apply the pretension load. > Main Menu > Solution > Define Loads > Apply > Structural > Pretensn Sectn Choose the section that you named Preload under Pretension Sections. Enter 18950 for Force (under Pretension Load) and click OK. 16) Change the title to: Application of PSMESH - preload only 17) Solve the model. 18) Plot the nodal solution for the stresses in the z-direction. 19) Select the nodes in the center of the bolt. To do this use the Select Entities option on the menu bar. The Select Entites toolbar appears. Set up the toolbar to select nodes by location. Click next to Reselect at the bottom. Enter the following ranges, and hit apply after each range (hit OK after the Z range): X: -.006,.006 Y: 0 Z: .1*.045,.045-.1*.045 Plot the nodes. Your model should now appear similar to the one shown to the right. 20) List the stress results for the selected nodes. > General Postprocessor > List Results > Nodal Solution Select the z-component of stress. The nodal solution list appears. You can save this data and import it into Excel to calculate the average preload stress in the bolt (should be near .449 GPa). When finished go to Select on the menu bar and choose Everything. 10

Bulk Head Bolt


Solution/Post Processing
21) Now apply the external load to the bolt. First, restart the solution. > Solution > Analysis Type > Restart 22) Apply a force of 5.3e3 in the z-direction (this is half of the external load because the model has half the area) to the keypoint centered at the top of the bolt. 23) Change the title to make this solution unique. 24) Solve. 25) Repeat steps 18-20. The stresses should appear similar to those in the model shown to the right. The average stress in the bolt should be around .473 GPa.

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Bulk Head Bolt


Hand Calculations
External Load per Bolt
1 (.150) 2 (6e6) 10 4 P = 10.6kN P=

First Frustra
t = .020 E = 207 e9 MN k1 = 4470 m

Preload Force
Fi = .75 At S p Fi = .75(.0000843 )(600e Fi = 37.9kN

Second Frustra
t = .0025 E = 113e9 k 2 = 59040 MN m

Preload Stress

preload = preload preload

Fi At

Third Frustra
t = .0225 E = 113e9 k 3 = 2343
k m = 1498

37.9kN = .0000843 m 2 = .4495GPa

MN m
MN m

Bolt Stiffness
kb = kb = At E lt

(.0000843 )( 207e9) .045 MN k b = 387.8 m

C= C=

kb kb + k m

387.8 387.8 + 1498 C = .2056

Material Stiffness 3 frustra


d w = 1.5(.012) = .018 D1 = 20 tan(30) * 2 + d w D1 = .04109

Final Stress in Bolt

= =

CP Fi + At At

(.2056)(10.6e3) 37.9e3 + .0000843 .0000843 = .475GPa

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