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ICAF2007 Stress Analyses of Mechanically Fastened Joints in Aircraft Fuselages
ICAF2007 Stress Analyses of Mechanically Fastened Joints in Aircraft Fuselages
1. INTRODUCTION
A thorough understanding of the stresses at the most critical fastener row is essential in
conducting fatigue and damage tolerance analysis of mechanically fastened joints. The critical
fastener row location is most susceptible to fatigue crack nucleation and subsequent crack
growth. The dominant loading condition for riveted lap-splice joints in an aircraft fuselage
structure is introduced by the Ground-Air-Ground (GAG) pressurization cycle. The hoop load
is transferred from one skin panel to the next panel by fasteners in a lap joint or a single strap
x1
a
x2
x3
x4
j=1
j=2
j=3
L1
L2
L3
L4
w
P
(1)
d 2x
dx 2
(2)
(3)
with
i2 =
P
(i = 1,2)
EI i
(4)
(5)
Ai and Bi are solved using the boundary conditions for the two parts with length L1 and L2
respectively.
x1 = 0 w1 = 0
x1 = L1 and x2 = 0 w2 = w1 e
x1 = L1 and x2 = 0
x2 = L2 w2 = 0
dw1 dw2
=
dx1 dx2
(6)
( symmetry)
After substitution of Eq. (5) in the in Eq. (6) the constants Ai and Bi of Eq. (5) can be solved.
The bending moment Mx is then obtained as:
d 2w
M x = EI 2
dx
The maximum secondary bending occurs at the first fastener row (x1 = L1). Defining the
bending factor kb as:
6M c
2
2
6 A
kb = bending = Wt = 1 1
P
tension
Pt
Wt
the solutions derived in [3] for ta = tb and L2 = L3 is:
(7)
(8)
Th
1 + 2 2 2
Th1
with the hyperbolic function Thi = tanh(iLi) it was shown in [3] that for a long specimen, i.e.
L1 significantly larger then L2, the value of Th1 is practically equal to 1. This implies that the
effect of the length of the specimen on the secondary bending can be ignored, and the
equation reduces to:
kb =
3
1 + 2 2 tanh ( 2 L2 )
(9)
with:
2 =
3
2t 2 E
(10)
The loading conditions at the ends of the specimen, i.e. far away of the overlap region, were
also explored in [3]. If the hinged load introduction in is replaced by a fixed clamping
(dw/dx1 = 0 at x1 = 0) the difference of the secondary bending at x1 = L1 with the hinged load
introduction is negligible. This also applies to a misalignment when the loads P at the two
ends of the specimen are applied along slightly shifted parallel lines.
Values of the bending factor kb calculated with (9) for different input data are shown in Table
I. The data in the first line of the table applies to the geometry of typical specimen
dimensions. The load P corresponds to an applied stress level of 100 MPa.
L1
[mm]
200
L2
[mm]
28
18
28
t
[mm]
2
1
2
E
[N/mm2]
72000
210000
(11)
T1
T3
T2
M1
M2
T1
M3
T2
P
T3
Figure 4 Simple lap-splice joint with load transmission from the upper sheet to the lower
sheet causing internal moments
P-T1
M1
T1
P
P
e1
M1
Figure 6 Moment as a result of the load transfer of original neutral line model
The loads in the various parts of the joint are indicated in Figure 4. In the elementary neutral
line model, the middle row did not contribute to load transmission (T2 = 0) and as a
consequence T1 and T3 were both equal to P/2. However, due to fastener flexibility, T1 and PT1 are no longer equal to P/2 because different tension loads occur in the upper and lower
segments of the overlap of the joint. As a consequence, an internal moment will be introduced
at the fastener rows, M1, M2 and M3, at the three fastener rows respectively. In view of
symmetry M3 = M1. The internal moment M1 at the first fastener row is indicated in Figure 5.
As mentioned earlier, the loads in the upper and lower sheet are different due to the load
transfer associated with different tensile elongations of the upper and lower sheet. In the
neutral line model the upper and lower sheets between the 1st and 3rd rivet row, in the overlap
region, are assumed to act as an integral beam subjected to secondary bending.
M 1 + T1
t
3
T1 t = 0
2
2
(12)
M 1 = T1t
This moment is associated with the influence of the load transfer of Figure 5 and thus the
neutral line model will behave as shown in Figure 6. For the moment in the second and third
fastener row using the same principle follows that:
M 2 = T2t
M 3 = T1t
(13)
The original neutral line model calculates the (non-linear) secondary bending moment in a
joint and assumes a moment introduced by the eccentricity e1. The influence of the load
trasnfer leads to a change of this moment. The changes per fastener row can be written as:
M 1 = M 1 + Pe1
M 2 = M 2
(14)
M 3 = M 3 + Pe3
These changes in moments must be taken into account when analyzing the deformations in
the joint. Note that for the original neutral line model, T2 = 0, T1 = T3 = P/2 and e1 = e3 = t/2, it
follows that Mi = 0.
The calculation of T1 and T2 is based on the different elongations of the upper and lower
sheetoccuring as a result of fastener tilting. This phenomenon is described here by a linear
function between the applied load (P) transmitted by a row of fasteners and the displacement
() occurring in the joint due to plastic deformation around the fastener holes.
f =
(15)
For the lap-splice joint, the symbol is the displacement of the lower sheet at a row relative to
the upper sheet, while P is the load associated with the relevant internal moment (T1 or T2).
The symbol f is an empirically obtained flexibility constant. For the first and the second row:
1 = f T1
2 = f T2
(16)
The fastener flexibility displacements and the tensile elongations of the upper and lower sheet
(Lupper and Llower) must be compatible, see Figure 7.
L+Lupper
T1
T2
T1
T2
L+Llower
L = load with =
L S load
= =
L E
AE
L
AE
(17)
where A is the cross sectional area. For the lap-splice joint in Figure 7 it implies:
Lupper = (P T1 )
Llower = T1
(18)
L + Lupper = 1 + (L + Llower ) 2
With L = 28 mm, A = 200 mm2 and E = 72000 N/mm2 the -value is:
= 1.944 10 6
mm
N
f = 3.523 10 5
mm
N
(19)
f
P
T2 =
2 + 3 f
(20)
With the above-mentioned value of and f the results for T1 and T2 are:
T1 = 7052
T2 = 5896
This load transmission is illustrated by Figure 8. As a result of the fastener flexibility the first
fastener row transmits 35 % (7052 N) of the load P, the second row 30 % (5896 N) and the
third row again 35 %.
20000
L1
12948 7052
7052 12948
L2
L3
20000
L4
Figure 8 load transfer in the simple lap-splice joint accounting for fastener flexibility
The calculation of the internal moment is entirely dependent on the location of the neutral
axis of the lap-splice joint [6]. The internal moment is therefore a function of both the load
transfer and the geometric lay-out of the joint. In case of a monolithic joint the neutral line is
located at the center of each element of the lap-splice joint. The moments can then be
calculated using e1 = -t/2 and Eqn. 13 and 14:
M 1 = 5896 Nmm
M 2 = 11792 Nmm
M 3 = 5896 Nmm
The bending factor was calculated in the previous Section 2.1 for the simple lap joint without
considering rivet tilting. The bending factor will now be derived for the same lap splice joint
accounting for rivet tilting and load transmission by all fastener rows.
Part 1
L1
Part 2
L2
M1
2t
e
x1
x2
Figure 9 Secondary bending in the simple symmetric lap-splice joint with the internal
moments at the first fastener row
For Part 1 in Figure 9 the equations for the bending moment and the displacements w(x) are
similar to the Eqn. 1 - 4 with the solution given in Eqn. 5. With the condition that w(x1) = 0
for x1 = 0, it is easily found that B1 = 0. The equation for w(x1) thus becomes:
w( x1 ) = A1 sinh(1 x1 )
(21)
d 2w
M x2 = Pw( x2 ) M 1 = EI 2
dx2 x2
(22)
M 1
P
(23)
The boundary conditions at the first fastener row (x1 = L1 and x2 = 0) are:
(w )
x2 x = L
2
2
( )
= wx1
x1 = L1
+ e1
dw
dw
=
dx x1 = L1 dx x2 =0
(24)
(25)
(26)
The constants A1, A2 and B2 can now be solved after substitution of Eqns 21 and 23 in Eqns.
24 to 26. With the boundary values of the hyperbolic function written as:
Si = sinh( i Li )
Ci = cosh( i Li )
Thi = tanh( i Li )
M 1
+ e1
P
1
AC
2 1 1
A2 S 2 + B2 C2 +
(27)
M 1
=0
P
The most critical bending moment occurring at the first fastener row is obtained as:
d 2w
M x1 = L1 = EI 2
dx x1 = L1
With 1 =
2
(28)
P
the result for the bending factor becomes:
EI1
6M c
2
2
6 A
kb = bending = Wt = 1 1
P
tension
Pt
(29)
Wt
After solving A1 and realizing that t2 = 2t and e = -t/2 for the simple lap-splice joint, a further
evaluation leads to:
1
6M 1
1 + 3
Pt C2
kb =
Th
1+ 2 2 2
Th1
(30)
It should be noted that for M1 = 0, i.e. no fastener flexibility and internal moments, Eqn. 30
reduces to the previous Eqn. 9. Results of the calculations of kb with fastener flexibility (Eqn.
30) are shown in Table II for similar values of L1, L2, t, E used previously.
L1
[mm]
200
L2
[mm]
t
[mm]
28
18
28
1
2
E
[N/mm2]
72000
210000
f
[mm/N]
3.542E-5
5.369E-5
1.214E-5
Table II Variation of input data for symmetrical lap-splice joint, f calculated using Huth [7]
this also effects the load transfer through the fastener rows.
3. RESULTS
In this section results are presented for surface stress levels in two butt splice joints and one in
service lap splice joint. Figure 10 shows calculated and measured results of stress levels in an
Al-2024 T3 Clad butt splice joint. Only one overlap of the symmetric simple strap joint is
shown. The calculations provide a continuous curve of the variation of the stress level along
the joint. The strain gage measurements give a number of local stress values only. Outside the
overlap the agreement between calculation and measurement is very good. Inside the overlap
the agreement is less, but it should be realised that the neutral line model is a one dimensional
model which does not take into account the non-homogenous stress distribution in the width
direction
Figure 11 shows a similar comparison for a fiber metal laminate butt-splice joint. The trends
are practically the same as for the Al-2024 T3 Clad butt splice joint, i.e. again a very good
agreement outside the overlap area, and a qualitatively correct trend inside the overlap.
350
s.g. 23
Strain gage data
250
150
s.g. 16
s.g.19
50
-50
s.g. 21
s.g. 18
200
220
240
260
t1
16
280
18
17
-150
300
320
19
21
20
22
340
360
23
380
400
t2
24
Location [mm]
Figure 10 Butt joint results from strain gages at the lower side of the butt splice joint, sheet
thickness t1 = 4.0 mm, t2 = 4.0 mm and material Al 2024-T3 Clad
350
300
250
200
s.g. 23
150
Surface stress
100
[MPa]
s.g. 16
s.g. 19
s.g. 21
s.g. 18
50
0
-50
200
220
240
16
-100
-150
17
260
t1
18
280
300
320
340
360
19
21
23
20
22
24
380
400
t2
Location [mm]
Figure 11 Butt joint surface stress representation for strain gages at the upper surface, sheet
thickness t1 = 4.25 mm, t2 = 4.25 mm and material sheet 1 is Glare 3-6/5-0.5 and sheet 2 is
Glare 2B-6/5-0.5
18
Row A
16
14
Tensile stress
12
Bending stress
10
8
Normal Stress
(ksi)
6
4
2
0
-2
-4
0
5000
10000
15000
20000
4. CONCLUSIONS
1. The internal moment concept gives a good representation of the load transfer
occurring in multi-row joints. The calculation of the load transfer can be made for
complicated lap-splice and butt joints in both monolithic and laminated sheet
materials. The calculated and the experimental stress levels agreed very well outside
the overlap area of the joints, while indicative results were obtained in the overlap
area. The results provide a base for further research into improved fastener flexibility
equations and load transfer.
2. The influence of the fastener flexibility is of less importance than previously expected.
3. Adding doublers and stringers do not offer complications. Only those parts adding
bending stiffness to the joint need to be taken into account.
LIST OF SYMBOLS
Latin
Greek
A
Ai, Bi
ei
E
f
I
kb
L
Mi, Mx
Minternal
P
ti
Ti
wi
W
x
y
Area
Constants for solving differential eq.
Eccentricity
Youngs modulus
Fastener flexibility
Moment of inertia
Bending factor
Length
Moment
Internal moment
Applied force
Thickness
Load transfer
Displacement neutral axis
Width
x-coordinate
y-coordinate
[mm2]
[mm]
[mm]
[MPa]
[mm/N]
[mm4]
[-]
[mm]
[Nm]
[Nm]
[kN]
[mm]
[kN]
[mm]
[mm]
[mm]
[mm]
f,i
i
b
bending
tension
j,i
Stiffness ratio
Displacement
Displacement of fastener
Displacement of sheet
Bending stress
Bending stress
Tensile stress
Stiffness ratio
[MPa]
[mm]
[mm]
[mm]
[MPa]
[MPa]
[MPa]
[mm/N]
REFERENCE LIST
[1]
[2]
[3]
[4]
Gere, J.M. and Timoshenko, S.P. (1991), Mechanics of Materials, Chapman & Hall,
London.
Hartman, A. and Schijve, J. (1968), Effects of dimensions of riveted lap joints and
single-strap butt joints on secondary bending (in Dutch). NLR-TR-68026, Amsterdam,
National Aerospace Laboratory
Schijve, J. (1972), Some Elementary Calculations on Secondary Bending in Simple Lap
Joints, NLR-TR-72036, Amsterdam, National Aerospace laboratory
Mller, R.P.G. (1995), An Experimental and Analytical investigation on the Fatigue
Behaviour of Fuselage Riveted Lap Joints, The Significance of the Rivet Squeeze Force,
and a Comparison of 2024-T3 and Glare 3, Dis. Delft University of Technology
[6]
[7]
[8]
De Rijck, J.J.M. and Fawaz, S.A. (2001), A Simplified Approach for Stress Analysis of
Mechanically Fastened Joints, 4th Joint DoD/FAA/NASA Conference on Aging
Aircraft
Rijck, J.J.M. (2005), Stress Analysis of Fatigue Cracks in Mechanically Fastened
Joints, Dis. Delft University of Technology
Huth, H. (1986), In: ASTM STP 927; Influence of Fastener Flexibility on the Prediction
of load transfer and Fatigue Life for Multiple-Row joints, p. 221-250
Fawaz, S.A. (2000), Equivalent Initial Flaw Size Testing and Analysis of Transport
Aircraft Skin Splices, In: Fatigue and Fracture of Engineering Materials and Structures,
Vol. 26 p. 279-290