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ISSN 2067-9238
Abstract: This paper presents a theoretical model and a simulation analysis of bolted joint deformations.
The bolt pretension force, friction coefficient and contact stiffness factor are considered as parameters
which are influencing the joint deformation. The bolted joint is modeled using CATIA software and imported in ANSYS WORKBENCH. The finite element analysis procedure required in ANSYS
WORKBENCH simulation is presented as a predefined process to obtain accurate results.
Key words: joints, bolts, machine tools, FEM, analysis, stiffness.
1. INTRODUCTION1
Machine tools are characterized by high precision,
even at heavy-duty regimes (high magnitudes of cutting
forces). This requires very high structural stiffness.
Static stiffness ks is defined as the ratio of the static
force Po, applied between tool and workpiece, to the resulting static deflection As between the points of force
application.
ks =
P0
.
As
(1)
Both the position and external load size have an influence on bolted joint deformation, and also the greatest
influence has the size of the contact area between components [8].
Contact deformations between contacting surfaces in
fixed and movable joints has played a significant role (
frequently up to 50 percent) in the breakdown of deformations between various components of the machine tool
structures. So far, it has been known that contact deformations are highly nonlinear and are due to surface imperfections on contacting surfaces [1].
A method that has been widely used in analyzing
bolted joint structures and other mechanical structures is
the finite element method (FEM) due to its convenience
and reliable results [2].
2. LITERATURE APPROACH INFORMATION
Pederson [3] made a contact analysis using finite
elements to calculate the elastic energy of both bolt and
flanges parts. From the energies the author directly calculated the stiffness.
In some papers, bolted joints are treated in more general terms as complex contact problems.
168
k=
(2)
AE
kb = b b ,
Lb
(3)
kf =
Ed tan( )
,
(2t tan ( ) + d b d h )(d b + d h )
ln
(4)
kf =
Af E f
Lf
(5)
k j = kb + k f .
(6)
Pb Pf
,
=
kb k f
(7)
P = Pb + Pf ,
(8)
Fb = Pb + Fv
(9)
F f = Pf Fv ,
Fig. 3. Bolted joint stiffness diagram [4].
(10)
169
Fig. 4. The FEA analysis steps of a bolted joint: CAD model; b) meshed model; c) deformed model.
U b = U + U = V =
2V
E
P 2 Ab L P 2 L
=
, (11)
2
EAb
Ab E
where V is the estimated volume obtained with the estimated length L that also account for the stiffness of
bolt head and nut. In terms of a reference displacement
P corresponding to the total force P, the bolt stiffness is
kb =
P2
P 2 EAb
=
=
,
P P U b
L
(12)
170
kf =
P2
P2
=
,
P m U m
(13)
([ ] + [S ] ){F } ,
e{1} = {Dbp } {D fp } = S bp
fp
cp
(19)
d c d h + L tan ( ) .
(14)
In traditional finite element analysis, detailed information on displacements, strains, stresses, energy densities and general stiffness are obtainable if the contact
pressure distribution p = p(r ) is available. Yet, it may
be rather complicated iteratively to determine this, but is
possible with most FE programs.
3.4. Contact pressure distribution with pretension
only
The distribution of the contact pressure [8] can be obtained in a direct procedure, due to the influence on the
global stiffness quantities, especially for components.
The bolt analysis is carried out as a super element FE
procedure
[S ]{D } = {F } {D } = [S ] {F },
1
bp
bp
cp
bp
bp
cp
(15)
P = {Fc } .
(16)
[S ]{D } = {F } {D } = [S ] {F } ,
1
fp
fp
cp
fp
fp
cp
(17)
{D } = e{1} ,
0
(18)
{F } = ([S ] + [S ] ) e{1}.
1 1
cp
bp
fp
(20)
([ ] + [S ] )
1 1
fp
is a stiffness ma-
trix, which is positive definite and strictly diagonal dominant. From this follows for each row (or column) in
[K ] that nj=1 K i j for all i, and therefore {Fcp } > {0} . Thus
the contact problem for the pure pretension state has a
solution with only positive contact pressure forces.
3.5. FEA contact formulation
There are several types of mathematical formulation
of the contact problem [9], which exists in the normal
and tangential direction of the surface contact.
Penalty function. Penalty function is a displacementbased solution:
[K ]{x} = {F } .
(21)
(22)
[K *]
= {F } ,
Fcontact
x
(23)
Software solves directly for contact forces (or pressure). Therefore, Lagrange multipliers add equations to
0.16
0.14
0.017483
0.12
0.1
0.08
0.017489
0.017503
0.06
0.04
0.017622
0.02
0
0.017691
[mm]
FKN
171
25
0.017403
20
0.017404
15
0.017405
10
5
0
0.017408
0.017417
0.017484
[mm]
172
Fig. 10. Dependence pretensioning force and contact deformations between components.
We started from the default stiffness factor as generated by the ANSYS Workbench software and increased to the point that the value of the deformation
remains constant. We found that the contact stiffness
has a non-linear variation;
We considered a friction coefficient between the
flanges of 0.02 minimum and a maximum of 0.14,
which is a non-linear variation because increasing the
friction coefficient will cause a decrease of the bolted
joint deformation.
5. ACKNOWLEDGEMENTS
The work has been funded by the Sectoral Operational
Programme Human Resources Development 2007-2013
of the Romanian Ministry of Labour, Family and Social
Protection
through
the
Financial
Agreement
POSDRU/88/1.5/S/60203.
REFERENCES
4. CONCLUSIONS
Defining joints is one of the most difficult aspects
when simulating the behavior of machine-tools, because
there are many variables that can affect the joints properties. By using finite element analysis software we can
optimize the design process of machine tool components
by identifying the parameters that has a influence on the
static behavior of machine tools. By analyzing the results
obtained in the post-processing phase, the user can evaluate the properties of machine tools still in the design
stage, without the need to make prototypes.
Based on these preliminary results of bolted joint
contact deformation analysis further research will be carried on the model optimization.