Bolt Design

Intro
BACKGROUND
The most basic design calculation for bolted joints is to divide the joint load (P max) by the bolt proof stress (Sp
to obtain the needed bolt cross section area (A t). And, of course, a design safety factor must also be included !
This calculation doesn't provide the number of bolts, but usually, many small bolts are better than a few large bolts.
The follow-up step is to tighten these bolts as much as possible, for fear that they might come loose in service.
While there are a number of more subtle joint design issues, this very basic design approach is surprizingly good !
Most textbooks apply the safety factor to the bolt strength, while most practicioners prefer the safety factor on joint loads.
Simply stated, this is because a safety factor of 1.2 satisfies nobody, while the safety factor of 4 means bolts may come loose.
There are two basic situations to be considered in evaluating the behavior of the bolted joint:
* When tightening the bolt, the force (Fb) stretching the bolt must be equal to the force compressing the joint (F
* When loads are applied to the joint, the length changes in the bolt (b) and joint (m) must be equal. Also, the
combined forces: bolt (Fb), joint (Fm), and applied (P) must balance (F = 0).
BOLTED JOINT BEHAVIOR
When a bolt is tightened, its grip is stretched by the bolt preload force (Fi). At the same time, the joint (or members) are
compressed by this same preload force (Fi). When an external load (P) is later applied to the joint, the bolt stretches more,
as illustrated by the top Figure. At the same time, this load (P) decreases the joint ( or member) compression, illustrated by
the second Figure. As the applied load is increased, the joint clamping force will approach zero, where upon the joint halves
will separate or unseat. Beyond the unseating load, the bolt tension (Fb) is equal to the joint load (P) ...as if the joint were
not there, which is illustrated by the dashed and solid lines in the top Figure. This parallel spring model (bolt in tension, and
joint in compression) is the basic method used to evaluate bolted joints. The first two Figures are combined in the third,
to provide a simple graphical basis for understanding. From this graph, it should be apparent that the designer would like
to choose the bolt preload that roughly matches the bolt strength to joint unseating load. This is the justification for the
opening statement, ...that the needed bolt section area (At) is roughly the joint load (P) divided by the proof stress (Sp).
The somewhat curious note is that bolts are often preloaded to 60-90% of proof strength, and then a similar load can be
applied to the joint ...without overloading the bolt !
The important "joint stiffness fraction" (C) is obtained from the parallel spring model. A spring constant (K) is defined
as the force divided by resulting deflection. The bolt is a cylinder that experiences uniform stretch, which means the spring
constant (Kb) is simply the elastic modulus (Eb) times the tensile stress area (At) divided by the grip length (L). The
distribution of stresss and strains in the joint is both very non-uniform, and a subject for lengthy analysis. The common
practice is to define an '"equivalent spring region" around each bolt. as illustrated by the cones in the second Figure. The
small ends are meant to represent the head and nut areas, while the conical shapes reflect the spreading of stresses in
the middle of the joint. A simple approximation for the spring constant of this volume is provided on the right. To avoid
very lengthy analysis, this should be considered a reasonable approximation that is neither precise, or highly repeatible.
The "joint stiffness fraction" (C) is obtained from the parallel spring model. The joint and member spring deflections must be
equal (assuming the joint doesn't unseat). This means that the ratio of spring force changes is the same as the ratio of
spring constants.
GENERAL COMMENTS
The factors to be considered (failure modes, or limiting cases) in the selection of the bolt preload are:
Page 1
Intro
1. Tensile yielding or failure in the bolt grip material.

2. Compressive yielding (crush) of the joint material under the bolt head or nut.
3. Unseating (or seperation) of the joint halves.
4. Shear failure (or strippiing) of the threads at the thread major diameter.
So, for example, if the bolts are loose, the allowable joint loads would be limited by premature joint unseating
At first glance, it would appear that the desired preload is the value that would maximize the allowed joint load is the case
that would produce simultaneous failures by all four modes above. However, this approach tends to be modified when the
consequences of each of the failure modes are considered. The first two modes tend to be somewhat "forgiving", while the
last two tend to be more serious concerns. With ductile materials, a small amount of yielding will stretch the bolt or crush the
joint, which often has the net effect of relaxing the preload (Fi) to the value that should have been selected. However this also
reduces the service safety factors. If these chosen safety factors were generous, the results may still be acceptable.
Joint unseating tends to be more catistrophic because even small side loads will cause abrasive wear of the joint asperities
which very quickly reduces the bolt preload to zero (loose bolts). Stripping threads also tends to be a catastropic failure mode
because they usually "strip one at a time" in cascading manner that quickly reduces the joint load capacity. These observation
help to justify the general practice, which is to "error on the tight side", so long as the engaged thread length is adequate. A fin
note on joint shear loads is needed. Bolts are intended to be tension members, so large shear loads can be very troublesome
The only resistance for shear loads is friction between the joint halves, which suggests a large number of bolts and high clamp
forces. The designer should consider the common practice of "cross bolting".
A related area of great interest is designing for fatigue loading. Since the fatigue strength is so much lower that the yield stren
the designer is often tempted to consider low bolt preloads, for fear of fatigue failures in the bolts. However by clever joint des
(low C) the alternating loads in the bolt can be significantly reduced. The joint alternating loads remain high, but it is in compre
where fatigue is rarely a concern. So with a large number of bolts, and a large preload the ratio of bolt alternating to mean stre
can be reduced to a low ratio where the bolt material failure is governed by yielding, rather than fatigue.
Page 2
Intro
oof stress (Sp)

o be included !
n a few large bolts.
ose in service.
urprizingly good !
ety factor on joint loads.

means bolts may come loose.
ssing the joint (F m).
e equal. Also, the
joint (or members) are

nt, the bolt stretches more,
ompression, illustrated by
where upon the joint halves
d (P) ...as if the joint were
model (bolt in tension, and
e combined in the third,
at the designer would like
the justification for the
y the proof stress (Sp).
en a similar load can be
nstant (K) is defined

h, which means the spring
grip length (L). The
nalysis. The common
the second Figure. The
preading of stresses in
on the right. To avoid
se, or highly repeatible.
pring deflections must be
he same as the ratio of
Page 3
Intro
nt unseating
wed joint load is the case
s to be modified when the
ewhat "forgiving", while the
stretch the bolt or crush the
n selected. However this also
y still be acceptable.
wear of the joint asperities
be a catastropic failure mode
d capacity. These observations
read length is adequate. A final
oads can be very troublesome.
umber of bolts and high clamping
much lower that the yield strength,

. However by clever joint design
emain high, but it is in compression,
of bolt alternating to mean stress
Page 4
Math
Background Discussion & Comments

BOLT INSTALLATION
* bolt torque to Initial Bolt Tension relation (approx)
Using these .xls worksheets

* The intent was to automate the joint analysis de
so the user can "what if" pick the % of yield for
bolt tension = joint compression

note: the running torque of locking features should be added to this desired preload
* Bolt tension to nominal stress (approx) relation

Sb = Fb / At ...At = Tensile stress area (from tables)
SUBSEQUENT JOINT LOADING IN SERVICE
* bolt tension increases & joint compression decreases
* bolt tension (Fb) to Applied Joint Load (Pmax) relation
Fb = Fi + C Pmax
...bolt force
Fm = Fi + (C-1) Pmax
...member or joint force
where: C = Kb / (Kb + Km ) ...the joint stiffness fraction
bolt stiffness: Kb = Eb (d/4) / L
joint stiffness: Km ~ Em (5/16) (d+L/4)
* Bolt Yielding: Fb -> SyAt
* Joint Unseating: Fm -> 0
COMPRESSIVE GRIP YIELDING UNDER THE HEAD
* Head bearing stresses (or face compression)
Fb = Shd (/4) (Dhd -OD)
TAPPED THREAD FAILURE IN SHEAR
* local stresses include shear, bending, & contact loads
* theoretical shear: ~ Ssy exp(-kz/L) which is changed by local plasticity
* we might estimate shear profile as a trapeziod: ~ S sy (1-k'z/L)
however, this is usually simplified to a triangle: Fthd ~ Ssy OD (L/2)
* handbooks list tensile yield, so Ssy ~ 0.58 Sy (von Mises)
* In pullout test of ductile threads, we use: S sut = f(Z/L) ...constant Ssut
but std thread form has p/8 flats, so : F thd ~ Ssut OD (7 Lthd /8)
Page 5
* The tab labels indicate: bolt mat'l, grip mat'l, and

* The left block provides the bolt installation torqu
* This torque is the lower of bolt strength or threa
* The 2nd left block provides the joint preload (or
* The remaining blocks list the max JOINT force f
* The joint will either unseat first, or bolt will yield
* For other cases, copy to a new sheet and edit th
* To alter the (L/D) ratios, try changing columns C
Math
automate the joint analysis details,

what if" pick the % of yield for the bolt and thread
icate: bolt mat'l, grip mat'l, and thread mat'l

vides the bolt installation torque
lower of bolt strength or thread shear limits
provides the joint preload (or clamping force)
cks list the max JOINT force for each failure mode
r unseat first, or bolt will yield first ...use lower value
opy to a new sheet and edit the materials table
ratios, try changing columns C & I, or H & D
Page 6
A286-Al
pick PRELOADS:
73% of BOLT YIELD Strength

for JOINT SHEAR:
73% of Tapped Thread SHEAR YIELD Strength
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ANSI size
0-80
2-56
4-40
6-32
8-32
10-32
1/4-20
% thread Ssy
BOLT
1.5
(in lb) (in lb)
2.0
1.7
6.0
5.1
12.8
11.2
24
21
44
35
72
55
151
125
Joint PRELOAD (Fi)

% Sb
% thread Ssy
2.0 BOLT
(in lb) (lb)
2.0
171
6.0
351
12.8
573
24
863
44 1329
72 1898
151 3018
%SyAt
1.5
(lb)
144
295
501
760
1073
1441
2494
%Ssy
2.0
(lb)
171
351
573
863
1329
1898
3018
od L/2
JSmax =
APPLIED DESIGN (joint) LOADS

..Unseat JOINT ..YIELD BOLT ..SHEAR thread
1.5
2.0
1.5
2.0
1.5
[smaller value ..unseat or yield first?]
(lb)
(lb)
(lb)
(lb)
(lb)
320
347
164
124
96
657
713
337
256
198
1115
1164
517
418
336
1692 1752
765
628
510
2390 2699 1355
968
720
3208 3855 2104 1383
967
5554 6130 2976 2199 1674
Fm = 0 = Fi(1-C) Fb = (SyAt-Fi)/C P = (Fb-Fi) /C
Fb = Ssy
TORQUE ()
% Sb
% thread Ssy
Joint PRELOAD (Fi)

% Sb
% thread Ssy
(L/D)grip
(L/D)thread
ISO Size
M2x0.4
M2.5x0.45
M3x0.5
M4x0.7
M5x0.8
M6x1.0
M8x1.25

1.5
2.0
1.5
2.0
1.5
(N)
(N)
(N)
(N)
(N)
2449 2749 1369
986
738
3827 4502 2392 1615
1154
5511 6680 3686 2396 1661
9797 11660 6289 4183 2953
15308 18615 10609 7001 4614
22044 26694 14711 9575 6644
39189 47653 27562 18361 11812
BOLT
1.5
2.0 BOLT
1.5
2.0
(Nm) (Nm)
(Nm)
(N)
(N)
(N)
0.54
0.44
0.54 1353
1100 1353
1.11
0.86
1.11 2217 1718 2217
1.97
1.48
1.97 3289 2474 3289
4.59
3.52
4.59 5741 4399 5741
9.28
6.87
9.16 9285 6874 9165
15.77 11.88 15.77 13143 9898 13143
38.29 28.15 37.54 23931 17596 23462
note: 4 Nm = 35.433 in lb
MATERIALS BOLT GRIP Thread
...other materials
A-286 6061-T66061-T6
3xx SS Ti6Al4V
E (psi)
29E+06 10E+06 10E+06
29E+06 16E+06
E (Pa)
20E+10 69E+09 69E+09
20E+10 11E+10
Stensile(psi) 160000 45000 45000
80000 150000
Stensile(Pa) 11E+08 31E+07 31E+07
55E+07 10E+08
Syield (psi)
130000 40000 40000
50000 140000
Syield (Pa)
90E+07 28E+07 28E+07
34E+07 96E+07
note: gsfc uses 75% Sut for Bolt proof
Page 7
A286-Al
JSmax = Fi
~ 0.3 (unlubricated joint)
ESIGN (joint) LOADS

..SHEAR thread ..CRUSH grip
2.0
(lb)
180
370
672
1035
1244
1444
3029
1.5
(lb)
78
160
286
447
675
877
-72
1.5
2.0
1.5
2.0
2.0 LIMIT CASE (C) joint K ratio
bolt data ...DON"T change
(lb)
(lb)
(lb)
OD(in) Dshd (in) At (in)
31
78
31
0.55
0.51
0.06 0.098
###
64 160
64
0.55
0.51 0.086 0.140
###
167 286 167
0.55
0.51 0.112 0.183
###
283 447 283
0.55
0.51 0.138 0.226
###
230 675 230
0.55
0.51 0.164 0.270
###
51 877
51
0.55
0.51
0.19 0.312
###
-1110
-72 -1110
0.55
0.51
0.25 0.375
###
P = (Fb-Fi) /C
P = (Fb-Fi) /C
Fb = SsyDL/2
Fb = Sy(D-d) /4
ESIGN (joint) LOADS

2.0
(N)
1291
1816
2424
4519
6677
9723
17093
1.5
(N)
2105
3290
3857
4980
6087
7178
9313
Socket Head Screws
2.0
(N)
1785
2589
2582
2762
2094
1400
-1446
Socket Head Screws

1.5
2.0
1.5
2.0
LIMIT CASE (C) joint K ratio
(N)
(N)
OD(m) Dshd(mm) At (m)
738 986
0.55
0.51 0.002 0.0038
###
1154 1615
0.55
0.51 0.003 0.0048
###
1661 2396
0.55
0.51 0.003 0.0055
###
2953 2762
0.55
0.51 0.004 0.0070
###
4614 2094
0.55
0.51 0.005 0.0085
###
6644 1400
0.55
0.51 0.006 0.0100
###
9313 -1446
0.55
0.51 0.008 0.0130
###
note: consider thick washers to improve joint crush
Page 8
sh3xx-Al
pick PRELOADS:

for JOINT SHEAR:
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ANSI size
0-80
2-56
4-40
6-32
8-32
10-32
1/4-20
% thread Ssy
BOLT
1.5
(in lb) (in lb)
0.8
0.8
2.3
2.3
4.9
4.9
9
9
17
17
28
28
58
58
Joint PRELOAD (Fi)

% Sb
% thread Ssy
2.0 BOLT
(in lb) (lb)
0.8
66
2.3
135
4.9
220
9
332
17
511
28
730
58
1161
%SyAt
1.5
(lb)
66
135
220
332
511
730
1161
%Ssy
2.0
(lb)
66
135
220
332
511
730
1161
od L/2
JSmax =

1.0
1.5
1.0
1.5
1.5
(lb)
(lb)
(lb)
(lb)
(lb)
163
146
41
44
219
336
301
84
91
451
548
491
136
148
779
824
739
205
223
1187
1270
1138
316
343 1605
1814 1626
452
490 2081
2884 2585
718
779 3775
Fb = Ssy
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ISO Size
M2x0.4
M2.5x0.45
M3x0.5
M4x0.7
M5x0.8
M6x1.0
M8x1.25
% thread Ssy
Joint PRELOAD (Fi)

% Sb
% thread Ssy
BOLT
1.5
2.0 BOLT
(Nm) (Nm)
(Nm)
(N)
0.21
0.21
0.21
521
0.43
0.43
0.43
853
0.76
0.76
0.76 1265
1.77
1.77
1.77 2208
3.57
3.57
3.57 3571
6.07
6.07
6.07 5055
14.73 14.73 14.73 9204
3xx SS 6061-T66061-T6
E (psi)
29E+06 10E+06 10E+06
E (Pa)
20E+10 69E+09 69E+09
Stensile(psi)
80000 45000 45000
Stensile(Pa) 55E+07 31E+07 31E+07
Syield (psi)
50000 40000 40000
Syield (Pa)
34E+07 28E+07 28E+07
1.5
(N)
521
853
1265
2208
3571
5055
9204
2.0
(N)
521
853
1265
2208
3571
5055
9204

1.0
1.5
1.0
1.5
1.5
(N)
(N)
(N)
(N)
(N)
1294
1159
322
349 1650
2118 1899
528
572 2513
3143 2817
783
849 3556
5487 4918 1367 1482 6390
8873 7953 2210 2397 9781
12560 11258 3129 3393 14231
22871 20499 5697 6179 24935
...other materials
3xx SS Ti6Al4V
29E+06 16E+06
20E+10 11E+10
80000 150000
55E+07 10E+08
50000 140000
34E+07 96E+07
Page 9
sh3xx-Al
JSmax = Fi
ESIGN (joint) LOADS

2.0
(lb)
357
733
1259
1917
2630
3450
6161
1.5
(lb)
202
416
732
1129
1563
1998
2165
Socket Head Screws
1.0
1.5
1.0
1.5
(lb)
(lb)
(lb)
219
41
44
0.60
0.55
0.06 0.098
###
451
84
91
0.60
0.55 0.086 0.140
###
794 136 148
0.60
0.55 0.112 0.183
###
1224 205 223
0.60
0.55 0.138 0.226
###
1696 316 343
0.60
0.55 0.164 0.270
###
2167 452 490
0.60
0.55
0.19 0.312
###
2348 718 779
0.60
0.55
0.25 0.375
###
P = (Fb-Fi) /C
P = (Fb-Fi) /C
Fb = SsyDL/2
Fb = Sy(D-d) /4
ESIGN (joint) LOADS

2.0
1.5
2.0
(N)
(N)
(N)
2701
2911 3157
4149 4482 4861
5907 5581 6052
10575 8259 8957
16304 11140 12081
23637 14724 15968
41625 22631 24544
Socket Head Screws

1.0
1.5
1.0
1.5
(N)
(N)
322 349
0.60
0.55 0.002 0.0038
###
528 572
0.60
0.55 0.003 0.0048
###
783 849
0.60
0.55 0.003 0.0055
###
1367 1482
0.60
0.55 0.004 0.0070
###
2210 2397
0.60
0.55 0.005 0.0085
###
3129 3393
0.60
0.55 0.006 0.0100
###
5697 6179
0.60
0.55 0.008 0.0130
###
Page 10
ph3xx-Al
pick PRELOADS:

for JOINT SHEAR:
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ANSI size
0-80
2-56
4-40
6-32
8-32
10-32
1/4-20
% thread Ssy
BOLT
1.5
(in lb) (in lb)
0.8
0.8
2.3
2.3
4.9
4.9
9
9
17
17
28
28
58
58
Joint PRELOAD (Fi)

% Sb
% thread Ssy
2.0 BOLT
(in lb) (lb)
0.8
66
2.3
135
4.9
220
9
332
17
511
28
730
58
1161
%SyAt
1.5
(lb)
66
135
220
332
511
730
1161
%Ssy
2.0
(lb)
66
135
220
332
511
730
1161
od L/2
JSmax =

1.0
1.5
1.0
1.5
1.5
(lb)
(lb)
(lb)
(lb)
(lb)
163
146
41
44
219
336
301
84
91
451
548
491
136
148
779
824
739
205
223
1187
1270
1138
316
343 1605
1814 1626
452
490 2081
2884 2585
718
779 3775
Fb = Ssy
TORQUE ()
% Sb
% thread Ssy
Joint PRELOAD (Fi)

% Sb
% thread Ssy
(L/D)grip
(L/D)thread
ISO Size
M2x0.4
M2.5x0.45
M3x0.5
M4x0.7
M5x0.8
M6x1.0
M8x1.25

1.0
1.5
1.0
1.5
1.5
(N)
(N)
(N)
(N)
(N)
1294
1159
322
349 1650
2118 1899
528
572 2513
3143 2817
783
849 3556
5487 4918 1367 1482 6390
8873 7953 2210 2397 9781
12560 11258 3129 3393 14231
22871 20499 5697 6179 24935
BOLT
1.5
2.0 BOLT
1.5
2.0
(Nm) (Nm)
(Nm)
(N)
(N)
(N)
0.21
0.21
0.21
521
521
521
0.43
0.43
0.43
853
853
853
0.76
0.76
0.76 1265 1265 1265
1.77
1.77
1.77 2208 2208 2208
3.57
3.57
3.57 3571 3571 3571
6.07
6.07
6.07 5055 5055 5055
14.73 14.73 14.73 9204 9204 9204
...other materials
3xx SS 6061-T66061-T6
3xx SS Ti6Al4V
E (psi)
29E+06 10E+06 10E+06
29E+06 16E+06
E (Pa)
20E+10 69E+09 69E+09
20E+10 11E+10
Stensile(psi)
80000 45000 45000
80000 150000
Stensile(Pa) 55E+07 31E+07 31E+07
55E+07 10E+08
Syield (psi)
50000 40000 40000
50000 140000
Syield (Pa)
34E+07 28E+07 28E+07
34E+07 96E+07
note: gsfc uses 75% Sut for Bolt proof
Page 11
ph3xx-Al
JSmax = Fi
ESIGN (joint) LOADS

2.0
(lb)
357
733
1259
1917
2630
3450
6161
1.5
(lb)
408
851
1493
2276
3182
4195
7498
1.0
1.5
1.0
1.5
(lb)
(lb)
(lb)
OD(in) Dpan (in) At (in)
443
41
44
0.60
0.55
0.06 0.116
###
923
84
91
0.60
0.55 0.086 0.167
###
1619 136 148
0.60
0.55 0.112 0.219
###
2469 205 223
0.60
0.55 0.138 0.270
###
3451 316 343
0.60
0.55 0.164 0.322
###
4550 452 490
0.60
0.55
0.19 0.373
###
8132 718 779
0.60
0.55
0.25 0.492
###
P = (Fb-Fi) /C
P = (Fb-Fi) /C
Fb = SsyDL/2
Fb = Sy(D-d) /4
ESIGN (joint) LOADS

2.0
(N)
2701
4149
5907
10575
16304
23637
41625
1.5
(N)
3476
5365
5983
13692
17660
30662
54146
Pan Head Screws
2.0
(N)
3769
5819
6488
14849
19152
33254
58722
Pan Head Screws

1.0
1.5
1.0
1.5
(N)
(N)
OD(m) Dpan(mm) At (m)
322 349
0.60
0.55 0.002 0.0040
###
528 572
0.60
0.55 0.003 0.0050
###
783 849
0.60
0.55 0.003 0.0056
###
1367 1482
0.60
0.55 0.004 0.0080
###
2210 2397
0.60
0.55 0.005 0.0095
###
3129 3393
0.60
0.55 0.006 0.0120
###
5697 6179
0.60
0.55 0.008 0.0160
###
Page 12
3xx-pcb-AL
pick PRELOADS:

for JOINT SHEAR:
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ANSI size
0-80
2-56
4-40
6-32
8-32
10-32
1/4-20
% thread Ssy
BOLT
1.0
(in lb) (in lb)
0.6
0.6
1.7
1.7
3.5
3.5
7
7
12
12
20
20
41
41
Joint PRELOAD (Fi)

% Sb
% thread Ssy
1.5 BOLT
(in lb) (lb)
0.6
47
1.7
96
3.5
157
7
236
12
364
20
520
41
827
%SyAt
1.0
(lb)
47
96
157
236
364
520
827
%Ssy
1.5
(lb)
47
96
157
236
364
520
827
od L/2
JSmax =

1.0
1.5
1.0
1.5
1.0
(lb)
(lb)
(lb)
(lb)
(lb)
1437
1195
45
45
87
2953 2457
92
92
179
4820
4011
150
151
310
7255 6037
226
227
473
11173 9297
347
350
637
15962 13282
496
500
822
25379 21118
789
794 1500
Fb = Ssy
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ISO Size
M2x0.4
M2.5x0.45
M3x0.5
M4x0.7
M5x0.8
M6x1.0
M8x1.25
% thread Ssy
BOLT
1.0
(Nm) (Nm)
0.15
0.15
0.30
0.30
0.54
0.54
1.26
1.26
2.54
2.54
4.32
4.32
10.49 10.49
note: 4 Nm =
MATERIALS BOLT GRIP
3xx SS G-10
E (psi)
29E+06 50E+04
E (Pa)
20E+10 34E+08
Stensile(psi)
80000 20000
Stensile(Pa) 55E+07 14E+07
Syield (psi)
50000 12000
Syield (Pa)
34E+07 83E+06
Joint PRELOAD (Fi)

% Sb
% thread Ssy

1.0
1.5
1.0
1.5
1.0
(N)
(N)
(N)
(N)
(N)
11383 9472
354
356
655
18641 15511
579
583
994
27659 23015
860
866 1404
48280 40174 1501
1511 2527
78084 64974 2427 2444 3859
110528 91970 3436 3459 5622
###
### 6256 6299 9834
1.5 BOLT
1.0
1.5
(Nm)
(N)
(N)
(N)
0.15
371
371
371
0.30
607
607
607
0.54
901
901
901
1.26 1573 1573 1573
2.54 2544 2544 2544
4.32 3601 3601 3601
10.49 6557 6557 6557
35.433 in lb
Thread
...other materials
6061-T6
3xx SS Ti6Al4V
10E+06
29E+06 16E+06
69E+09
20E+10 11E+10
45000
80000 150000
31E+07
55E+07 10E+08
40000
50000 140000
28E+07
34E+07 96E+07
Page 13
3xx-pcb-AL
JSmax = Fi
ESIGN (joint) LOADS

1.5
(lb)
156
321
550
837
1151
1513
2695
1.0
(lb)
48
100
183
280
372
466
895
1.0
1.5
1.0
1.5
(lb)
(lb)
(lb)
OD(in) Dpan (in) At (in)
48
45
45
0.97
0.96
0.06 0.116
###
101
92
92
0.97
0.96 0.086 0.167
###
184 150 151
0.97
0.96 0.112 0.219
###
282 226 227
0.97
0.96 0.138 0.270
###
374 347 350
0.97
0.96 0.164 0.322
###
469 466 469
0.97
0.96
0.19 0.373
###
901 789 794
0.97
0.96
0.25 0.492
###
P = (Fb-Fi) /C
P = (Fb-Fi) /C
Fb = SsyDL/2
Fb = Sy(D-d) /4
ESIGN (joint) LOADS

1.5
(N)
1182
1818
2590
4635
7152
10364
18263
1.0
(N)
422
631
569
1596
1750
3527
6110
Pan Head Screws
1.5
(N)
425
635
573
1607
1762
3551
6152
Pan Head Screws

1.0
1.5
1.0
1.5
(N)
(N)
OD(m) Dpan(mm) At (m)
354 356
0.97
0.96 0.002 0.0040
###
579 583
0.97
0.96 0.003 0.0050
###
569 573
0.97
0.96 0.003 0.0056
###
1501 1511
0.97
0.96 0.004 0.0080
###
1750 1762
0.97
0.96 0.005 0.0095
###
3436 3459
0.97
0.96 0.006 0.0120
###
6110 6152
0.97
0.96 0.008 0.0160
###
note: the Binding Head is a little better for PCB's
Dbind(in)
0.126
0.181
0.235
0.290
0.344
0.399
0.525
Page 14
A286-Al-Ti
pick PRELOADS:

for JOINT SHEAR:
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ANSI size
0-80
2-56
4-40
6-32
8-32
10-32
1/4-20
% thread Ssy
BOLT
1.5
(in lb) (in lb)
2.0
2.0
6.0
6.0
12.8
12.8
24
24
44
44
72
72
151
151
Joint PRELOAD (Fi)

% Sb
% thread Ssy
2.0 BOLT
(in lb) (lb)
2.0
171
6.0
351
12.8
573
24
863
44 1329
72 1898
151 3018
%SyAt
1.5
(lb)
171
351
573
863
1329
1898
3018
%Ssy
2.0
(lb)
171
351
573
863
1329
1898
3018
od L/2
JSmax = Fi

Socket Head Screws
..Unseat JOINT ..YIELD BOLT ..SHEAR thread ..CRUSH grip
1.5
2.0
1.5
2.0
1.5
2.0
1.5
2.0
1.5
2.0
1.5
2.0 LIMIT CASE (C) joint K ratio bolt data ...DON"T change
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
380
347
115
124
940 1473
29
31
29
31 0.55 0.51
0.06 0.098
###
782
713
236
256 1931 3025
59
64
59
64 0.55 0.51 0.086 0.140
###
1277
1164
385
418 3315 5174
154
167 154 167 0.55 0.51 0.112 0.183
###
1921 1752
579
628 5047 7870
261
283 261 283 0.55 0.51 0.138 0.226
###
2959 2699
892
968 6928 10898
212
230 212 230 0.55 0.51 0.164 0.270
###
4227 3855 1274 1383 9091 14401
47
51
47
51 0.55 0.51
0.19 0.312
###
6721 6130 2026 2199 16225 25462 -1023 -1110 -1023 -1110 0.55 0.51
0.25 0.375
###
Fb = SsyDL/2
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ISO Size
M2x0.4
M2.5x0.45
M3x0.5
M4x0.7
M5x0.8
M6x1.0
M8x1.25
% thread Ssy
Joint PRELOAD (Fi)

% Sb
% thread Ssy
BOLT
1.5
2.0 BOLT
(Nm) (Nm) (Nm)
(N)
0.54
0.54
0.54 1353
1.11
1.11
1.11 2217
1.97
1.97
1.97 3289
4.59
4.59
4.59 5741
9.28
9.28
9.28 9285
15.77 15.77 15.77 13143
38.29 38.29 38.29 23931
A-286 6061-T6Ti6Al4V
E (psi)
29E+06 10E+06 16E+06
E (Pa)
20E+10 69E+09 11E+10
Stensile(psi) 160000 45000 150000
Stensile(Pa) 11E+08 31E+07 10E+08
Syield (psi)
130000 40000 140000
Syield (Pa)
90E+07 28E+07 96E+07
1.5
2.0
(N)
(N)
1353 1353
2217 2217
3289 3289
5741 5741
9285 9285
13143 13143
23931 23931
P = (Fb-Fi) /C
Fb = Sy(D-d) /4

1.5
2.0
1.5
2.0
1.5
2.0
1.5
2.0
(N)
(N)
(N)
(N)
(N)
(N)
(N)
(N)
3014 2749
909
986
7113 11183 1645 1785
4937 4502 1488 1615 10930 17273 2385 2589
7325 6680 2208 2396 15563 24681 2379 2582
12786 11660 3854 4183 27860 44087 2545 2762
20678 18859 6233 6765 42960 68266
1711 1857
29270 26694 8822 9575 62276 98751 1290 1400
53298 48607 16064 17436
###
### -2184 -2371
...other materials
3xx SS Ti6Al4V
Socket Head Screws

1.5
2.0
1.5
2.0
LIMIT CASE (C) joint K ratio bolt data ...DON"T change
(N)
(N)
909 986 0.55 0.51 0.002 0.0038
###
1488 1615 0.55 0.51 0.003 0.0048
###
2208 2396 0.55 0.51 0.003 0.0055
###
2545 2762 0.55 0.51 0.004 0.0070
###
1711 1857 0.55 0.51 0.005 0.0085
###
1290 1400 0.55 0.51 0.006 0.0100
###
-2184 -2371 0.55 0.51 0.008 0.0130
###
note: consider thick washers to improve joint crush
29E+06 16E+06
20E+10 11E+10
80000 150000
55E+07 10E+08
50000 140000
34E+07 96E+07
Page 15
A286-Al-Ti
.DON"T change
At (in)
.DON"T change
At (m)
prove joint crush
Page 16
A286-Ti-Al
pick PRELOADS:

for JOINT SHEAR:
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ANSI size
0-80
2-56
4-40
6-32
8-32
10-32
1/4-20
% thread Ssy
BOLT
1.5
(in lb) (in lb)
2.4
1.7
7.0
5.1
15.0
11.2
28
21
51
35
84
55
176
125
Joint PRELOAD (Fi)

% Sb
% thread Ssy
2.0 BOLT
(in lb) (lb)
2.3
199
6.8
409
15.0
667
28 1004
47 1547
73 2210
166 3514
%SyAt
1.5
(lb)
144
295
501
760
1073
1441
2494
%Ssy
2.0
(lb)
192
394
667
1004
1431
1921
3325
od L/2
JSmax = Fi

Socket Head Screws
1.5
2.0
1.5
2.0
1.5
2.0
1.5
2.0
1.5
2.0
1.5
2.0 LIMIT CASE (C) joint K ratio bolt data ...DON"T change
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
(lb)
254
315
208
108
122
181
1174
1178 122 108 0.43 0.39
0.06
0.098 1.80E-3
521
647
428
223
251
371 2412 2420 251 223 0.43 0.39 0.086
0.140 3.70E-3
884 1098
656
301
427
630 4153 4174 427 301 0.43 0.39 0.112
0.183 6.04E-3
1343 1652
972
452
648
979 6364 6424 648 452 0.43 0.39 0.138
0.226 9.09E-3
1896 2353 1720
993
915 1351 9181 9256 915 993 0.43 0.39 0.164
0.270 1.40E-2
2545 3159 2671 1733 1228 1813 12196 12282 1228 1733 0.43 0.39
0.19
0.312 2.00E-2
4407 5468 3778 2063 2125 3138 14045 13435 2125 2063 0.43 0.39
0.25
0.375 3.18E-2
Fb = SsyDL/2
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ISO Size
M2x0.4
M2.5x0.45
M3x0.5
M4x0.7
M5x0.8
M6x1.0
M8x1.25
% thread Ssy
Joint PRELOAD (Fi)

% Sb
% thread Ssy
BOLT
1.5
2.0 BOLT
(Nm) (Nm) (Nm)
(N)
0.63
0.44
0.59 1576
1.29
0.86
1.15 2581
2.30
1.48
1.98 3830
5.35
3.52
4.69 6685
10.81
6.87
9.16 10811
18.36 11.88 15.84 15303
44.58 28.15 37.54 27865
A-286 Ti6Al4V 6061-T6
E (psi)
29E+06 16E+06 10E+06
E (Pa)
20E+10 11E+10 69E+09
Stensile(psi) 160000 150000 45000
Stensile(Pa) 11E+08 10E+08 31E+07
Syield (psi)
130000 140000 40000
Syield (Pa)
90E+07 96E+07 28E+07
1.5
(N)
1100
1718
2474
4399
6874
9898
17596
2.0
(N)
1466
2291
3299
5865
9165
13197
23462
...other materials
3xx SS Ti6Al4V
29E+06 16E+06
20E+10 11E+10
80000 150000
P = (Fb-Fi) /C
Fb = Sy(D-d) /4

1.5
2.0
1.5
2.0
1.5
2.0
1.5
2.0
(N)
(N)
(N)
(N)
(N)
(N)
(N)
(N)
1943
2411 1738
989
937 1384 15688 16441
3036 3768 3037 1902 1464 2162 24513 25688
4372 5426 4679 3078 2109
3114 31389 32661
7773 9645 7983 5100 3749 5536 47464 48828
12145 15071 13467 9069 5857 8650 66635 67957
17489 21702 18674 12264 8434 12455 88902 90047
31092 38582 34987 23784 14994 22143
### 143115
Socket Head Screws

1.5
2.0
1.5
2.0
LIMIT CASE (C) joint K ratio bolt data ...DON"T change
(N)
(N)
937 989 0.43 0.39 0.002 0.0038 2.07E-6
1464 1902 0.43 0.39 0.003 0.0048 3.39E-6
2109 3078 0.43 0.39 0.003 0.0055 5.03E-6
3749 5100 0.43 0.39 0.004 0.0070 8.78E-6
5857 8650 0.43 0.39 0.005 0.0085 1.42E-5
8434 ### 0.43 0.39 0.006 0.0100 2.01E-5
### ### 0.43 0.39 0.008 0.0130 3.66E-5
MY TEST CASE
failure failure failure
test result
8-32 sh (L/D) torque preloa stress
thread shear
1/8" pla
0.76
48 1463 ### 45 ksi
broke head
1/4" pla
1.52
78 2378 ### min 160 ksi
55E+07 10E+08
50000 140000
34E+07 96E+07
Page 17
Al Inserts
pick PRELOADS:

for JOINT SHEAR:
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ANSI size
2-56
4-40
6-32
8-32
10-32
1/4-20
% thread Ssy
BOLT
1.5
(in lb) (in lb)
6.0
3.3
12.8
7.3
24
14
44
22
72
35
151
78
Joint PRELOAD (Fi)

% Sb
% thread Ssy
2.0 BOLT
(in lb) (lb)
4.4
351
9.7
573
18
863
30 1329
47 1898
104 3018
%SyAt
1.5
(lb)
190
324
493
675
931
1557
%Ssy
2.0
(lb)
253
432
658
901
1242
2076
od L/2
JSmax =

1.5
2.0
1.5
2.0
1.5
(lb)
(lb)
(lb)
(lb)
(lb)
336
417
670
581
362
572
710 1063
901
625
872 1082 1586 1336
958
1193 1481 2637 2346 1223
1646 2042 3844 3466 1791
2751 3414 5937 5252 2767
Fb = Ssy
TORQUE ()
% Sb
(L/D)grip
(L/D)thread
ISO Size
M2x0.4
M3x0.5
M4x0.7
M5x0.8
M6x1.0
M8x1.25
% thread Ssy
Joint PRELOAD (Fi)

% Sb
% thread Ssy
BOLT
1.5
2.0 BOLT
(Nm) (Nm)
(Nm)
(N)
0.54
0.44
0.54 1353
1.97
1.25
1.66 3289
4.59
2.66
3.54 5741
9.28
4.84
6.46 9285
15.77
7.97 10.63 13143
38.29 17.72 23.62 23931
A-286 Ti6Al4V 5083-0 Al
E (psi)
29E+06 16E+06 10E+06
E (Pa)
20E+10 11E+10 69E+09
Stensile(psi) 160000 150000 42000
Stensile(Pa) 11E+08 10E+08 29E+07
Syield (psi)
130000 140000 21000
Syield (Pa)
90E+07 96E+07 14E+07
1.5
2.0
(N)
(N)
1107 1353
2076 2768
3322 4429
4844 6459
6644 8858
11073 14764

1.5
2.0
1.5
2.0
1.5
(N)
(N)
(N)
(N)
(N)
1957 2226 1721 1277 4738
3669 4552 5597 4433 6605
5870 7284 10465 8765 8747
8560 10622 18142 15973 11161
11739 14567 26172 23336 13849
19565 24279 50016 45979 20044
...other materials
3xx SS Ti6Al4V
29E+06 16E+06
20E+10 11E+10
80000 150000
55E+07 10E+08
50000 140000
34E+07 96E+07
Page 18
Al Inserts
JSmax = Fi
ESIGN (joint) LOADS

Socket Head Screws & Helicoils
1.5
2.0
1.5
2.0
thread
2.0
1.5
bolt data ...DON"T change Insert
(lb)
(lb)
(lb)
(lb)
(lb)
OD(in) Dshd (in) At (in) OD(m)
535 2654 2778 336 417
0.43
0.39 0.086 0.140
### 0.110
922 4559 4774 572 710
0.43
0.39 0.112 0.183
### 0.144
1415 6978 7309 872 1082
0.43
0.39 0.138 0.226
### 0.178
1805 10098 10610 1193 1481
0.43
0.39 0.164 0.270
### 0.205
2645 13369 14015 1646 2042
0.43
0.39
0.19 0.312
### 0.244
4086 16204 16623 2751 3414
0.43
0.39
0.25 0.375
### 0.310
P = (Fb-Fi) /C
P = (Fb-Fi) /C
Fb = SsyDL/2
Fb = Sy(D-d) /4
ESIGN (joint) LOADS

2.0
(N)
7310
9755
12917
16482
20451
29601
1.5
(N)
15671
32307
49945
71310
96400
###
2.0
(N)
16729
34016
52493
74860
101119
###
Socket Head Screws

1.5
2.0
1.5
2.0
thread
bolt data ...DON"T change Insert
(N)
(N)
OD(m) Dshd(mm) At (m) OD(m)
1721 1277
0.43
0.39 0.002 0.0038
### 0.004
3669 4433
0.43
0.39 0.003 0.0055
### 0.005
5870 7284
0.43
0.39 0.004 0.0070
### 0.006
8560 ###
0.43
0.39 0.005 0.0085
### 0.007
11739 ###
0.43
0.39 0.006 0.0100
### 0.008
### ###
0.43
0.39 0.008 0.0130
### 0.010
Page 19

Bolt Design

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Bolt Design

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Intro

1. Tensile yielding or failure in the bolt grip material.

oof stress (Sp)

ety factor on joint loads.

ssing the joint (F m).

e equal. Also, the

joint (or members) are

nstant (K) is defined

much lower that the yield strength,

Background Discussion & Comments

Using these .xls worksheets

bolt tension = joint compression

* Bolt tension to nominal stress (approx) relation

* The tab labels indicate: bolt mat'l, grip mat'l, and

automate the joint analysis details,

icate: bolt mat'l, grip mat'l, and thread mat'l

73% of BOLT YIELD Strength

Joint PRELOAD (Fi)

APPLIED DESIGN (joint) LOADS

Joint PRELOAD (Fi)

APPLIED DESIGN (joint) LOADS

~ 0.3 (unlubricated joint)

ESIGN (joint) LOADS

ESIGN (joint) LOADS

Socket Head Screws

Socket Head Screws

73% of BOLT YIELD Strength

Joint PRELOAD (Fi)

APPLIED DESIGN (joint) LOADS

Joint PRELOAD (Fi)

APPLIED DESIGN (joint) LOADS

~ 0.3 (unlubricated joint)

ESIGN (joint) LOADS

Socket Head Screws

ESIGN (joint) LOADS

Socket Head Screws

73% of BOLT YIELD Strength

Joint PRELOAD (Fi)

APPLIED DESIGN (joint) LOADS

Joint PRELOAD (Fi)

APPLIED DESIGN (joint) LOADS

~ 0.3 (unlubricated joint)

ESIGN (joint) LOADS

ESIGN (joint) LOADS

Pan Head Screws

Pan Head Screws

52% of BOLT YIELD Strength

Joint PRELOAD (Fi)

APPLIED DESIGN (joint) LOADS

Joint PRELOAD (Fi)

APPLIED DESIGN (joint) LOADS

~ 0.3 (unlubricated joint)

ESIGN (joint) LOADS

ESIGN (joint) LOADS

Pan Head Screws

Pan Head Screws

73% of BOLT YIELD Strength

Joint PRELOAD (Fi)

APPLIED DESIGN (joint) LOADS

Joint PRELOAD (Fi)

~ 0.3 (unlubricated joint)

APPLIED DESIGN (joint) LOADS

Socket Head Screws