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 (Db) and joint (Dm) must be equal. Also, the
combined forces: bolt (Fb), joint (Fm), and applied (P) must balance (S 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:
1. Tensile yielding or failure in the bolt grip material.
Page 1
Intro
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 !
fety 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
n 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 Using these .xls worksheets

BOLT INSTALLATION * The intent was to automate the joint analysis de
* bolt torque to Initial Bolt Tension relation (approx) so the user can "what if" pick the % of yield for
… bolt tension = joint compression * The tab labels indicate: bolt mat'l, grip mat'l, and
note: the running torque of locking features should be added to this desired preload * The left block provides the bolt installation torqu
* Bolt tension to nominal stress (approx) relation * This torque is the lower of bolt strength or threa
Sb = Fb / At ...At = Tensile stress area (from tables) * The 2nd left block provides the joint preload (or
* The remaining blocks list the max JOINT force f
SUBSEQUENT JOINT LOADING IN SERVICE * The joint will either unseat first, or bolt will yield
* bolt tension increases & joint compression decreases * For other cases, copy to a new sheet and edit th
* bolt tension (Fb) to Applied Joint Load (Pmax) relation * To alter the (L/D) ratios, try changing columns C
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 (pd²/4) / L
joint stiffness: Km ~ Em (5p/16) (d+L/4) ²
* Bolt Yielding: Fb -> SyAt
* Joint Unseating: Fm -> 0
COMPRESSIVE GRIP YIELDING UNDER THE HEAD

* Head bearing stresses (or face compression)
Fb = Shd (p/4) (D²hd -OD²)
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: F thd ~ Ssy p 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 p OD (7 Lthd /8)
Page 5
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: JSmax =
73% of Tapped Thread SHEAR YIELD Strength
TORQUE () Joint PRELOAD (Fi) APPLIED DESIGN (joint) LOADS
% Sb % thread Ssy % Sb % thread Ssy ..Unseat JOINT ..YIELD BOLT ..SHEAR thread
(L/D)grip 1.5 2.0 1.5 2.0
(L/D)thread BOLT 1.5 2.0 BOLT 1.5 2.0 [smaller value ..unseat or yield first?] 1.5
ANSI size (in lb) (in lb) (in lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb)
0-80 2.0 1.7 2.0 171 144 171 320 347 164 124 96
2-56 6.0 5.1 6.0 351 295 351 657 713 337 256 198
4-40 12.8 11.2 12.8 573 501 573 1115 1164 517 418 336
6-32 24 21 24 863 760 863 1692 1752 765 628 510
8-32 44 35 44 1329 1073 1329 2390 2699 1355 968 720
10-32 72 55 72 1898 1441 1898 3208 3855 2104 1383 967
1/4-20 151 125 151 3018 2494 3018 5554 6130 2976 2199 1674
%SyAt %Ssy p od L/2 Fm = 0 = Fi(1-C) Fb = (SyAt-Fi)/C P = (Fb-
Fb = pSsy
(L/D)grip 1.5 2.0 1.5 2.0
ISO Size (Nm) (Nm) (Nm) (N) (N) (N) (N) (N) (N) (N) (N)
M2x0.4 0.54 0.44 0.54 1353 1100 1353 2449 2749 1369 986 738
M2.5x0.45 1.11 0.86 1.11 2217 1718 2217 3827 4502 2392 1615 1154
M3x0.5 1.97 1.48 1.97 3289 2474 3289 5511 6680 3686 2396 1661
M4x0.7 4.59 3.52 4.59 5741 4399 5741 9797 11660 6289 4183 2953
M5x0.8 9.28 6.87 9.16 9285 6874 9165 15308 18615 10609 7001 4614
M6x1.0 15.77 11.88 15.77 13143 9898 13143 22044 26694 14711 9575 6644
M8x1.25 38.29 28.15 37.54 23931 17596 23462 39189 47653 27562 18361 11812
note: 4 Nm = 35.433 in lb
MATERIALS BOLT GRIP Thread ...other materials
A-286 6061-T6 6061-T6 3xx SS Ti6Al4V
E (psi) 29E+06 10E+06 10E+06 29E+06 16E+06
E (Pa) 20E+10 07E+10 07E+10 20E+10 11E+10
Stensile(psi) 160000 45000 45000 80000 150000
Stensile(Pa) 11E+08 03E+08 03E+08 06E+08 10E+08
Syield (psi) 130000 40000 40000 50000 140000
Syield (Pa) 09E+08 03E+08 03E+08 03E+08 01E+08
note: gsfc uses 75% Sut for Bolt proof
Page 7
A286-Al
JSmax = m Fi m ~ 0.3 (unlubricated joint)
ESIGN (joint) LOADS Socket Head Screws

..SHEAR thread ..CRUSH grip
1.5 2.0 1.5 2.0
2.0 1.5 2.0 LIMIT CASE (C) joint K ratio bolt data ...DON"T change
(lb) (lb) (lb) (lb) (lb) OD(in) Dshd (in) At (in²)
180 78 31 78 31 0.55 0.51 0.06 0.098 1.80E-3
370 160 64 160 64 0.55 0.51 0.086 0.140 3.70E-3
672 286 167 286 167 0.55 0.51 0.112 0.183 6.04E-3
1035 447 283 447 283 0.55 0.51 0.138 0.226 9.09E-3
1244 675 230 675 230 0.55 0.51 0.164 0.270 1.40E-2
1444 877 51 877 51 0.55 0.51 0.19 0.312 2.00E-2
3029 -72 -1110 -72 -1110 0.55 0.51 0.25 0.375 3.18E-2
P = (Fb-Fi) /C P = (Fb-Fi) /C
Fb = pSsyDL/2 Fb = pSy(D²-d²) /4
1.5 2.0 1.5 2.0
(N) (N) (N) (N) (N) OD(m) Dshd(mm) At (m²)
1291 2105 1785 738 986 0.55 0.51 0.002 0.0038 2.07E-6
1816 3290 2589 1154 1615 0.55 0.51 0.003 0.0048 3.39E-6
2424 3857 2582 1661 2396 0.55 0.51 0.003 0.0055 5.03E-6
4519 4980 2762 2953 2762 0.55 0.51 0.004 0.0070 8.78E-6
6677 6087 2094 4614 2094 0.55 0.51 0.005 0.0085 1.42E-5
9723 7178 1400 6644 1400 0.55 0.51 0.006 0.0100 2.01E-5
17093 9313 -1446 9313 -1446 0.55 0.51 0.008 0.0130 3.66E-5
note: consider thick washers to improve joint crush
Page 8
sh3xx-Al
(L/D)grip 1.0 1.5 1.0 1.5
0-80 0.8 0.8 0.8 66 66 66 163 146 41 44 219
2-56 2.3 2.3 2.3 135 135 135 336 301 84 91 451
4-40 4.9 4.9 4.9 220 220 220 548 491 136 148 779
6-32 9 9 9 332 332 332 824 739 205 223 1187
8-32 17 17 17 511 511 511 1270 1138 316 343 1605
10-32 28 28 28 730 730 730 1814 1626 452 490 2081
1/4-20 58 58 58 1161 1161 1161 2884 2585 718 779 3775
%SyAt %Ssy p od L/2 Fm = 0 = Fi(1-C) Fb = (SyAt-Fi)/C P = (Fb-
Fb = pSsy
(L/D)grip 1.0 1.5 1.0 1.5
M2x0.4 0.21 0.21 0.21 521 521 521 1294 1159 322 349 1650
M2.5x0.45 0.43 0.43 0.43 853 853 853 2118 1899 528 572 2513
M3x0.5 0.76 0.76 0.76 1265 1265 1265 3143 2817 783 849 3556
M4x0.7 1.77 1.77 1.77 2208 2208 2208 5487 4918 1367 1482 6390
M5x0.8 3.57 3.57 3.57 3571 3571 3571 8873 7953 2210 2397 9781
M6x1.0 6.07 6.07 6.07 5055 5055 5055 12560 11258 3129 3393 14231
M8x1.25 14.73 14.73 14.73 9204 9204 9204 22871 20499 5697 6179 24935
3xx SS 6061-T6 6061-T6 3xx SS Ti6Al4V
E (psi) 29E+06 10E+06 10E+06 29E+06 16E+06
E (Pa) 20E+10 07E+10 07E+10 20E+10 11E+10
Stensile(psi) 80000 45000 45000 80000 150000
Syield (psi) 50000 40000 40000 50000 140000
Syield (Pa) 03E+08 03E+08 03E+08 03E+08 01E+08
Page 9
sh3xx-Al

1.0 1.5 1.0 1.5
(lb) (lb) (lb) (lb) (lb) OD(in) Dshd (in) At (in²)
357 202 219 41 44 0.60 0.55 0.06 0.098 1.80E-3
733 416 451 84 91 0.60 0.55 0.086 0.140 3.70E-3
1259 732 794 136 148 0.60 0.55 0.112 0.183 6.04E-3
1917 1129 1224 205 223 0.60 0.55 0.138 0.226 9.09E-3
2630 1563 1696 316 343 0.60 0.55 0.164 0.270 1.40E-2
3450 1998 2167 452 490 0.60 0.55 0.19 0.312 2.00E-2
6161 2165 2348 718 779 0.60 0.55 0.25 0.375 3.18E-2
1.0 1.5 1.0 1.5
(N) (N) (N) (N) (N) OD(m) Dshd(mm) At (m²)
2701 2911 3157 322 349 0.60 0.55 0.002 0.0038 2.07E-6
4149 4482 4861 528 572 0.60 0.55 0.003 0.0048 3.39E-6
5907 5581 6052 783 849 0.60 0.55 0.003 0.0055 5.03E-6
10575 8259 8957 1367 1482 0.60 0.55 0.004 0.0070 8.78E-6
16304 11140 12081 2210 2397 0.60 0.55 0.005 0.0085 1.42E-5
23637 14724 15968 3129 3393 0.60 0.55 0.006 0.0100 2.01E-5
41625 22631 24544 5697 6179 0.60 0.55 0.008 0.0130 3.66E-5
Page 10
ph3xx-Al
(L/D)grip 1.0 1.5 1.0 1.5
0-80 0.8 0.8 0.8 66 66 66 163 146 41 44 219
2-56 2.3 2.3 2.3 135 135 135 336 301 84 91 451
4-40 4.9 4.9 4.9 220 220 220 548 491 136 148 779
6-32 9 9 9 332 332 332 824 739 205 223 1187
8-32 17 17 17 511 511 511 1270 1138 316 343 1605
10-32 28 28 28 730 730 730 1814 1626 452 490 2081
1/4-20 58 58 58 1161 1161 1161 2884 2585 718 779 3775
 %SyAt %Ssy p od L/2 Fm = 0 = Fi(1-C) Fb = (SyAt-Fi)/C P = (Fb-
Fb = pSsy
(L/D)grip 1.0 1.5 1.0 1.5
M2x0.4 0.21 0.21 0.21 521 521 521 1294 1159 322 349 1650
M2.5x0.45 0.43 0.43 0.43 853 853 853 2118 1899 528 572 2513
M3x0.5 0.76 0.76 0.76 1265 1265 1265 3143 2817 783 849 3556
M4x0.7 1.77 1.77 1.77 2208 2208 2208 5487 4918 1367 1482 6390
M5x0.8 3.57 3.57 3.57 3571 3571 3571 8873 7953 2210 2397 9781
M6x1.0 6.07 6.07 6.07 5055 5055 5055 12560 11258 3129 3393 14231
M8x1.25 14.73 14.73 14.73 9204 9204 9204 22871 20499 5697 6179 24935
3xx SS 6061-T66061-T6 3xx SS Ti6Al4V
E (psi) 29E+06 10E+06 10E+06 29E+06 16E+06
E (Pa) 20E+10 07E+10 07E+10 20E+10 11E+10
Stensile(psi) 80000 45000 45000 80000 150000
Syield (psi) 50000 40000 40000 50000 140000
Syield (Pa) 03E+08 03E+08 03E+08 03E+08 01E+08
note: gsfc uses 75% Sut for Bolt proof
Page 11
ph3xx-Al
ESIGN (joint) LOADS Pan Head Screws

1.0 1.5 1.0 1.5
(lb) (lb) (lb) (lb) (lb) OD(in) Dpan (in) At (in²)
357 408 443 41 44 0.60 0.55 0.06 0.116 1.80E-3
733 851 923 84 91 0.60 0.55 0.086 0.167 3.70E-3
1259 1493 1619 136 148 0.60 0.55 0.112 0.219 6.04E-3
1917 2276 2469 205 223 0.60 0.55 0.138 0.270 9.09E-3
2630 3182 3451 316 343 0.60 0.55 0.164 0.322 1.40E-2
3450 4195 4550 452 490 0.60 0.55 0.19 0.373 2.00E-2
6161 7498 8132 718 779 0.60 0.55 0.25 0.492 3.18E-2
1.0 1.5 1.0 1.5
(N) (N) (N) (N) (N) OD(m) Dpan(mm) At (m²)
2701 3476 3769 322 349 0.60 0.55 0.002 0.0040 2.07E-6
4149 5365 5819 528 572 0.60 0.55 0.003 0.0050 3.39E-6
5907 5983 6488 783 849 0.60 0.55 0.003 0.0056 5.03E-6
10575 13692 14849 1367 1482 0.60 0.55 0.004 0.0080 8.78E-6
16304 17660 19152 2210 2397 0.60 0.55 0.005 0.0095 1.42E-5
23637 30662 33254 3129 3393 0.60 0.55 0.006 0.0120 2.01E-5
41625 54146 58722 5697 6179 0.60 0.55 0.008 0.0160 3.66E-5
Page 12
3xx-pcb-AL
(L/D)grip 1.0 1.5 1.0 1.5
0-80 0.6 0.6 0.6 47 47 47 1437 1195 45 45 87
2-56 1.7 1.7 1.7 96 96 96 2953 2457 92 92 179
4-40 3.5 3.5 3.5 157 157 157 4820 4011 150 151 310
6-32 7 7 7 236 236 236 7255 6037 226 227 473
8-32 12 12 12 364 364 364 11173 9297 347 350 637
10-32 20 20 20 520 520 520 15962 13282 496 500 822
1/4-20 41 41 41 827 827 827 25379 21118 789 794 1500
 %SyAt %Ssy p od L/2 Fm = 0 = Fi(1-C) Fb = (SyAt-Fi)/C P = (Fb-
Fb = pSsy
(L/D)grip 1.0 1.5 1.0 1.5
M2x0.4 0.15 0.15 0.15 371 371 371 11383 9472 354 356 655
M2.5x0.45 0.30 0.30 0.30 607 607 607 18641 15511 579 583 994
M3x0.5 0.54 0.54 0.54 901 901 901 27659 23015 860 866 1404
M4x0.7 1.26 1.26 1.26 1573 1573 1573 48280 40174 1501 1511 2527
M5x0.8 2.54 2.54 2.54 2544 2544 2544 78084 64974 2427 2444 3859
M6x1.0 4.32 4.32 4.32 3601 3601 3601 110528 91970 3436 3459 5622
M8x1.25 10.49 10.49 10.49 6557 6557 6557 ### ### 6256 6299 9834
3xx SS G-10 6061-T6 3xx SS Ti6Al4V
E (psi) 29E+06 50E+04 10E+06 29E+06 16E+06
E (Pa) 20E+10 34E+08 07E+10 20E+10 11E+10
Stensile(psi) 80000 20000 45000 80000 150000
Syield (psi) 50000 12000 40000 50000 140000
Syield (Pa) 03E+08 83E+06 03E+08 03E+08 01E+08
Page 13
3xx-pcb-AL

1.0 1.5 1.0 1.5
(lb) (lb) (lb) (lb) (lb) OD(in) Dpan (in) At (in²)
156 48 48 45 45 0.97 0.96 0.06 0.116 1.80E-3
321 100 101 92 92 0.97 0.96 0.086 0.167 3.70E-3
550 183 184 150 151 0.97 0.96 0.112 0.219 6.04E-3
837 280 282 226 227 0.97 0.96 0.138 0.270 9.09E-3
1151 372 374 347 350 0.97 0.96 0.164 0.322 1.40E-2
1513 466 469 466 469 0.97 0.96 0.19 0.373 2.00E-2
2695 895 901 789 794 0.97 0.96 0.25 0.492 3.18E-2
1.0 1.5 1.0 1.5
(N) (N) (N) (N) (N) OD(m) Dpan(mm) At (m²)
1182 422 425 354 356 0.97 0.96 0.002 0.0040 2.07E-6
1818 631 635 579 583 0.97 0.96 0.003 0.0050 3.39E-6
2590 569 573 569 573 0.97 0.96 0.003 0.0056 5.03E-6
4635 1596 1607 1501 1511 0.97 0.96 0.004 0.0080 8.78E-6
7152 1750 1762 1750 1762 0.97 0.96 0.005 0.0095 1.42E-5
10364 3527 3551 3436 3459 0.97 0.96 0.006 0.0120 2.01E-5
18263 6110 6152 6110 6152 0.97 0.96 0.008 0.0160 3.66E-5
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: 73% of BOLT YIELD Strength for JOINT SHEAR: JSmax = m Fi m ~ 0.3 (unlubricated joint)
TORQUE () Joint PRELOAD (Fi) APPLIED DESIGN (joint) LOADS Socket Head Screws
% Sb % thread Ssy % Sb % thread Ssy ..Unseat JOINT ..YIELD BOLT ..SHEAR thread ..CRUSH grip
(L/D)grip 1.5 2.0 1.5 2.0 1.5 2.0 1.5 2.0
(L/D)thread BOLT 1.5 2.0 BOLT 1.5 2.0 [smaller value ..unseat or yield first?] 1.5 2.0 1.5 2.0 LIMIT CASE (C) joint K ratio bolt data ...DON"T change
ANSI size (in lb) (in lb) (in lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) OD(in) Dshd (in) At (in²)
0-80 2.0 2.0 2.0 171 171 171 380 347 115 124 940 1473 29 31 29 31 0.55 0.51 0.06 0.098 1.80E-3
2-56 6.0 6.0 6.0 351 351 351 782 713 236 256 1931 3025 59 64 59 64 0.55 0.51 0.086 0.140 3.70E-3
4-40 12.8 12.8 12.8 573 573 573 1277 1164 385 418 3315 5174 154 167 154 167 0.55 0.51 0.112 0.183 6.04E-3
6-32 24 24 24 863 863 863 1921 1752 579 628 5047 7870 261 283 261 283 0.55 0.51 0.138 0.226 9.09E-3
8-32 44 44 44 1329 1329 1329 2959 2699 892 968 6928 10898 212 230 212 230 0.55 0.51 0.164 0.270 1.40E-2
10-32 72 72 72 1898 1898 1898 4227 3855 1274 1383 9091 14401 47 51 47 51 0.55 0.51 0.19 0.312 2.00E-2
1/4-20 151 151 151 3018 3018 3018 6721 6130 2026 2199 16225 25462 -1023 -1110 -1023 -1110 0.55 0.51 0.25 0.375 3.18E-2
 %SyAt %Ssy p od L/2 Fm = 0 = Fi(1-C) Fb = (SyAt-Fi)/C P = (Fb-Fi) /C P = (Fb-Fi) /C
(L/D)grip 1.5 2.0 1.5 2.0 1.5 2.0 1.5 2.0
ISO Size (Nm) (Nm) (Nm) (N) (N) (N) (N) (N) (N) (N) (N) (N) (N) (N) (N) (N) OD(m) Dshd(mm) At (m²)
M2x0.4 0.54 0.54 0.54 1353 1353 1353 3014 2749 909 986 7113 11183 1645 1785 909 986 0.55 0.51 0.002 0.0038 2.07E-6
M2.5x0.45 1.11 1.11 1.11 2217 2217 2217 4937 4502 1488 1615 10930 17273 2385 2589 1488 1615 0.55 0.51 0.003 0.0048 3.39E-6
M3x0.5 1.97 1.97 1.97 3289 3289 3289 7325 6680 2208 2396 15563 24681 2379 2582 2208 2396 0.55 0.51 0.003 0.0055 5.03E-6
M4x0.7 4.59 4.59 4.59 5741 5741 5741 12786 11660 3854 4183 27860 44087 2545 2762 2545 2762 0.55 0.51 0.004 0.0070 8.78E-6
M5x0.8 9.28 9.28 9.28 9285 9285 9285 20678 18859 6233 6765 42960 68266 1711 1857 1711 1857 0.55 0.51 0.005 0.0085 1.42E-5
M6x1.0 15.77 15.77 15.77 13143 13143 13143 29270 26694 8822 9575 62276 98751 1290 1400 1290 1400 0.55 0.51 0.006 0.0100 2.01E-5
M8x1.25 38.29 38.29 38.29 23931 23931 23931 53298 48607 16064 17436 ### ### -2184 -2371 -2184 -2371 0.55 0.51 0.008 0.0130 3.66E-5
MATERIALS BOLT GRIP Thread ...other materials note: consider thick washers to improve joint crush
A-286 6061-T6Ti6Al4V 3xx SS Ti6Al4V
E (psi) 29E+06 10E+06 16E+06 29E+06 16E+06
E (Pa) 20E+10 07E+10 11E+10 20E+10 11E+10
Stensile(psi) 160000 45000 150000 80000 150000
Syield (psi) 130000 40000 140000 50000 140000
Syield (Pa) 09E+08 03E+08 01E+08 03E+08 01E+08
Page 15
A286-Ti-Al
pick PRELOADS: 85% of BOLT YIELD Strength for JOINT SHEAR: JSmax = m Fi m ~ 0.3 (unlubricated joint)
(L/D)grip 1.5 2.0 1.5 2.0 1.5 2.0 1.5 2.0
ANSI size (in lb) (in lb) (in lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb) OD(in) Dshd (in)
0-80 2.4 1.7 2.3 199 144 192 254 315 208 108 122 181 1174 1178 122 108 0.43 0.39 0.06 0.098
2-56 7.0 5.1 6.8 409 295 394 521 647 428 223 251 371 2412 2420 251 223 0.43 0.39 0.086 0.140
4-40 15.0 11.2 15.0 667 501 667 884 1098 656 301 427 630 4153 4174 427 301 0.43 0.39 0.112 0.183
6-32 28 21 28 1004 760 1004 1343 1652 972 452 648 979 6364 6424 648 452 0.43 0.39 0.138 0.226
8-32 51 35 47 1547 1073 1431 1896 2353 1720 993 915 1351 9181 9256 915 993 0.43 0.39 0.164 0.270
10-32 84 55 73 2210 1441 1921 2545 3159 2671 1733 1228 1813 12196 12282 1228 1733 0.43 0.39 0.19 0.312
1/4-20 176 125 166 3514 2494 3325 4407 5468 3778 2063 2125 3138 14045 13435 2125 2063 0.43 0.39 0.25 0.375
 %SyAt %Ssy p od L/2 Fm = 0 = Fi(1-C) Fb = (SyAt-Fi)/C P = (Fb-Fi) /C P = (Fb-Fi) /C
(L/D)grip 1.5 2.0 1.5 2.0 1.5 2.0 1.5 2.0
ISO Size (Nm) (Nm) (Nm) (N) (N) (N) (N) (N) (N) (N) (N) (N) (N) (N) (N) (N) OD(m) Dshd(mm)
M2x0.4 0.63 0.44 0.59 1576 1100 1466 1943 2411 1738 989 937 1384 15688 16441 937 989 0.43 0.39 0.002 0.0038
M2.5x0.45 1.29 0.86 1.15 2581 1718 2291 3036 3768 3037 1902 1464 2162 24513 25688 1464 1902 0.43 0.39 0.003 0.0048
M3x0.5 2.30 1.48 1.98 3830 2474 3299 4372 5426 4679 3078 2109 3114 31389 32661 2109 3078 0.43 0.39 0.003 0.0055
M4x0.7 5.35 3.52 4.69 6685 4399 5865 7773 9645 7983 5100 3749 5536 47464 48828 3749 5100 0.43 0.39 0.004 0.0070
M5x0.8 10.81 6.87 9.16 10811 6874 9165 12145 15071 13467 9069 5857 8650 66635 67957 5857 8650 0.43 0.39 0.005 0.0085
M6x1.0 18.36 11.88 15.84 15303 9898 13197 17489 21702 18674 12264 8434 12455 88902 90047 8434 12264 0.43 0.39 0.006 0.0100
M8x1.25 44.58 28.15 37.54 27865 17596 23462 31092 38582 34987 23784 14994 22143 142728 143115 14994 22143 0.43 0.39 0.008 0.0130
A-286 Ti6Al4V 6061-T6 3xx SS Ti6Al4V MY TEST CASE failure failure failure
E (psi) 29E+06 16E+06 10E+06 29E+06 16E+06 test result 8-32 shs (L/D) torque preload stress
E (Pa) 20E+10 11E+10 07E+10 20E+10 11E+10 thread shear 1/8" plat 0.76 48 1463 44774 45 ksi
Stensile(psi) 160000 150000 45000 80000 150000 broke head 1/4" plat 1.52 78 2378 169861 min 160 ksi
Syield (psi) 130000 140000 40000 50000 140000
Syield (Pa) 09E+08 01E+08 03E+08 03E+08 01E+08
Page 16
A286-Ti-Al
ocket Head Screws
olt data ...DON"T change

At (in²)
1.80E-3
3.70E-3
6.04E-3
9.09E-3
1.40E-2
2.00E-2
3.18E-2
ocket Head Screws
olt data ...DON"T change

At (m²)
2.07E-6
3.39E-6
5.03E-6
8.78E-6
1.42E-5
2.01E-5
3.66E-5
Page 17
Al Inserts
pick PRELOADS: 73% of BOLT YIELD Strength for JOINT SHEAR:

% Sb % thread Ssy % Sb % thread Ssy ..Unseat JOINT ..YIELD BOLT
(L/D)grip 1.5 2.0 1.5 2.0
(L/D)thread BOLT 1.5 2.0 BOLT 1.5 2.0 [smaller value ..unseat or yield first?]
ANSI size (in lb) (in lb) (in lb) (lb) (lb) (lb) (lb) (lb) (lb) (lb)
2-56 6.0 3.3 4.4 351 190 253 336 417 670 581
4-40 12.8 7.3 9.7 573 324 432 572 710 1063 901
6-32 24 14 18 863 493 658 872 1082 1586 1336
8-32 44 22 30 1329 675 901 1193 1481 2637 2346
10-32 72 35 47 1898 931 1242 1646 2042 3844 3466
1/4-20 151 78 104 3018 1557 2076 2751 3414 5937 5252
%SyAt %Ssy p od L/2 Fm = 0 = Fi(1-C) Fb = (SyAt-Fi)/C

% Sb % thread Ssy % Sb % thread Ssy ..Unseat JOINT ..YIELD BOLT
(L/D)grip 1.5 2.0 1.5 2.0
(L/D)thread BOLT 1.5 2.0 BOLT 1.5 2.0 [smaller value ..unseat or yield first?]
ISO Size (Nm) (Nm) (Nm) (N) (N) (N) (N) (N) (N) (N)
M2x0.4 0.54 0.44 0.54 1353 1107 1353 1957 2226 1721 1277
M3x0.5 1.97 1.25 1.66 3289 2076 2768 3669 4552 5597 4433
M4x0.7 4.59 2.66 3.54 5741 3322 4429 5870 7284 10465 8765
M5x0.8 9.28 4.84 6.46 9285 4844 6459 8560 10622 18142 15973
M6x1.0 15.77 7.97 10.63 13143 6644 8858 11739 14567 26172 23336
M8x1.25 38.29 17.72 23.62 23931 11073 14764 19565 24279 50016 45979
A-286 Ti6Al4V 5083-0 Al 3xx SS Ti6Al4V
E (psi) 29E+06 16E+06 10E+06 29E+06 16E+06
E (Pa) 20E+10 11E+10 07E+10 20E+10 11E+10
Stensile(psi) 160000 150000 42000 80000 150000
Syield (psi) 130000 140000 21000 50000 140000
Syield (Pa) 09E+08 01E+08 01E+08 03E+08 01E+08
Page 18
Al Inserts
PLIED DESIGN (joint) LOADS Socket Head Screws & Helicoils

1.5 2.0 1.5 2.0 thread
1.5 2.0 1.5 2.0 LIMIT CASE (C) joint K ratio bolt data ...DON"T change Insert
(lb) (lb) (lb) (lb) (lb) (lb) OD(in) Dshd (in) At (in²) OD(m)
362 535 2654 2778 336 417 0.43 0.39 0.086 0.140 3.70E-3 0.110
625 922 4559 4774 572 710 0.43 0.39 0.112 0.183 6.04E-3 0.144
958 1415 6978 7309 872 1082 0.43 0.39 0.138 0.226 9.09E-3 0.178
1223 1805 10098 10610 1193 1481 0.43 0.39 0.164 0.270 1.40E-2 0.205
1791 2645 13369 14015 1646 2042 0.43 0.39 0.19 0.312 2.00E-2 0.244
2767 4086 16204 16623 2751 3414 0.43 0.39 0.25 0.375 3.18E-2 0.310
PLIED DESIGN (joint) LOADS Socket Head Screws
1.5 2.0 1.5 2.0 thread
1.5 2.0 1.5 2.0 LIMIT CASE (C) joint K ratio bolt data ...DON"T change Insert
(N) (N) (N) (N) (N) (N) OD(m) Dshd(mm) At (m²) OD(m)
4738 7310 15671 16729 1721 1277 0.43 0.39 0.002 0.0038 2.07E-6 0.004
6605 9755 32307 34016 3669 4433 0.43 0.39 0.003 0.0055 5.03E-6 0.005
8747 12917 49945 52493 5870 7284 0.43 0.39 0.004 0.0070 8.78E-6 0.006
11161 16482 71310 74860 8560 ### 0.43 0.39 0.005 0.0085 1.42E-5 0.007
13849 20451 96400 101119 11739 ### 0.43 0.39 0.006 0.0100 2.01E-5 0.008
20044 29601 ### ### ### ### 0.43 0.39 0.008 0.0130 3.66E-5 0.010
Page 19

Bolt Design

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Bolt Design

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Intro

BOLTED JOINT BEHAVIOR

oof stress (Sp)

fety factor on joint loads.

ssing the joint (F m).

joint (or members) are

nstant (K) is defined

much lower that the yield strength,

Background Discussion & Comments Using these .xls worksheets

COMPRESSIVE GRIP YIELDING UNDER THE HEAD

TAPPED THREAD FAILURE IN SHEAR

automate the joint analysis details,

JSmax = m Fi m ~ 0.3 (unlubricated joint)

ESIGN (joint) LOADS Socket Head Screws

note: consider thick washers to improve joint crush

JSmax = m Fi m ~ 0.3 (unlubricated joint)

ESIGN (joint) LOADS Socket Head Screws

JSmax = m Fi m ~ 0.3 (unlubricated joint)

ESIGN (joint) LOADS Pan Head Screws

JSmax = m Fi m ~ 0.3 (unlubricated joint)

ESIGN (joint) LOADS Pan Head Screws

note: the Binding Head is a little better for PCB's

ocket Head Screws

olt data ...DON"T change

ocket Head Screws

olt data ...DON"T change

pick PRELOADS: 73% of BOLT YIELD Strength for JOINT SHEAR:

TORQUE () Joint PRELOAD (Fi) APPLIED DESIGN (joint) LOADS

JSmax = m Fi m ~ 0.3 (unlubricated joint)

PLIED DESIGN (joint) LOADS Socket Head Screws & Helicoils

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