FINITE ELEMENT MODELING OF RIVETED

LAP JOINT AND T-JOINT FILLET WELD

A
DISSERTATION
Submitted in partial fulfilment for the award of the degree of

MASTER OF TECHNOLOGY (INTEGRATED)

IN
MECHANICAL ENGINEERING

Submitted by

E SASHIKANT SINGHA
BETI1ME12012

Under the Guidance of

TRILOK CHAUHAN
DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF ENGINEERING & TECHNOLOGY

ITM UNIVERSITY GWALIOR, (M.P.), INDIA

2012-2017

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 CERTIFICATE

I hereby certify that the dissertation entitles “Finite Element Modeling of Riveted
Lap Joint and T-joint Fillet Weld” submitted by “E Sashikant Singha
(BETI1ME12012)” in partial fulfilment for the award of degree of M.Tech.
(Integrated), ITM University, Gwalior has been carried out under my/our
supervision.

To the best of my knowledge and belief, the dissertation

(i) Is original piece of work of candidate himself / herself.

(ii) Has duly been completed.

(iii) Is up to the standard both in respect of contents and language.

(iv) Work has not been submitted partially or wholly to any other university or
Institute for the award of this or any other degree or diploma.

(Trilok Chauhan)

Supervisor

(Dr. R.K Jain)

Head of the Department

(Dr. Ranjeet Singh Tomar)

Dean, School of Engineering & Technology

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 DECLARATION

I hereby declare that the work entitled “FINITE ELEMENT MODELING OF

RIVETED LAP JOINT AND T-JOINT FILLET WELD” submitted to the
Department of Mechanical Engineering, School of Engineering and Technology,
ITM University, Gwalior (M.P.) is my own work done under the supervision of
“Trilok Chauhan”. The dissertation doesn’t contain any part which has been
submitted for award of any degree either in this University or in any other University.

I further declare that the work is free from any plagiarism.

(Signature of the candidate)

(E Sashikant Singha)

(BETI1ME12012)

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 ACKNOWLEDGEMENT

I have given a lot of effort in this work. However, it would never have been
possible without the kind support and help of many individuals and organizations.
I would like to extend my sincere thanks to all of them.

First of all, I am very thankful to God and parents on the successful completion of
the work. No doubt without his blessings this would never have been possible. I
am highly indebted to Dr. R.K Jain, Head of Department Mechanical
Engineering for providing me an opportunity to do my M. Tech (Integrated) from
this institute.

I would like to express my deepest gratitude to my supervisor “Trilok Chauhan”

for their excellent guidance, caring nature, patience and for providing necessary
information regarding the project. I would like to thank them for their valuable
advice and constant encouragement throughout my project. Without their
tremendous support and time, it would have been impossible for me to complete
this project timely.

I would like to express my special gratitude and thanks to Mr. Shaheen Beg
Mughal (Assistant Professor), Mr. Jai Kumar Sharma (Assistant Professor) and
Mr. Sateesh Kumar (Assistant Professor). They have encouraged, supported and
helped me in completing this project successfully.

Last but not the least I would like to extend my heartfelt thanks to my loving
family, my parents and caring friends for their strength, help and for everything.
They were always supporting me and encouraging me with their best wishes.

(E Sashikant Singha)

(BETI1ME12012)

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 ABBRIVIATION

LEFM Linear Elastic Fracture Mechanics

FEM Finite Element Modelling
ISO International Organization For Standardization
HSS Hot Spot Stress
CHS Circular Hollow Section

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 LIST OF FIGURES
CHAPTER 1
Figure 1.1: Rivet parts ................................................................................................................ 2
Figure 1.2: Lap joint................................................................................................................... 3
Figure 1.3: Butt joint .................................................................................................................. 3
Figure 1.4: Single riveted lap joint............................................................................................. 3
Figure 1.5: Double riveted lap joint ........................................................................................... 3
Figure 1.6: Chain riveted lap joint ............................................................................................. 4
Figure 1.7: Zigzag riveted lap joint ............................................................................................ 4
Figure 1.8: Weld geometry ........................................................................................................ 5
Figure 1.9: Single parallel fillet weld......................................................................................... 5
Figure 1.10: Double paralel fillet weld ...................................................................................... 6
Figure 1.11: Combination of transverse and parallel fillet weld ................................................ 6
Figure 1.12: Flactuating stresses ................................................................................................ 7
Figure 1.13: Repeated stresses ................................................................................................... 7
Figure 1.14: Reversed stress ...................................................................................................... 7

CHAPTER 2
Figure 2.1: Circular disc heat source ......................................................................................... 9
Figure 2.2: Physical properties of steel .................................................................................... 10
Figure 2.3: Multi-pass geometry of butt weld.......................................................................... 11
Figure 2.4: Graphical representation of stress ......................................................................... 12
Figure 2.5: Fatigue specimen design ........................................................................................ 13
Figure 2.6: Cylindrical shaft .................................................................................................... 15

CHAPTER 3
Figure 3.1: Layout of ANSYS Workbench .............................................................................. 17
Figure 3.2: Layout of Design Modeler..................................................................................... 18
Figure 3.3: Dimension selection .............................................................................................. 18
Figure 3.4: First rectangle L=80mm, W=12mm ...................................................................... 19
Figure 3.5: Second rectangle L=80mm, W=12mm ................................................................. 19
Figure 3.6: Trimming the common part of two rectangles ...................................................... 20
Figure 3.7: Creating fillet on intersecting lines of two rectangles ........................................... 20

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Figure 3.8: Extruded view of the fillet weld ............................................................................ 21
Figure 3.9: Front view of the upper plate of riveted lap joint .................................................. 21
Figure 3.10: Isometric view of the upper plate of riveted lap joint ......................................... 22
Figure 3.11: Front view of the bottom plate of riveted lap joint .............................................. 22
Figure 3.12: Isometric view of the bottom plate of riveted lap joint ....................................... 22
Figure 3.13: Three dimensional view of the chain riveted lap joint ........................................ 23
Figure 3.14: Three dimensional view of the zigzag riveted lap joint ...................................... 23
Figure 3.15: Meshed view of the T-joint fillet weld ................................................................ 24
Figure 3.16: Meshed view of the riveted lap joint ................................................................... 24

CHAPTER 4
Figure 4.1: Boundary condition on T-joint fillet weld ............................................................. 26
Figure 4.2: Boundary condition on riveted lap joint ................................................................ 27

CHAPTER 5
Figure 5.1: Maximum shear stress and shear stress on chain riveted lap joint ........................ 29
Figure 5.2: Maximum shear stress and shear stress on zigzag riveting lap joint ..................... 29
Figure 5.3: Maximum shear stress and shear stress on chain riveting lap joint ....................... 30
Figure 5.4: Maximum shear stress and shear stress on zigzag riveted lap joint ...................... 31
Figure 5.5: Maximum shear stress and shear stress on chain riveted lap joint ........................ 31
Figure 5.6: Maximum shear stress and shear stress on zigzag riveted lap joint ...................... 32
Figure 5.7: Mode shapes with natural frequencies .................................................................. 33
Figure 5.8: Stress and fatigue life at 180 KN ........................................................................... 34
Figure 5.9: Stress and fatigue life at 160 KN ........................................................................... 34
Figure 5.10: Stress and fatigue life at 140 KN ......................................................................... 35
Figure 5.11: Stress and fatigue life at 120 KN ......................................................................... 35
Figure 5.12: Stress and fatigue life at 100 KN ......................................................................... 36
Figure 5.13: Stress and fatigue life at 80 KN ........................................................................... 36
Figure 5.14: Stress and fatigue life at 60 KN ........................................................................... 37
Figure 5.15: Stress and fatigue life at 40 KN ........................................................................... 37
Figure 5.16: Stress and fatigue life at 34 KN ........................................................................... 38
Figure 5.17: SN diagram .......................................................................................................... 40
Figure 5.18: Typical SN curve ................................................................................................. 40

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 LIST OF TABLES
CHAPTER 2
Table 2.1: Mechanical properties of SM8YA steel .................................................................... 9
Table 2.2: Dimensions of T-shape CHS joint .......................................................................... 14

CHAPTER 4
Table 4.1: Material properties of structural steel and aluminium ............................................ 26

CHAPTER 5
Table 5.1: Shear stress and Maximum Shear stress on chain and zigzag riveting ................... 30
Table 5.2: Shear stress and Maximum Shear stress on chain and zigzag riveting24 ............... 30
Table 5.3: Shear stress and maximum shear stress .................................................................. 32
Table 5.4: Shear stress and maximum shear stress .................................................................. 32
Table 5.5: Mode with frequency .............................................................................................. 33
Table 5.6: Load, stress and no. of cycles ................................................................................. 38
Table 5.7: Load and reverse stress ........................................................................................... 39
Table 5.8: Reverse stress and no. of cycles.............................................................................. 39
Table 5.9: ANSYS and theoretical fatigue life ........................................................................ 41

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 ABSTRACT

Manufacturers always face problem in manufacturing large and complex

structures. The easy way to manufacture large and complex structures is to divide
that large structure or component into smaller components. It is also cheaper to
manufacture small components first and then assembled them to get the desired
structure. For assembling and joining these small components mechanical
fasteners are used. Riveted and welded joints are the most widely used mechanical
fasteners. The focus of present work is on Riveted lap joint and T-joint fillet weld.
Modling and Finite Element Analysis of Riveted lap joint and T-joint fillet weld is
done in present work. Present work shows the Stress analysis on different riveted
lap joint (Chain and Zigzag riveting joint) and Fatigue analysis of T-joint fillet
weld. In present work include validation of stress analysis. Further comparison
between Fatigue life determined through Finite Element Analysis and Fatigue life
calculated through theoretically is shown in present work. Finite Element Analysis
of Riveted lap joint and T-joint fillet weld is done with the help of ANSYS
Workbench 15.0. Modal Analysis of Riveted lap joint is also performed.

Keywords: Finite Element Analysis, Riveted lap joint, T-joint fillet weld, Stress,
Fatigue.

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 LIST OF CONTENTS

CERTIFICATE ........................................................................................................................ii
DECLARATION .................................................................................................................... iii
ACKNOWLEDGEMENT ...................................................................................................... iv
ABBRIVIATION ..................................................................................................................... v
LIST OF FIGURES ................................................................................................................ vi
LIST OF TABLES ............................................................................................................... viii
ABSTRACT ............................................................................................................................. ix

CHAPTER 1
INTRODUCTION ................................................................................................................ 1-7
1.1 Introduction ............................................................................................................................... 2
1.2 Rivet joints .................................................................................................................................. 2
1.3 Types of rivet joints ................................................................................................................... 2
1.3.1 Lap joint................................................................................................................................. 2
1.3.2 Butt joint ............................................................................................................................... 2
1.4 Types of lap joint ........................................................................................................................ 3
1.5 Fillet weld ................................................................................................................................... 4
1.6 Weld geometry ........................................................................................................................... 5
1.6.1 Toe......................................................................................................................................... 5
1.6.2 Face ....................................................................................................................................... 5
1.6.3 Root ....................................................................................................................................... 5
1.6.4 Weld throat ........................................................................................................................... 5
1.7 Strength of transverse fillet welds ............................................................................................. 5
1.8 Fatigue failure ............................................................................................................................ 6
1.9 Types of cyclic stresses ............................................................................................................... 6
1.9.1 Fluctuating or alternating stresses......................................................................................... 6
1.9.2 Repeated stresses .................................................................................................................. 7
1.9.3 Reversed stresses ................................................................................................................... 7

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CHAPTER 2
LITERATURE REVIEW.................................................................................................. 8-15
2.1 Literature review..................................................................................................................... 9

CHAPTER 3
MODELING AND MESHING ....................................................................................... 16-24
3.1 Introduction .......................................................................................................................... 17
3.2 Layout of ANSYS WORKBENCH ............................................................................................. 17
3.3 Model Generation ................................................................................................................. 17
3.3.1 T-joint fillet weld ........................................................................................................... 18
3.3.2 Riveted lap joint ............................................................................................................ 21
3.4 Meshing................................................................................................................................. 24

CHAPTER 4
MATERIALS AND BOUNDARY CONDITION ......................................................... 25-27
4.1 Materials .................................................................................................................................. 26
4.2 Boundary conditions ................................................................................................................ 26

CHAPTER 5
RESULT AND DISCUSSION......................................................................................... 28-41
5.1 Validation ................................................................................................................................. 29
5.2 Effect of thickness .................................................................................................................... 30
5.3 Modal analysis of riveted lap joint ........................................................................................... 32
5.4 Fatigue analysis of T-joint......................................................................................................... 34

CHAPTER 6
CONCLUSION AND FUTURE SCOPE ....................................................................... 42-43
Conclusion ......................................................................................................................................... 43
Future scope ..................................................................................................................................... 43

Reference................................................................................................................................. 44
List of publication .................................................................................................................. 47

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