Manuf. and Ind. Eng.

, 11(1), 2012, ISSN 1338-6549

© Faculty of Manuf. Tech. TUKE

Spontaneous Unfastening and Fatigue of Bolted Joints

Jozef Dominik, Milan Zmindak

Abstract
This paper deals with unfastening and fatigue of bolted joints. In this work will try to give answer on question when
occurs fatigue fracture. Statistically, it is proven that the joint decay usually occurs when self-unscrewing. It is due to a
combination of statically and dynamically operating axial, radial or torsional forces. The superposition of forces causes that
the original, i.e. assembly prestressing may not be preserved but by improper installation and adverse operating conditions it
gradually decreases, in extreme case right to zero. It is proven that the most frequent spontaneous release of bolted joints
occurs after the first loaded cycles. Finally, are apparent areas which need to be focused on when bolt connections is
dynamically loaded.
Keywords: bolted joints, spontaneous unscrewing, fatigue fracture

1 Introduction
Bolts are an integral part of engineering designs, and 2 Spontaneous unscrewing
bolted structures can show a complex mechanical behavior. Unlike the destruction of parts from excessive effects of
Structural deterioration or failure of the structure systems by static force, spontaneous loosening is time-dependent gra-
aging is generally attributed to the degradation of joint dual process of decline of bolting prestress leading to their
structures [5]. This is because the discontinuity of rigidity complete disintegration with parallel cumulation (Fig. 2) of
and stress concentration at the joint make it ready to initiate the fatigue material damage.
and propagate fatigue cracks. There are a number of factors
that influence the performance of a bolted joint within the
structure. An important one is the level of preload, or
torque, applied to the bolt, which compresses the joined
elements and increases the friction between them, thus
facilitating the load transmission from one to another [4].
If we do not take into consideration the destruction of
screw connections by excessive static load and corrosion
cracking (or hydrogen embrittlement), then their life can
collapse in two ways: fatigue fracture of bolts or a
spontaneous unscrewing of a nut (Fig. 1). In both cases, the
screw joints lose their ability to function, so both cases are
dangerous. When, however, there is unscrewing and when
the fatigue fracture? The following contribution will try to
give the answer to this question.

Fig. 2 Disintegration of bolted joint

Fig. 1 Disintegration of bolted joints due to repeated
dynamical stressing and vibrations
Statistically, it is proven that the joint decay usually oc-
curs when self-unscrewing. However, there are not isolated
instances of fatigue fracture of screws after preceding half-
way loosening while the joint itself is not completely
disintegrated. The reason for this is cyclical repeated dy-
namic shocks and vibrations transmitted to the relevant
nodes.
For functioning it means correctly tightened bolted joint
have effect two types of forces:
a) Internal or assembly induced by tightening the joint
forces to a value of prestressing. Internal forces can be
defined quite accurately and also applied to the assembly
by using of torque wrenches with more or less precision.
b) External forces caused by additional operational loading.
External and internal forces are mutually interrelated and
complement one another proportionally and disproportio-

41
 nally or counteract each other. Therefore, we are talking
about a superposition of the forces. It is complicated and
difficult to control. It is often a random process depen-
ding on many factors. In most cases, it is a combination
of statically and dynamically operating axial, radial or
torsional forces which can be hard to predict.
Absence of exact data on the operating conditions
designers usually offset by increasing the safety coefficient
by sizing of bolted connections, increasing the coefficient of
friction on the contacts surfaces, choice of fine pitch thread
or by other measures. However, the designer can never
guarantee 100% operational safety because he is not
responsible for the installation and subsequent handling.
The mentioned superposition of forces causes that the
original, i.e. assembly prestressing may not be preserved but
by improper installation and adverse operating conditions it
gradually decreases, in extreme case right to zero.
Precondition for the right working of bolted connections
is assembly prestressing that achieves by required tighte-
ning torque. During operation the prestressing serves as
reservoir of assembly forces and it may not drop below a
certain critical value. On the contrary, it may not exceed the
strength characteristics of material even for short additional
operational burden.
Fig. 3 Moment distribution
Fig. 3 shows that just a little proportion of energy sup-
plied in form of torque (Mef) is used effectively for
preloading required to maintain associated parts in the
tightened state. The rest of energy (Mfr) is used for over-
coming friction between threads and under the head of the
screw and under the nut and is converted into reactive heat.
Here is valid:
M ef  M  M fr
In terms of safety it is not torque what is important, but
the prestressing that causes it. The higher friction between
the screw and the head of screw and the nut entails the
lower constant M prestressing, it means that the connection
will be sufficiently tightened. Untightened or ragged
although not fully disassembled screw connection repre-
sents a significant security risk because in a short period of
time, there is a bore to discharge mounting holes with
subsequent spontaneous disintegration service or fatigue
fracture of screws and it occurs preferably in locations of
the biggest stress concentration, in this case, in the interface
of external and internal thread.
Not long ago, bolted structural parts were commonly
treated as rigidly connected. With recent advances in com-
puter-aided modeling and finite element analysis, engineers
can now get insight into bolted connections that was
previously difficult to obtain. Engineers can ask questions
regarding, e.g., the bolt forces required to prevent leaking of
fluid, the frequencies of a bolted structure when contact and
42
friction play an important role, and the contribution of the
bolted connections to noise and vibration. The application
of FEM in the analysis of bolt pre-tension can help to pre-
dict the stress concentration and distribution of the con-
nected parts in advance, and to guide the design and pro-
duction [1,6]. Fig.4 describes von Mises stress around most
loaded threads.
Fig. 4 Course of von Mises stress in bolted joint
. 3 Fatigue fracture
As it was already mentioned, if we omit the brutal con-
gestion, then bolted joint can collapse either due to
spontaneous release or fatigue fracture (Fig. 1 and Fig. 2).
Both cases are, equally, dangerous and the causes are also
the same - the vibration and repeated dynamic stress. But
when is there the spontaneous release, when the fatigue and
when fracture? The answer is not so simple, but on the
knowledge about the behaviour of bolting, we can, at least,
formulate a core argument. As it is generally known, the
process of spontaneous release is proceeding in three known
phases: 1. the relaxation, 2. the spontaneous unfastening and
3. the decay (or disintegration). The relaxation takes occurs
without the nut/screw turn over. The cause lies on aligning
the contact surfaces and on inequalities of microplastic
deformation in these areas. The second stage begins with
gradual of scrolling matrix and/or screws in assembly
dependent current downturn which results into the third
stage - total separation from the nut screws. The case of
total unscrewing is clear. But what will happen if the
prestressing falls to zero and the nut is not detached from
the screw? Will the first two stages occur? This state may
occur due to using of the lock nut with nylon ring according
to DIN 985, or another safety element with similar pro-
perties [2,3]. If the dynamic loading exposition continues,
after certain number of cycles, the critical cumulation of
fatigue damage and subsequent fatigue fracture will occur,
which is, from the point of safety, certainly worse state. The
reason is simple. While a loose screw can be checked and
possibly tightened, fatigue failure comes suddenly, without
warning.
Fatigue failure and actins to increase the bolt capacity
Fatigue failure develops in parts loaded by variable loads
mostly in areas of stress concentration although the value of
the nominal stress is far below the ultimate strength. Sta-
tistics confirm that from the total number of observed stan-
dardized bolts which have been damaged by fatigue
fracture, the fatigue failure occurred in 65% of the bolts in
the first support thread, 20% in the thread run-out and 15%
in transition from the shank to the bolt head. From the given
statistics if fatigue failures, there are apparent areas which
need to be focused on when constructing dynamically loa-
ded bolt connections.
1. The reduction of the notch coefficient in thread run-out
by rounded transition to bolt shank.
2. The radius transition increase from head to bolt shank.
3. If possible, do not uses bolt with fine pitch thread.
4. If possible, do not use bolts with large diameters. Prefer
two smaller bolts to one large.
5. Use suitable structural design of joints with studs.
6. Use cross-thread bolt design for through-hole
7. Use stud with nut cross-thread bolts for dead hole. For
dead hole is preferred to use stud with nut, based on the
bottom of the hole, instead of the standard bolts. The
best stud is with ball end, or with inserted ball.
We also note that for the dynamic load of bolted joints
must be designed bolt satisfying “static” control with regard
to yield strength for the load from maximal axial force.
4 Conclusions
The loosening of bolts causes improper assembly,
followed by the loss of their self-locking during the ope-
ration. Then, it depends on the particular circumstances
whether a classical breakdown of bolt joint occurs or its
destruction occurs by material fatigue. Statistically, it is
proven that the most frequent spontaneous release of bolted
joints occurs after the first loaded cycles. Therefore, it is
important their current monitoring, especially in that inter-
val.
Dominik Jozef, M.Sc., PhD.,
FERODOM, s.r.o.,
Street Stefánikova 58, 01001 Zilina,
Slovak Republic
E-mail: ferodom@ferodom.sk
Prof. Zmindak Milan, M.Sc., PhD.,
University of Zilina,
Faculty of Mechanical Engineering,
Street Univerzitná 1, 01026 Zilina,
Slovak Republic
E-mail: milan.zmindak@fstroj.uniza.sk
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