1.

INTRODUCTION
Bolted joints play an important role in stress formation in an assembly, so they are given
structural assembly and flanged joints. Continious improvement is necessary in these structural
joints which help improving the capacity of stress it can withstand and structural integrity, with a
reduction of structural weight and number of parts. Bolted joints are of two types, first is the
tensile joint which comes into play when the forces on the bolted joint act parallel to the bolt axis
and the second is the shear joint, when the forces on the joint are act normal to the top of the bolt
axis. In these two categories, regularly tensile joint is used in the assemblies.

2.A STUDY ON STRESS CONCENTRATION

For pressure vessels and piping systems which are to be subjected to unusually high
pressures, hostile environments, or other situations where conventional or code- based design
procedures may be inadequate, an accurate stress analysis for all loading conditions is essential.

The purpose of this analysis is to determine the effects of stress concentrations on the
bolt hole. A steel plate measuring 150mm x 100mm x 10mm will be used. One hole is drilled
through the vertical centre line of the plate. The plate is constrained in all dof at the bottom and,
an uniform distributed load is pulling on the top of the plate. To create and provide extra details
during post processing, path operations are used. In figure 3.1, first part shows the stress
intensities around the bolt hole. A line path is generated between the two points (0,75) and
(100,75). The stress concentrations along this line path is represented in the second part of figure
3.1
 Figure 3.1 Stress analysis in a bolt hole

3.1 INGLIS SOLUTION

This is an analytical solution, developed by Inglis, which determines stress field around
an elliptical hole in a large plate. The plate was loaded under the tensile stress σ 0. This is
illustrated in figure 3.2.
 Figure 3.2 Plate containing elliptical hole subjected to uniform applied tension

The maximum stress developed on the elliptical hole is given by,

2a
σmax = σo(1+ ¿
b

σmax = maximum stress

σ0 = applied stress

a = major axis distance

b = minor axis distance

For a circular hole a=b and plate containing plate containing circular hole subjected to
uniform applied tension is shown in figure 3.3
 Figure 3.3 Plate containing circular hole subjected to uniform applied tension

For a circular hole σmax is three times greater than σ0

σmax =3σo

Using design data book page number 7.6: for infinite wide plate,

a 10
= =¿ 0.1
w 100

Kt = 2.7

100 X 100 X 10
σnom =
90 X 10

=111.1 MPa

σmax = 2.7x111.1 = 300 MPa

The maximum stress obtained in finite element analysis is validated with the theoretical
value which is shown in the table 3.1.

Table 3.1 Comparison of stress values in a bolt hole

Maximum stress in bolt hole (MPa)

Theoretical ANSYS
300 299.89
 3.CONTACT ZONE ANALYSIS
Contact stress at the bolt and plate interface was analyzed by generating contact pairs
between the plate and the bolt interface. Bolt surface was taken as target and all degrees of
freedom arrested at both ends of bolt. Surface area of hole in the plates taken as contact and
contact pair was generated by using contact wizard. The contact pair elements were selected by
element name ELEMENTS 174.

Components used in the bolted connection (Fig3.4) are, two steel

plates(100mmX30mmX10mm)and one steel bolt of 10mm dia. Left end of the bottom plate is
constrained in all degrees of freedom and the surfaces of plates in XY planes were constrained in
UZ. At the top plate’s right end a pressure of 100 MPa was applied at perpendicular to the bolt
axis. Surface to surface contact occurs between the plates and bolt. At the top plates right end, a
pressure of 100 MPa was applied perpendicular to the bolt axis (in X direction).

F
igure 3.4 Finite element modeling of a bolted connection
 Contact pair generated between the bolt and plates of bolted connection are shown in
Figure 3.5.

Figure 3.5 Development and modeling of contact surfaces

Deformed surface areas of the bolt and contact pressure distribution on the bolt are
represented in figure 3.6.

Figure 3. 6 Contact pressure distribution on the bolt

 CHAPTER 4

CONTACT ZONE ANALYSIS BETWEEN TWO PLATES

In finite element analysis, if two independent parts are present, there is no stiffness
relationship defined between them. The resulting stiffness matrices will be uncoupled
consequently, one part may pass through the other during the course of simulation. Contact
elements are required to define the interaction of two or more steps of meshes to prevent such
penetration.

ANSYS contact elements typically support four different algorithms: augmented

Lagrangian, pure penalty, Multipoint constraint, and Lagrange multiplier methods. The default
and most commonly used option is the augmented lagrangian formulation, which can be thought
of as a variation of the pure penalty method.

In the analysis of bolted connections, a finite element research program was initiated to
determine the contact stress distribution and the limits of the surface to surface contact area. The
factors influencing the stresses developed are the fallowing; the geometry and elastic constants
of the components, the magnitude, location and area over which the bolt forces act, and
additional forces caused by internal pressures, temperature variations etc. In order to overcome
the range of geometric parameters which would be normally encountered in practice, the study
considered the fallowing.

Loading disc diameter = 25.4mm, 38.1mm, 50.8mm

Bolt hole diameter = 0, 6.35mm, 12.70mm, 19.05mm

Plate diameter = 152.5mm

Plate thickness = 19.05mm

The modeling program was limited to the study of the contact of plates having equal
thickness. The magnitude of contact pressure (MPa) and contact zone diameter (mm) can be
represented in graphical form by using ANSYS path operations.
 This study aims to determine the effects of stress concentrators along a certain path, rather
than plotting the entire contour plot, a plot of the stress along that path can be made. Figure 4.1
demonstrates the following;

(i) Contact elements between the plates and the contact zone
(ii) Graph showing magnitude of contact pressure along the contact diameter
(iii) Bolted connection with pretension
(iv) Geometric representation of contact pressure in a line path between the plates through
the bolt hole.

The contact zone diameter along the plate diameter and maximum values of contact
pressure were analyzed for different loading disc diameters of the bolted connection as shown in
figure 4.1.

Figure 4.1 Contact pressure between the plates

Any mathematical or numerical model which assumes linear elasticity or

viscoelasticity and perfectly flat contacting surfaces between two bodies will predict that the
region of contact is independent of the load levels, provided that the relative magnitudes of all
external tractions (and body forces) are kept constant. As a consequence it follows that the
strains, stresses, displacements, rotations, etc., must vary linearly with level of loading.
 Four bolt hole sizes are introduced for each loading disc diameter. The pretension load is
varied from 0 to 6000 N for each bolt hole size. Tables 4.1, 4.2 & 4.3 clearly show the
geometries and results obtained for each test.

Table 4.1 Contact zone size at 25.4 mm loading disc dia

Plate Plate Loading Bolt hole Load– Contact Maximum

dia thickness disc dia size pretension zone dia contact pressure
(mm) (mm) (mm) (mm) (N) (mm) (MPa)

152.5 19.05 25.4 0 0 irregular 4.90x10-10

1000 91.5 0.698
2000 91.5 1.396
3000 91.5 2.094
4000 91.5 2.792
5000 91.5 3.49
6000 91.5 4.188

6.35 0 irregular 4.39x10-10

1000 76.25 0.809
2000 76.25 1.619
3000 76.25 2.428
4000 76.25 3.237
5000 76.25 4.047
6000 76.25 4.856

12.70 0 irregular 3.61x10-10

1000 76.25 1.006
2000 76.25 2.012
3000 76.25 3.018
4000 76.25 4.024
5000 76.25 5.03
6000 76.25 6.036

19.05 0 irregular 2.65x10-10

1000 76.25 0.709
2000 76.25 1.418
3000 76.25 2.127
4000 76.25 2.835
5000 76.25 3.544
600 76.25 4.253
Table 4.2 Contact zone size at 38.1 mm loading disc dia

Plate dia Plate Loading Bolt hole Load– Contact Maximum

(mm) thickness disc dia size (mm) pretension zone dia contact
(mm) (mm) (N) (mm) pressure
(MPa)

152.5 19.05 38.1 0 0 irregular 5.60x10-10

1000 91.5 0.518
2000 91.5 1.036
3000 91.5 1.554
4000 91.5 2.072
5000 91.5 2.59
6000 91.5 3.18

6.35 0 irregular 2.694x10-10

1000 91.5 0.478
2000 91.5 0.955
3000 91.5 1.433
4000 91.5 1.91
5000 91.5 2.388
6000 91.5 2.865

12.70 0 irregular 3.056x10-10

1000 91.5 0.477
2000 91.5 0.953
3000 91.5 1.429
4000 91.5 1.906
5000 91.5 2.383
6000 91.5 2.86

19.05 0 irregular 3.083x10-10

1000 91.5 0.493
2000 91.5 0.987
3000 91.5 1.48
4000 91.5 1.927
5000 91.5 2.467
6000 91.5 2.96
Table 4.3 Contact zone size at 50.8 mm loading disc dia

Plate dia Plate Loading Bolt hole Load – Contact Maximum

zone dia
(mm) thickness disc dia size (mm) pretension contact
(mm)
(mm) (mm) (N) Pressure
(MPa)

152.5 19.05 50.8 0 0 irregular 4.903x10-10

1000 122 0.175
2000 122 0.349
3000 122 0.524
4000 122 0.698
5000 122 0.873
6000 122 1.047

6.35 0 irregular 3.07x10-10

1000 106.75 0.274
2000 106.75 0.548
3000 106.75 0.822
4000 106.75 1.096
5000 106.75 1.37
6000 106.75 1.644

12.70 0 irregular 4.46x10-10

1000 106.75 0.279
2000 106.75 0.559
3000 106.75 0.838
4000 106.75 1.117
5000 106.75 1.396
6000 106.75 1.676

19.05 0 irregular 2.43x10-10

1000 106.75 0.301
2000 106.75 0.603
3000 106.75 0.904
4000 106.75 1.206
5000 106.75 1.507
6000 106.75 1.808

The contacting surface will not be perfectly flat in reality. As a result the contact region
can be expected to vary with load until a level is reached at which the deformations due to load
substantially override the irregularities, roughness, and waviness of the surfaces. The dependence
of contact diameter on load for various loading discs and various bolt hole sizes are indicated in
figure 4.2. As the load level increases the contact diameter ‘c’ for each case converges toward
the stabilized contact diameter value.The bolt hole size `a´ has no significant influence on the
diameter of the contact zone. It is shown in figure. These observations were from the results of
the finite element study.

7000

6000
a
b
5000 c
a
b
c
4000
a
LOAD (N)

b
c
3000

2000

1000

0
70 75 80 85 90 95 100 105 110
CONTACT DIA (C) mm

a = bolt hole size b = loading disc dia h = plate thickness d = dia of plate

Figure 4.2 Dependence of contact diameter on load for various loading discs and various bolt
hole sizes
The contact region can be predicted from the simple expression as follows:

c/ht = ((b/ht)3+c13+c2))^(1/2)

Where c1 = 0.61 and c2 = 0.53 for two identical plates, and c 1 = 0.52 and c2 = 0.50 for
three identical plates. The normalized contact stress is analyzed for one particular pretension load
(60000 N) by varying bolt hole size and loading disc diameters.
 Normalized contact stress is the ratio between contact stress and average disc stress.
Here the term “disc stress” denotes the stress developed in bolt loading disc for the particular
pretension load. Normalized contact stress and contact zone in the plate along diameter are
recorded in table 4.4.

Table 4.4 Normalised contact stress, contact zone

Loading disc Bolt hole contact Contact Average normalized Contact

dia (b) Size (a) radius/h stress disc stress contact zone in
mm mm (r/h) mm MPa MPa stress Plate along
͠ σc diameter(mm)

25.4 0 0 4.188 11.841 0.353 76.25

(1.33h) 0.8 2.3 0.1942 61,91.5
1.6 0.738 0.062 45.75,106
6.35 0.166 4.856 11.841 0.4101 73,79.42
0.8 3.2 0.270 61,91.5
1.6 0.243 0.020 45.75,106
9.53 0.25 4.94 11.841 0.417 71.4,81
0.8 3.458 0.292 61,91.5
1.6 0.247 0.020 45.7,106.7

19.05 0 0 7.448 21.05 0.353 76.25

(1h) 0.8 3.9 0.185 61,91.5
1.6 1.29 0.061 45.75,106
6.35 0.166 6.079 21.05 0.288 73,79.42
0.8 3.648 0.173 61,91.5
1.6 0.06 0.0028 45.75,106
9.53 0.25 6.25 21.05 0.296 71.4,81
0.8 3.75 0.178 61,91.5
1.6 0.156 0.007 45.7,106.7

12.70 0 0 16.757 47.36 0.353 76.25

(0.76h) 0.8 9 0.190 61,91.5
1.6 3 0.063 45.75,106
6.35 0.166 7.299 47.36 0.154 73,79.42
0.8 3.65 0.077 61,91.5
1.6 0 0 45.75,106
9.53 0.25 7.4 47.36 0.156 71.4,81
0.8 3.7 0.078 61,91.5
1.6 0 0 45.7,106.7

Plate dia (d) =152.5mm Plate thickness (h) =19.05mm

Pretension (load) =6000 N
 Since the load level and size of bolt holes have no important influence on the diameter of
the contact zone, it is possible to present the dependence of that latter variable solely on the
plate thickness and loading disc diameter. Two bolt hole sizes are considered for each of three
loading disc diameter / combined plate thickness ratios for normalized contact stress analysis.
The distribution of the contact stress developed between the plates, normalized with respect to
the average loading stress, is given in figure 4.3.

0.45

0.4

0.35

0.3

0.25

0.2

0.15 a
a
0.1 b
0.05

0
40 50 60 70 80 90 100 110 120

analysed limits of contact

Fig 4.3 Normalized contact stress distribution for various loading discs and
various bolt hole sizes
From the shape the various contact stress distribution curves, it is possible to explain, in
an approximate manner, why the diameter of the contact zone is insensitive to the size of a bolt
hole. It would appear that it is only those stresses near the perimeter of the loading disc are
dispersed radially while the stresses under the remaining portion of the disk are transmitted
directly through the plate. The presence of a hole could then be viewed as simply eliminating
some of the latter stresses.
 4.FAILURE OF BOLTED JOINTS
Preloads in bolts and other structural components often have significant effect on deflection and
stresses. The pretension load is used to model a pre-assembly load in a joint fastener. Initial
tightening is given to the bolted connections for the following reasons; to prevent joint
separation, to increase contact between two bolted members and to increase fatigue life cycle.
The effect of pretension on shear stress and vonmises stress on bolt has to be analyzed.

The preload on the bolts is extremely important for the successful performance of the
joint. The pretension load direction is along the bolt axis. After pretensioning the bolts, pressure
is perfectly distributed around the bolt holes. The bolted connection shown in figure 5.1 having
following specifications was considered for pretension analysis.

Dimensions of plate Dimensions of bolt

Length = 150mm bolt dia = 20mm
Width = 75mm bolt head dia = 40 mm
Thickness = 20mm bolt head thickness =
16mm

Figure 5.1 Bolted connection for pretension analysis

 The bolted connection shown in figure 5.1 was subjected to tensile load varying from
1000 N to 10000 N, which is applied on the plates in X direction. The stresses developed in the
bolt and plates are analyzed.

Pretension load is given to the bolt by creating a pretension section on the mid position of
shank portion by means of simulating the pre-tightening force with PREST179 Elements. The
pretension section generated in the bolt is shown in figure 5.2.

Figure 5.2 Pretension section in the bolt

Pre tension value can be determined using the formula,

T = KxDxP (N-m)

T=Torque

K=friction coefficient

D= nominal diameter

P= preload
A more accurate value can be determined using the formula,

F p . d m p+ π . μ . d m sec α
T=
2 ( π . d m−μ . p . sec α )
+ F p . μc . r c

F p = Desired bolt Preload (N)

p = Thread pitch (m)

d m = Mean diameter of thread (m)

μ = Coefficient of Thread friction

μ c = Coefficient of collar friction

α is the thread angle / 2 (α = 30 o for standard metric threads & α = 29 o/2 for acme
threads).

r c = Collar friction radius (m)

 The analysis conducted by applying tensile load on plates with an increment of 1000 N.
Pretension was not applied to the bolt at first stage. The following values obtained are given in
table 5.1.

(i) X component stress in two plates

(ii) bolt shear stress in XZ plane
(iii) vonmises stresses on bolt.

Table 5.1 Stresses acting on plates and bolt (without pretension)

Tensile load X component X component Bolt shear stress Vonmises stress

applied to plate stress in plate 1 stress inmplate 2 in XZ plane in bolt

in X direction(N) (MPa) (MPa) (MPa) (MPa)

1000 0.076 24.838 6.851 102.743
2000 0.1534 49.677 13.703 205.0487
3000 0.230 74.515 20.554 308.23
4000 0.3068 99.316 27.395 410.82
5000 0.3831 124 34.206 513.717
6000 0.460 149.031 41.109 616.46
7000 0.5372 173.869 47.96 719.204
8000 0.6139 198.707 54.811 821.947
9000 0.690 223.546 61.663 924.691
10000 0.767 248.384 68.514 1027

Analysis is performed for various load values keeping a constant pretension of 10,000 N
applied to the bolt in the bolted assembly. The X component stress in plates, bolt shear stress in
XZ plane, vonmises stress on bolt obtained are shown in the table 5.2.

Table 5.2 Stresses acting on plates and bolt (with pretension 1000 N on bolt)

Tensile load X component X component Bolt shear stress Vonmises stress

applied to plate stress in plate 1 stress inmplate 2 in XZ plane in bolt

in X direction(N) (MPa) (MPa) (MPa) (MPa)

 1000 0.2233 44.448 18.405 101.262
2000 0.2344 49.286 23.139 203.913
3000 0.2590 74.124 27.874 306.625
4000 0.320 98.963 32.608 409.352
5000 0.389 123.801 37.343 512.085
6000 0.4575 148.639 42.007 614.821
7000 0.526 173.477 48.06 717.559
8000 0.5944 198.315 54.911 820.298
9000 0.6629 223.153 61.763 923.038
10000 0.7314 247.991 68.614 1026

Tensile load applied to the plates in bolted joint has greater influence on stress formation
and material deformation. This is important for designing and ensuring the safe working of bolts
in bolted connections.

Shear stress and vonmises stress values of bolt are obtained from number of analysis
conducted on bolted connection under the conditions “with pretension” and “without
pretension”. The deformed state of each component in the bolted connection and regions where
maximum stresses developed is shown in figure 5.3.
 Figure 5.3 Deformed shapes of plates and bolt

The effects of pretension on stress are represented in the figure 5.4. From the previous
tables 5.1, 5.2 and figure 5.4; it is observed that, the pretension applied to the bolt is having a
small impact on bolt stresses. From figure 5.4, it is identified that, vonmises stress on bolt under
pretension is higher than that without pretension on the bolt.
 Effect of pretension on shear stress, vonmises stress on bolt for various loads
1200

1000
Stress on bolt (Mpa)

800
a
a
600 b
b

400

200

0
0 20000 40000 60000 80000 100000 120000

Figure 5.4 Effect of pretension on bolt stress

The shear stress values plotted in previous tables and figures are the average values
computed using ANSYS. For obtaining more accurate values on a particular section, nodes on
that section and stress values on that nodes are identified. These values are compared with the
theoretical results. The nodal stress values along a particular section of bolt for prestress values
of 12,000 N and 10,000N are highlighted in Tables 5.3 and 5.5 respectively. The comparison of
these nodal stress values with those calculated theoretically are given in tables 5.4 and 5.6. These
comparison tables show that, the results found in ANSYS and theoretical calculations having a
deviation less than 2% only.

Validation of the shear stress values on bolt

Prestress given to the bolt = 12000 N

Z component stress on bolt

 Maximum stress = 71.564 MPa

Average stress on mid position of shank = 35.15 MPa

Table 5.3 Nodal stress values at 12000 N prestress

Node no Stress (Z direction) MPa

2933 38.007

2775 38.084

3794 38.592

3762 38.389

3760 38.363

Average stress on nodes = 38.287 MPa

Table 5.4 Comparison of stress values at 12000 N prestress

Stress by theoretical calculation Average stress on nodes by ANSYS

38.197 MPa 38.287 MPa

Prestress given to the bolt = 10000 N

Z component stress on bolt

Maximum stress = 59.637 MPa

Average stress on mid position of shank = 29.295 MPa

 Table 5.5 Nodal stress values at 10000 N prestress

Node no Stress (Z direction) MPa

3021 31.027

3095 31.601

4938 31.557

2934 31.655

3093 31.011

Average stress on nodes = 31.3702 MPa

Table 5.6 Comparison of stress values at 10000 N prestress

Stress by theoretical calculation Average stress on nodes by ANSYS

31.83 MPa 31.372 MPa

 800 Material curve for NICUAGE steel
700

600
stress σO (MPa)

500

400

300

200

100

0
0 0 0 0.01 0.01 0.01 0.01 0.01

Strain ε

Stress values obtained by inverse Ramber

Osgood relationship
Strain (ε) Stress (σ) N/mm2
0.0001 20.5999
0.001 205.965
0.002 408.1602
0.003 570.4529
0.004 644.79
0.005 666.3699
0.006 672.4889
0.007 674.4872
0.008 675.2407
0.009 675.5604
0.01 675.7096
Applied load (KN) Effective stress on nodes (N/mm2)
Node 549 Node 693 Node 72
0 0 0 0
11.199 12.766 25.099 45.89
22.398 25.707 50.471 92.166
33.597 40.271 77.776 141.15
44.796 58.055 108.93 195.52
55.995 80.127 145.12 256.5
67.194 107.31 187.09 326.41
78.393 140.58 235.6 404.62
89.592 182.39 290.58 489.34
100.791 238 353.78 574.63
111.99 327.24 432.87 630.84
123.189 488.92 539.46 646.32
 134.388 642 606.44 608

700

Effective stress on nodes (N/mm2) 600

500

400

300 549
693
72
200

100

0
0 .2 2.4 3.6 4.8 56 .19 .39 .59 .79 .99 .19 .39
11 2 3 4 67 7 8 89 10 0 1 1 1 12 3 1 3 4

Applied load (N)

5.CONCLUDING REMARKS
An investigation of stress analysis in bolt holes, contact zone analysis between two
plates, pretension analysis in bolted connections has been done. The analysis in bolts reveals the
following points:

(i) The stress field is highly three dimensional between the regions on the outer surface
loaded by the bolt.

(ii) The bolt hole has no important influence on the extent of the contact zone.
(iii) The bolt shear stress on XZ plane under pretension is slightly greater than that of
without pretension when tensile loads applied to the plates.