Engineer s Guide to Finite Element

Analysis of Part-to - Part Connections

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 Engineers Guide to Finite Element Analysis of Part-to-Part Connections
Copyright 2014
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Published by Computer Aided Engineering Associates Inc.

All rights reserved. Except as permitted under U.S. Copyright Act of 1976, no part of
this publication may be reproduced, distributed, or transmitted in any form or by any
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Engineer s Guide to Finite Element Analysis of Par t-to -Par t Connections / 2

 Table of Contents

Chapter 1
Modeling Bolted Connections 4

Chapter 2
Modeling Bolted Joints & Understanding Load Transfer 9

Chapter 3
Large Scale Modeling Techniques 12
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Chapter 4
Using Constraint Equations in a Structural Analysis
with Large Deformations 15

Chapter 5
About CAE Associates 18

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 Chapter 1: Modeling Bolted Connections

Bolted connections are common to many industries where standards (ASME, AISC, San-
dia National Labs, ASTM, etc.) exist for bolt design procedures.

These regulations and recommended practices provide tools to size bolts and deter-
mine bolt torque loads based on the design environment. Yet, when it comes to includ-
ing your bolted joint in your finite element model there is often confusion on how to
proceed. How much detail is needed and how do I account for the bolt pre-load? Can I
determine if I will lose my pre-load? Do I need to model the bolt? the nut? the threads?

Bolted connection analysis is no different than any other finite element calculation, in
that the engineer needs to understand the analysis end goal prior to any calculations.
Three basic requirements of a bolted connection are that the bolt must have adequate
strength, the joint must remain intact and the connection must have adequate fatigue
and fracture life. These requirements may or may not need to be addressed using the
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finite element method. The following list provides three levels of modeling recommen-
dations based on the listed assumed analysis goals. They are listed in order of increas-
ing level of finite element analysis complexity and accuracy, with each method requiring
more work than the previous simulation:

1) I just need the bolt loads and I will design my bolts by hand using industry
standards, spreadsheets, etc. Cyclic loading is not an issue.

(a) One does not need to always include the bolt in the finite element model, but can
use shared nodes or couples to join two bodies. Forces and moments can then be
extracted from the finite element model at these nodes and applied to the bolt design
hand calculation.

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 Chapter 1

(b) If there is a gap between the parts, use a rigid beam or multi-point constraint ele-
ment to tie the two bodies together. Spoke elements or constraint equations can also
be used to distribute the load locally so that singular stresses do not occur at the fas-
tener (bolt head and/or nut) connection. Many finite element codes have automated
features such as spot welds (Figure 1) that can be used to simulate this type of connec-
tion automatically.
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Figure 1: Spot Weld Modeling of a

Series of Bolts using Beam Elements
Plate Deformation

2) I need to understand the load history in the bolts to assure that the minimum
and/or maximum bolt forces are not exceeded.

(a) The components to be bolted together must have contact elements defined along
their mating surfaces. The bolt needs to be modeled explicitly, but can be simplified
using one or two beam element(s) to model the nominal bolt shaft. Bolt pre-load forces
are typically generated in the first step of the analysis using one of the following meth-
ods:

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 Chapter 1

i. Constraint equations (The bolt is split into two elements and a relative
overlap is induced to create tensile forces in the beams) Figure 2).
ii. Imposed initial strain
iii. Contact interference if the bolt head/nut are modeled
iv. Thermally induced initial strain via contraction of the bolt shaft. Iterations
are required to get the correct bolt initial pre-load modeled since the re-
quired bolt strain is a function of both the bolt and connecting plate
assembly stiffness.

(b) A sequential load history is needed to track the bolt force behavior over the entire
load history. The final bolt force will be a function of the load history. Be careful not to
use constant constraint equations if large rotations of the bolt are expected.

(c) Most standard bolts are designed for the bolt to fail prior to thread slippage, so there
is no need to model the threads in most bolt design-analyses.
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Figure 2: Bolt Preload Modeled E xplicitly

using Automated Constraint Equations
Maximum Principal Stress

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 Chapter 1

3. My bolt is non-standard and I would like to design the bolt such that the
transfer of loading to the threads is more uniform than a standard bolt where
the first couple threads carry all the load.

(a) In addition to including the items listed above, explicit modeling of a threaded con-
nection is required in this case, but can be greatly simplified by assuming an axisym-
metric thread profile.

(b) Contact elements with or without friction should be modeled between the thread
and nut and between the plates and bolt assembly if lift-off and onset of slippage
need to be evaluated.

(c) A material model including plasticity is likely required in the thread regions since lo-
cal yielding is common at the thread root.

(d) Fillet radii need to be included as well along with a refined mesh at the contact
interface and thread roots where stresses peak (Figure 3).

(e) A fracture mechanics evaluation might also be warranted to examine potential

crack growth at the locations of peak tensile stresses.
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Figure 3: Hoop Stress in Detailed T hreaded

Connec tion A xis ymmetric Analysis

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 Chapter 1

There are many other scenarios that could be included in the finite element model of
a bolted connection. Submodeling can often be used to develop more detailed bolt
modeling with a local independent finite element model that accesses interpolated
displacements boundary conditions from the global analysis. More details about mod-
eling of bolted connections can be found in the 2012 NAFEMS publication FEM Ideali-
sation of Joints, compiled by Peter Hopkins, ISBN 978-1-874376-72-9.

Remember to develop a clear objective prior to building your model and note that
the simplest approach is often the best!

Chapter 2 will discuss the importance of load transfer through mechanically fastened
joints - like some of the connections described in Chapter 1.
A S SOC I
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 Chapter 2: Modeling Bolted Joints &
Understanding Load Transfer

Understanding how structural parts interact and transfer load through mechanically
fastened joints has long been a critical aspect of design. Even with the development
of integrally machined parts, additive manufacturing, friction stir welding, and adhesive
joining to name a few, many assemblies large or small still require some form of good
old fashioned nuts and bolts.

To support the investigation of joint load transfer and the resultant material stresses in
parts, many companies turn to finite element (FE) modeling and analysis to investigate
the details. Engineers responsible for the structure have many pressing questions: Will
my parts stay assembled together in their load environment? Will the fasteners or the
parent material break first? Is the joint durable and can the parts sustain repeated load?
These questions have to be answered!

Fortunately, we can accurately assess load transfer and material response through FE
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modeling of the representative parts. Of course, there are many approaches to this
based on the focus of your analysis. There are different levels of pertinent analyses rang-
ing from coarse mesh shell & beam modeling to sophisticated detailed 3D solid model-
ing.

While there are merits to simple forms of FE modeling, here is an approach that is very
useful in a variety of applications : model the 3D assembly and fasteners with detailed
solid finite elements. Most structures analyzed these days are modeled in a 3D CAD
system to ensure the three fs : form, fit, and function of our parts. We can take advan-
tage of the existing CAD assembly of those parts combined with parametrically defined
hole size, fastener pattern, and addition of the 3D solid FE fastener in the model.

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 Chapter 2

Fortunately, with modern software capabilities we have automated 3D modeling tools

(note Figure 1) to help us create these types of sophisticated assemblies and set up mat-
ing surfaces with contact describing the interaction between parts.

Figure 1 - 3D Solid FE Model of a Bolted Joint.

Some investigative failure problems show the importance of this approach. As one
example, a part was prematurely cracking in a primary load transfer joint. However, the
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initiation of the crack was not at a hole edge or stress concentration location, as one
may expect. The crack origin was originating under the head of the fastener and out-
side of the hole. After some detailed FEA of the scenario, there was a collective aahh
from the customer while reviewing the FE results presentation that finally correlated
the crack initiation site using the FE predictive tools. The 3D analysis captured the load
transfer through frictional shear between the parts rather than pure bolt bearing. As
shown in Figure 2, considering the same fastener clamp-up load, low values of friction
resulted in peak stresses occurring at the edge of the hole. As the friction was in-
creased, more load was transferred through shear between the plates and peak stresses
occurred away from the hole. Fastener clamp-up, parent material stiffness, surface cur-
vature, and bearing transfer were all captured by this 3D joint analysis method.

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 Chapter 2

Figure 2 - Dif ferent Load Transfer Mechanisms in a Bolted Joint.

Simpler tools based on analytical solutions often cannot capture some of these nuances
of load transfer. A 3D modeling approach at critical joint areas is recommended in
order to best understand the mechanisms of load transfer. Also, to assess uncertainties,
sometimes you must bound the answers to the problem. For example, run solutions
with small or large bolt preload and small or large friction coefficients in the analysis.

Using some automated postprocessing techniques with the 3D solid model can yield
useful information regarding load transfer in your joint. In addition to investigating
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critical material stress results, the various contact pairs can be automatically queried to
determine load per fastener through each layer in the material. This approach is helpful
to plan out your most efficient joint load transfer.

But, with the additional accuracy comes the cost of performing the analysis. As with
other general nonlinear analyses and larger problems, these runs will often take signifi-
cant computing time. But, dont let this deter you.

In Chapter 3, learn how to tackle these larger scale problems with greater accuracy and
efficiency!
A S SOC I

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 Chapter 3: Large Scale Modeling
Techniques

Finite Element models continue to grow in size and analyzing a large number of com-
ponents in an assembly is becoming easy. Multiple CPU machines are common-place
and, with the ability to mesh and solve in parallel, the actual work that the computer
performs is continually scaling up. Yet, one of the main bottlenecks in the simulation
process is how quickly a engineer can set up the simulation.

Multiple analysts working on building the same model is nothing new; however it
makes a lot of sense to do this regularly for large assemblies. Its an easy way to decrease
the lead time for obtaining the result. In order to accomplish this in an efficient manner,
a common plan needs to be created and followed by all engineers ahead of time. Some
of the important details that should be included a modular simulation plan are:

Break Up the Assembly: The goal of having multiple engineers build one finite ele-
ment model is to arrive at the finished assembly model faster. Therefore; each individual
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needs to work on one or a subset of components in the assembly, and at the end, all
engineers will save their individual databases and assemble them together to create the
full assembly model.

Part Alignment: Each engineer should have their part built in the correct modeling
space so that all the parts once assembled will align properly. A master file relating all
the positions of all the components could also be used when combining the models;
but this can easily be avoided in the up front planning.

Tagged Properties: A set of identifying feature/ attribute names (i.e. components,

named selections, tagged surfaces, etc.) should be built into each component database.

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 Chapter 3
These common and consistent names across all databases in the assembly should be
used to identify material properties, boundary conditions, loads and contact pairs. De-
pending upon the software, it might be easier to assign materials, for example, within
each database. In other FEA software, it might be easier to use the named attributes
within each database to assign the materials once combined into the full assembly.
Whichever approach is used, these properties saved into each individual database must
transfer into the main assembly and will be used to define their respective conditions.

Assembly Contact: All the individual databases will eventually be assembled and
connected together in the full model. The use of bonded contact will be of great im-
portance in assembly modeling as it allows for all the components to be meshed inde-
pendently by each engineer, without having to know what the mesh on all the other
components will look like. Some FEA software, like ANSYS Mechanical, has the built in
capability to automatically recognize mating surfaces and create a bonded contact pair.
If this capability is not available when combining the full assembly, this is when the con-
sistent naming of surfaces facilitates manually setting up the contact between compo-
nents. For example, two flanges each meshed and saved into two different databases
by two different FEA consulting engineers. The two flanges are to be bonded together
in the full assembly. The surface on one flange could be named bond_A1_to_B1 and
in the other database the mating surface is named bond_B1_to_A1. Listing all the con-
tacts that need to be bonded together in a master file will make it easy to automate the
contact creation with a short script.
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 Chapter 3

The above figure is an illustration of two independent databases that are meshed,
setup with boundary conditions, loads, material properties, named selections and con-
tacts. Once the bonded contact pair is defined between the identified surfaces in the
assembled model, its ready to solve.

Model Documentation: Lastly, all the details of each database should be documented
by the engineer throughout the setup process. This document will allow for all the FEA
consulting engineers to keep track of whats in each model and how theyll all come
together once assembled. Clear and consistent communication between all engineers
is critically important for the final model to be assembled accurately.

This modular simulation system technique for creating a large assembly model also
makes it possible and very easy to swap in and out new components without affecting
the rest of the assembly. This modular simulation approach scales very well when used
in a design of experiments (DOE analyses) to perform quick design changes on the
component level and determine the full systems response to the new design.

In Chapter 4, the pitfalls of relying on constraint equations when modeling bolted con-
nections are explained.
A S SOC I
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 Chapter 4: Using Constraint Equations in a
Structural Analysis with Large Deformations

You may have heard the disclaimer in CAE Associates ANSYS update seminars, training
classes and e-Learning webinars: be careful about using constraint equations in a large
deformation analysis. Well, whats that all about? Constraint equations are a very con-
venient way to connect and/or define relative motion between bodies. They allow us
to create cyclic and repetitive symmetry boundaries. They provide a way to control the
displacement of a collection of nodes all tied to a single master node. Best of all they do
all these useful things while reducing the size of the mathematical problem by remov-
ing degrees of freedom from the model. Why then are they a cause for concern in large
deformation analyses?

First lets talk about what happens when we include large deformation effects in our
finite element analysis models. Large deformation, a type of geometric nonlinearity,
includes the following items:
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Updating certain load vectors (pressure, for instance) to account for the defor-
mation of a structure. These are so-called follower forces.

Updating the stiffness of elements experiencing significant deformation (large

strain effects) or rigid body rotation.

Considering the deformed shape in the calculation of stress. The change in the
length of the moment arm in a beam under a bending load is a typical example of this.

Including stress-stiffening effects that result from loading like the membrane or
in-plane stiffness of a thin structure subjected to an out of plane load.

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 Chapter 4

One thing that is typically not modified during this process is the orientation of the
nodal coordinate systems. These remain in their initial orientation as the structure un-
dergoes large rotations, which is the key reason why we need to be careful when using
constraint equations in a large deformation analysis. The constraint relation is defined in
the original nodal coordinate system, which does not change as the structure deforms
or experiences large rotations.

Consider the bolted connection between two flexible plates shown in Figure 1. It is
common practice to define a bolt preload using constraint equations. These equations
are written at the beginning of the analysis using the original nodal locations and orien-
tations. If we assume that the Z-direction is along the undeformed axis of the bolt, the
preload will be produced via constraint equations relating the Z-deformations of bolt
nodes. Whether or not this approach is valid with large deformation will depend on the
amount of rotation that the bolt axis experiences as the plates deform. In a small defor-
mation solution we assume that the angle between the deformed and undeformed
bolt axis is negligible.
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Figure 1

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 Chapter 4

If the bolt experiences large rotation, the bolt preload direction needs to be updated
with respect to the current bolt axis. However, when a constraint equation preload is
used, the pretension direction remains in the undeformed Z-axis direction as illustrated
in Figure 2 below. For a large rotation angle, , the error in preload direction could
cause significant error in the results.

Figure 2

The good news is that if your bolt preload is applied in regions of the model that are
not undergoing large rotations, they will still be valid. For this reason, it is important to
check your initial results carefully. If you do see large rotations of the bolts in preloaded
regions there are other ways to apply bolt preload correctly. One approach is to use
a multi point constraint (MPC) with preload capabilities in place of the actual bolt ge-
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ometry, if your FEA software supports it. This is a more advanced form of a constraint
equation that will update with large deformation.
A S SOC I

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 Chapter 5: About CAE Associates Inc.

Since 1981, CAE Associates been helping companies large and small maximize value
from engineering simulation through expert FEA consulting and CFD consulting ser-
vices.

As an ANSYS channel partner since 1985, we provide full service technical support to
over 100 companies in our region, including some of the worlds largest and sophisti-
cated users of simulation like General Electric and United Technologies.

We offer a range of consulting options to fit unique and specialized needs of our clients.
It could be as simple as getting to the bottom of a product failure, or as complex as
developing the infrastructure and process for simulation within the entire organization
using a combination of software, training, mentoring and automation.
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Our team of senior technical specialists bring graduate-level educations and an average
of 15 years of real-world experience in a variety of industries including: aerospace, elec-
tronics, consumer product, turbomachinery, civil engineering, manufacturing, biomedi-
cal, energy, and nuclear power.

For questions and to find out more about how CAE Associates can help you solve
your engineering analysis challenges, please contact us at info@caeai.com.

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