European Journal of Mechanics A/Solids 29 (2010) 675–682

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European Journal of Mechanics A/Solids

journal homepage: www.elsevier.com/locate/ejmsol

An investigation about interference fit effect on improving fatigue life of a holed

single plate in joints
T.N. Chakherlou a, M. Mirzajanzadeh a, B. Abazadeh a, *, K. Saeedi b
a
Faculty of Mechanical Engineering, University of Tabriz, Iran
b
Mechanical Engineering Department, University of Concordia, Canada

a r t i c l e i n f o a b s t r a c t

Article history: In this article, the effect of interference fit on fatigue life of holed plate of mechanical joints was
Received 18 October 2008 investigated both experimentally and numerically. In the experimental part, fatigue tests were carried
Accepted 31 December 2009 out on the holed specimens of Al 7075-T6 alloy in which oversized steel pins were force fitted to them.
Available online 18 January 2010
These fatigue tests were conducted on open hole specimen and specimens with 1, 1.5, 2 and 4% nominal
interference fit sizes at different cyclic longitudinal loads. From these tests the stress-life (S–N) data for
Keywords:
different interference fit sizes were obtained. The results show that interference fit increases fatigue life
Interference fit
compared to open hole specimens. In the numerical part of the investigation, 3D finite element simu-
Fatigue
Mechanical joint lations have been performed to obtain stress (or strain) histories and distributions around the hole due to
Finite element interference fit and subsequent cyclic longitudinal loading using FEM package. The stress history from
finite element (FE) simulation was used to explain the reason for fatigue life improvement in the
interference fitted specimens.
Ó 2010 Elsevier Masson SAS. All rights reserved.

1. Introduction fastener hole of the components or plates is cold expanded using an

Fatigue is one of the main agents for failure of mechanical
components or plates in aerospace and automotive industries
when the components are subjected to cyclic loading (Wuanlin and
Xiangjiong, 1991). Different components in aerospace structures
are jointed together using rivets or bolts so as to be easily
dismantled, repaired or replaced by a new part. Furthermore
experiments show that the fatigue resistance of rivet or bolt joints
are better than welded joints (Valtinat et al., 2000). However, in
bolt joints the components must be drilled to have holes. These
holes cause geometrical discontinuities and entail local stress (or
strain) concentration during loading. Furthermore drilling may
create rough surface or damage the components thus making them
more prone to fatigue crack initiation and propagation (Chakherlou
et al., 2008; Crew, 1975; Iyer et al., 2001; Rich and Impellizzeri,
1977; Chakherlou and Vogwell, 2003). In order to compensate
these drawbacks and increase fatigue resistance in holed compo-
nents, different fatigue life improving techniques such as cold
expansion or interference fit are used. In these techniques either
compressive or tensile tangential (circumference) residual stress is
introduced around the fastener holes. In cold expansion, the
* Corresponding author. Tel.: þ98 914 4002567.
E-mail address: abazadeh@tabrizu.ac.ir (B. Abazadeh).
oversized mandrel or pin before assembling. During cold expansion
process the oversized mandrel is inserted to the hole from one side
of the plate and removed from the other side. This process creates
compressive residual tangential stress around the fastener hole
(Chakherlou et al., 2008). This stress reduces the resultant tensile
stress around the fastener hole when the components are subjected
to tensile cyclic loading. However, in the interference fit, the
fastener that could be an oversized pin or bolt is inserted to the hole
during component assembling (unlike cold expansion technique).
This process leaves mainly tensile tangential residual stress around
the hole (Dowling, 1999). Although interference fit (especially for
low level) creates mainly tensile tangential stress and so increases
mean stress in cyclic tensile loading, but as shown in Fig. 1, it
considerably reduces the stress (or strain) amplitude, which is
more influential than mean stress in fatigue crack initiation or crack
propagation (Wuanlin and Xiangjiong, 1991).
There are scatter studies about the effect of interference fit on
fatigue life of bolted or pinned joints in literature (Crew, 1975; Iyer
et al., 2001; Rich and Impellizzeri, 1977; Mann and Jost, 1983;
Sundarraj et al., 1995; Jost and Carey, 1984; Finney, 1993). However,
in these studies the direct (or isolated) effect of interference fit was
shadowed by either cold expansion or bolt clamping effect or both
of them. Therefore, it is not clear what part of fatigue life
improvement was only due to interference fit. As the isolated effect
of cold expansion and bolt clamping force on fatigue life were

0997-7538/$ – see front matter Ó 2010 Elsevier Masson SAS. All rights reserved.
doi:10.1016/j.euromechsol.2009.12.009
676 T.N. Chakherlou et al. / European Journal of Mechanics A/Solids 29 (2010) 675–682
Fig. 1. Stress variations before and after interference fit in hole edge.
studied in the previous researches by the authors (Chakherlou
et al., 2008; Chakherlou and Vogwell, 2003), in the case of knowing
the isolated effect of interference fit, it will be much easier to
a mechanical joint designer to decide which combination of them
will create the best joint from fatigue life point of view. So in this
paper in order to investigate the isolated effect of interference fit on
fatigue life improvement, a holed plate with an oversized pin force
fitted was studied experimentally and numerically. In the experi-
mental part four batches of Al 7075-T5 alloy specimens with four
different sizes of interference fit also one batch of open hole were
fatigue tested to obtain S–N data. In the numerical part, contrary to
2D FEM models investigated in the literature, 3D finite element
method (FEM) models were used to capture stress and strain
variations through the plate thickness around the hole and also to
explain fatigue crack initiation location for different sizes of the
interference fit. Although the effect of interference fit was studied
on only one holed plate in this research, its results can be used in
much complicated practical joints to some extent.
2. Experimental test specifications
In experimental part of the research to observe interference fit
effect on fatigue life improvement, fatigue test specimens, their
dimensions are shown in Fig. 2, were prepared. These specimens
were made from a 4.5 mm thick Al-alloy 7075-T6 plate. They were
cut from the plate with planar dimensions of 1.2 m  1.2 m. The
longitudinal direction of the specimens was aligned in rolling
direction of the plate. As the figure shows the specimens have
a 5 mm diameter hole in the centre, which was drilled and reamed
to achieve the precise size of hole (i.e. 5  0.005 mm).
Although the mechanical properties of Al-alloy 7075-T6 were
available in many references (Wuanlin and Xiangjiong, 1991; Shah
and Ramachandran, 2002; Mechanical Engineer’s Handbook, 1998)
Fig. 2. Fatigue test specimen dimensions (mm) without inserted pin.
Fig. 3. s–3 curve of Al 7075-T6.
however, standard tests were performed on tensile specimens to
obtain s–e curve and Poisson’s ratio. The true stress versus the true
strain curve obtained from tests is shown in Fig. 3. The elasticity
modulus, Poisson’s ratio and hardness were measured to be
E ¼ 71.5 GPa, y ¼ 0.33 and 188 HV, respectively. Also the yield
strength and ultimate strength of the Al alloy were 503 MPa and
600 MPa, respectively.
In experimental tests, in addition to Al-alloy 7075-T6, steel pins
were also used. These pins, which force fitted to fatigue specimens’
hole to create interference fit, were made from AISI-D2 steel with
mechanical properties of E ¼ 207 GPa, y ¼ 0.26, hardness ¼ 62 HRC
(746 HV) and yield strength of more than 1000 MPa. The dimen-
sions of the pin which caused a 2% interference fit are shown in
Fig. 4. The big diameters of used pins to create various percentages
of interference fit are shown in Table 1, the tolerance of the pins
diameter was (0.000 and þ0.003 mm) during manufacturing. The
interference fit size was defined as
Dd
I ¼  100;
d
where D is the big diameter of pin and d is the diameter of fatigue
specimen hole.
To force fit the pins into the fatigue specimens’ hole, a 60 kN
capacity Roel pull–push test machine was used. To do so, the con-
tacting surfaces, including the hole inner surface and the pin outer
surfaces, were smeared with MoS2 lubricant (a special lubricant
which is used in metal forming and has a friction coefficient of 0.1).
Then flat end of the pin was located inside a specially pre-designed
fixture that was fixed to the upper grip of the test machine. After
that a washer with 8 mm inner and 12 mm outer diameters was put
around the hole under the specimens (as a support) on the lower
Fig. 4. Dimensions of the pin for 2% interference fit size (mm) and force fitting it into
a specimen hole.
 T.N. Chakherlou et al. / European Journal of Mechanics A/Solids 29 (2010) 675–682
Table 1
Big diameter of the pins for various sizes of interference fit.
Pin diameter (mm) 5.050 5.075 5.100 5.200
Interference fit size %, I 1 1.5 2 4
Table 2
Maximum applied tensile loads to specimens and their equivalent remote sress
amplitudes.
Pmax (kN) 29 31 33 35 37 39 41
Corresponding remote stress 128.85 137.75 146.65 155.55 164.4 173.3 182.2
amplitude (MPa)
grip of the machine. In the last stage the lower grip was moved up
to insert the pin into the hole (see Fig. 4).
After interference fitting the specimens, fatigue tests were
performed for four different interference fitted and open hole
specimens. Fatigue tests were carried out at seven different load
magnitudes (as shown in Table 2) to obtain S–N data. In conducting
fatigue tests, sinusoidal cyclic loads were applied using a Zwick
Roel Amsler HA250 fatigue machine (see Fig. 5) with zero load ratio
(R ¼ Pmin/Pmax ¼ 0 as shown in Fig. 6) and frequency of 15 Hz.
Experimental fatigue test results are shown in Fig. 7 as semi-log
(S–N) chart where Sa ¼ Pa/A (Sa is the remote stress amplitude, Pa is
the applied load amplitude and A ¼ 25  4.5 mm2 is the remote
cross-sectional area). It is worth mentioning that a number of
fatigue tests were carried out at load levels lower than 29 kN for
interference fitted specimens, but in all of them the fatigue crack
initiated and propagated at region far from the hole at fillet area
(their S–N data were not shown in Fig. 7).
3. Finite element models
3.1. Modeling and solution process
There are a number of researches about interference fit (Crew,
1975; Shah and Ramachandran, 2002) but these studies were based
on 2D models in which the effect of stress variations have not been
considered through the plate thickness. However, in this paper a 3D
model is used to include stress (or strain) variations in the plate
thickness. To do numerical simulation for the interference fit, only
the middle part of the 4.5 mm thick fatigue test specimen (see
Fig. 2) was considered to have an optimum model size (i.e. the plate
model size is 25 mm  40 mm). As the geometry of the specimen
Fig. 5. Interference fitted specimen before and after fracture in fatigue test machine.
677
and loading (during pin force fitting) are symmetric respect to X–Z
and Y–Z planes, only a quarter of the plate and the pin were
included in the FEM simulation.
To mesh the plate and the pin, linear isoparametric cubic
Solid45 elements were used. This 2  2  2 integration point
element has 8 nodes (one node at each vertex) and each node has 3
DOF (degree of freedom) displacement in X, Y and Z directions. This
element was preferred to 20 node quadratic isoparametric cubic
Solid95 as it has the same accuracy in plasticity but well-conju-
gated with contact elements (Swanson Analysis Systems Inc,
2007b).
To include contact between the pin and the hole surfaces,
CONTA 173 and TARGE 170 were used to mesh the pin outer surface
and the hole inner surface. These contact elements allow pressure
to be transferred between the contacting surfaces but without
penetrating each other (Swanson Analysis Systems Inc, 2007a). In
the model the friction between contacting surfaces was included
using the elastic Coulomb friction model with friction coefficient of
m ¼ 0.1, this value was obtained from experimental test (Chakherlou
and Vogwell, 2003).
In the FEM model, an elastic–plastic kinematic hardening
material behavior was considered for the Al-alloy plate in which
stress–strain curve (see Fig. 3), elastic modulus and Poisson’s ratio
were provided by experimental test results. For the steel pin elastic
material behavior was used as the pin deforms elastically during
interference fit and subsequent longitudinal loading.
Regarding to the model constraints, symmetric (displacement)
boundary condition was applied to the plate and the pin in the X–Z
and Y–Z planes due to the model symmetry.
As explained in the previous section a steel support washer was
placed the test specimen underneath around the hole during the
experimental pin force fitting to restrain it in Z direction. In the FEM
simulation to account for this support washer, the nodes on the
plate bottom face, which located on the area between the radii
8 mm and 12 mm from the hole centre (showing the washer inner
and outer diameters), were constrained in the Z direction.
The FEM solution process was conducted in three load steps
(stages). In the first load step, the pin upper surface nodes were
displaced 8 mm in -Z direction through the hole to simulate the
experimental pin force fitting. In the model as shown in Fig. 8, the
conical part of the pin was modeled through the hole in a near
contact condition so as to avoid extra and unnecessary displacing
the pin during solution process. After that, in the second load step
a tensile stress (remote stress) was applied to the right end of plate
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Fig. 8. Meshed model using FEM.

Fig. 6. Sinusoidal applied cyclic loads.

(see Fig. 8) to simulate the longitudinal loading during experi-

mental fatigue tests. The remote stress magnitude (Smax ¼ 2  Sa)
was chosen so as to create the load level that was applied to the
specimens during fatigue testing. In the last load step, this remote
stress was removed from the model to simulate unloading.
Therefore, with these three load steps the experimental process of
pin force fitting and one cycle of cyclic loading during experimental
fatigue tests were implemented in the FEM simulations. However,
to investigate that if the number of cyclic loading affects the stress
(or strain) distributions in the plate further cyclic loading was
Fig. 9. Longitudinal stress, sx (MPa) distributions around the interference fitted hole
continued in the other load steps. The results showed that the for I ¼ 1% (pin was not shown).
stress (or strain) distributions did not alter by the second or third
cyclic loading (see the following sub-sections).
initiates and propagates, three paths are chosen and shown in
3.2. Stress distribution due to interference fit Fig. 11.
The results of longitudinal stress distributions after first load
The distributions of longitudinal stress which are left from 1% step (interference fitting) at the smallest cross-sectional area for
and 4% interference fit sizes after first load step are shown in Figs. 9 the defined paths and for different interference fit sizes are shown
and 10 as contours. As the figures show interference fit (depends on in Figs. 12–15.
its size) can leave tensile or compressive longitudinal stress or both As the graphs show the created tangential stress (or longitudinal
of them around interference fitted hole. stress at the smallest cross-sectional area) due to pin force fitting is
In order to indicate stress distribution as graphs in the following not uniform through the plate thickness and its value depends on
discussions at the smallest cross-sectional area, where fatigue crack the interference fit size. This stress is tensile at the top, middle and

Fig. 10. Longitudinal stress, sx (MPa) distributions around the interference fitted hole
Fig. 7. Fatigue lives obtained from experimental tests. for I ¼ 4% (pin was not shown).
 T.N. Chakherlou et al. / European Journal of Mechanics A/Solids 29 (2010) 675–682
Fig. 11. Paths chosen for stress distribution as graphs in the following discussions.
Fig. 12. Longitudinal stress, sx distributions in the defined paths for the interference fit
size of I ¼ 1%.
bottom planes (for the smallest cross-sectional area) for the smaller
interference fit size. However, with increasing the interference fit
size the longitudinal stress becomes compressive at the middle
plane around the hole (this is similar to tangential stress created
around a hole in an infinite holed plate with elastic–plastic material
behavior, that is subjected to a big internal pressure at the hole
surface (Kim and Lee, 2006; Hsu and Forman, 1975)). At the bigger
interference fit sizes, the longitudinal stress still remains tensile for
the top and bottom planes at the hole edge. Scrutinizing the bottom
Fig. 13. Longitudinal stress, sx distributions in the defined paths for the interference fit
size of I ¼ 1.5%.
679
Fig. 14. Longitudinal stress, sx distributions in the defined paths for the interference fit
size of I ¼ 2%.
plane stress distribution for 4% interference fit size shows
compressive stress a little distance away from the hole. This could
be due to the plate material bulge out that compresses the elements
at that region.
3.3. Longitudinal stress history from FEM simulation
Stress distribution due to different interference fit sizes was
shown for three paths at the smallest cross-sectional area in the
previous section. However, in order to have an overview of the
effect of interference fit on the stress history at some critical loca-
tions (nodes in the FEM model around hole), longitudinal cyclic
loading was continued on the FEM model (this could be a simula-
tion of cyclic loading in fatigue tests). The positions of nodes to
which the stress history is shown are illustrated in Fig. 16.
The longitudinal stress history for three nodes at the hole edge
on the top, middle and bottom planes is shown in Fig. 17 for 1.5%
interference fit size with maximum 29 kN longitudinal (zero to
tension) cyclic loading. As the figure shows the stress amplitude is
almost the same for the three nodes, but the mean stress at node 1
is the biggest. For this model the stress history is also shown in
Fig. 18 for four adjacent nodes at the top plane at the smallest cross-
sectional area. Node 1 again has bigger stress amplitude and mean
Fig. 15. Longitudinal stress, sx distributions in the defined paths for the interference fit
size of I ¼ 4%.
680 T.N. Chakherlou et al. / European Journal of Mechanics A/Solids 29 (2010) 675–682
Fig. 16. Node locations at the smallest cross-sectional area in the FEM simulation.
Fig. 17. Longitudinal stress, sx (MPa) history at nodes No. 1, 100 and 200 for model
with 1.5% interference fit size which subjected to a maximum longitudinal load of
29 kN cyclic loading.
stress compared to the other three nodes as can be seen from the
figure.
The longitudinal stress, sx history at node 1 for different
percentages of interference fit and open hole model (not explained
Fig. 18. Longitudinal stress, sx history at nodes No. 1, 2, 3 and 4 for model with 1.5%
interference fit size which subjected to a maximum longitudinal load of 29 kN cyclic
loading.
Fig. 19. Longitudinal stress, sx history of node No.1 for different interference fit sizes
and open hole models for maximum 29 kN of cyclic loading.
Fig. 20. Fatigue crack growth in interference fitted specimens for 29 kN and more
cyclic loading.
in Section 3.1) is shown in Fig. 19 for maximum 29 kN cyclic
loading. As the figure shows interference fit reduces stress ampli-
tude and increases mean stress compared to open hole model.
However, with increasing interference fit size the rate of stress
amplitude reduction decreases so that the stress amplitude
reduction for 2% and 4% interference fit sizes is almost the same, but
increasing interference fit sizes entails mean stress increase.
4. Fracture section survey
In order to investigate the effect of interference fit on fatigue
crack initiation and propagation region in test specimens, fracture
sections were shown to a number of specimens in this section. Figs.
20 and 21 show the locations of fatigue crack growth for different
range of load from top view. As it is shown in Fig. 21 for cyclic
loading less than 29 kN fatigue failure occurs somewhere far from
hole edge regardless of interference fit size whereas in the speci-
mens subjected to 29 kN cyclic loading and more, fatigue failure
occurs from hole edge (see Fig. 20).
Fig. 21. Fatigue crack growth in interference fitted specimens for cyclic loading less
than 29 kN.
 T.N. Chakherlou et al. / European Journal of Mechanics A/Solids 29 (2010) 675–682
Fig. 22. Crack initiation, growth and fracture locations of an open hole specimen for
35 kN cyclic loading.
Fracture sections at the smallest cross-sectional area to show
the fatigue crack initiation locations are displayed in Figs. 22–25 for
open hole and interference fitted fatigue specimens. As the figures
show for open hole fatigue crack initiates around the mid-plane but
for interference fitted specimens it initiates from the top plane.
5. Discussion
The obtained S–N data from experimental tests for open hole
and interference fitted specimens shown in Fig. 7 indicate the effect
of interference fit on increasing the fatigue life compared to open
hole specimen which confirms the results presented in literature.
Also, as the figure shows increasing the interference fit size from 1%
to 1.5% and 2% entails more fatigue life improvement, however,
further fatigue life improvement is not appreciable when interfer-
ence fit size increases to I ¼ 4% and even in a number of specimens
the fatigue life decreases a little compared to the specimens with
I ¼ 2%.
Also the fatigue life improvement in the interference fitted
specimens compared to open hole ones is explained using FEM
simulation. As Fig. 19 shows, interference fit generally decreases
cyclic stress amplitude (the most effective parameter in fatigue life)
and increases a little mean stress at the hole edge at the smallest
cross-sectional area compared to open hole. With increasing the
interference fit size from I ¼ 1% to I ¼ 2% this phenomenon is much
appreciable (see Fig.19) thus causing more fatigue life improvement.
However, in bigger interference fit size (i.e. I ¼ 4%) the cyclic stress
amplitude reduction is almost the same as interference fit size of
Fig. 23. Crack initiation, growth and fracture locations of 1.5% interference fit size
specimen for 35 kN cyclic loading.
681
Fig. 24. Crack initiation, growth and fracture locations of 2% interference fit size
specimen for 35 kN cyclic loading.
Fig. 25. Crack initiation, growth and fracture locations of 4% interference fit size
specimen for 35 kN cyclic loading.
I ¼ 2%, but the mean stress is much bigger in comparison. This could
be the reason why no more fatigue life improvement was appeared
in the experimental fatigue tests for interference fit size of I ¼ 4%.
Investigating the fracture section at the smallest cross-sectional
area of the specimens reveals that the fatigue crack initiates and
propagates around the middle plane for the open hole (see Fig. 22)
but from the top plane for the interference fitted specimens (see Figs.
23–25) at hole edge. This also could be explained from FEM simu-
lation by prying Figs. 17 and 18. As the first figure shows the stress
amplitudes (in cyclic longitudinal loading) for three nodes in the top,
middle and bottom planes at the hole edge (for interference fitted
models) are almost the same, however, the mean stress in node one
on the top plane is bigger in comparison with node 100 and 200.
Likewise such a phenomenon can be observed for node 1 in Fig. 18
when its amplitude and mean stress are compared with those of
nodes 2, 3, 4 at the top plane. So the location of node 1 is the critical
point (or region, loosely saying) to early fatigue crack initiation.
6. Conclusion
Experimental test results show that the interference fitted
specimens have improved fatigue life compared to open hole
specimens.
Experimental results show that with increasing interference fit
size from 1% to 1.5% and 2% fatigue life increases in the interference
682 T.N. Chakherlou et al. / European Journal of Mechanics A/Solids 29 (2010) 675–682
fitted specimens, however, further interference fit size increase (i.e.
I ¼ 4%) showed no more fatigue life improvement.
As the FEM simulations show longitudinal stress, at the smallest
cross-sectional area, varies through the plate thickness in the
interference fitted specimens. This stress is generally tensile
through the plate thickness at the small interference fit size (i.e.
I ¼ 1%) but it is compressive around mid-plane for bigger interfer-
ence fit sizes (i.e. I ¼ 1.5%, 2% and 4%).
The FEM simulations indicate that interference fit (depend on its
size) reduces cyclic stress amplitude and increases mean stress.
Fractured sections at the smallest cross-sectional area show that
fatigue crack initiates and propagates mostly around the mid-plane
in the open hole specimens and around the top plane at the hole
edge in the interference fitted specimens. This location (node 1, see
Fig. 16) was also predicted by longitudinal stress history from FEM
simulation.
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