Stress Concentrations in Bolt-Thread: Roots
Stress Concentrations in Bolt-Thread: Roots
Stress Concentrations in Bolt-Thread: Roots
by James D. Chalupnik
~ s s r ~ ~ c r - ~ -allparent
The geometric origin of fatigue
fractures in oversize shank holts is considered in this
report. Bolt-nut interaction hetweeu the holt and both
a standard nut and a special nut are investigated. T h e
"frozen stress" method of three-dimensional stress
analysis was used to deter~ninethe magnitudes and loca-
tions of points of stress conretltrat.ion in plastic models
of both the oversize shank holt and a standard holt in
cornhinations with standard and special nuts,
T h e results indicate that. for i n s t a l l a t i o ~ ~ins which
the special nut is used, bolt geometry may he the cnll-
trolling factor in determining the f a ~ i g u elife of' the bolt
nut cornbillation, hrcausr the stress-cil>nce~rtratio~r factors
due to the nut loading are of the sameorder of magnitudeas
thestress-co~rcrntratio~if';~cLorsdue solely to holtgeo~netry.
On the other hand. fur install;rtionsi~lwhich standard nuts
are used, the nut-induced stress-cntrrrr~tratio~ifactors
are n ~ u c hlarger than those due In holt geometry; so.
holt gronretry will have less effect on the fatigue per-
form;mcr of the cornhination. If the n u t is threaded
onto the bolt so far that the first loaded thread of the
nut is in the t h r e a d - r u n m ~area
~ of the holt, fatigue per-
formance of the installation will ! w greatly reduced due
to the coml)ination of s~rt,ss-cil~ticetitratioli factors fronr
thread loadin# iirrcl section ch;tn#r and. again, 111)lt gewn-
etry may he a prominent causative factor.
Introduction
I+
for 21 stLrn(lr~rd
bolt under thc same contiitions in tions. Not long there fter, HetBnyil pul)lishecl a
this rrrvJri. paper which contains i this author's opinion t h e
most information a v s lablr. in one sourt.e ahout
Previous Work stress concrntrations i nuts ancl holts. HeLenyi
invesLigntecl the t.ff(vt of six different n u t designs
&1~1cli h,rs heen ~vrittennlmut scrc:w fastmers and
on Lhe stress t l i s t r i l ) ~ion in bolts. This paper
~ l i e i rspplicutions I ~ u teven
, so, t h e volunie of these
points o u t the impor ance of investigaLing t h e
reports is stn;ill when one considers t h e massive
interaction of the n u t a d holt in tlireatlerl fasteners
~1st.of these devices in industry. Published re-
and has particular sign'ficance in the investigation
ports of actual stress analysis of screw fasteners
are few. no doubt due to t h e complicated geometry
of the screw fastener. Because of t h e geometrical
outlined in this report.
1
T h e work of HetBnyi,and Horger and Buckwalter
difficulties. many of t h e significant analyses of
stresses in screw fasteners have been experimental
in narurr and, generally, they utilize photoelastic
trchniqurs.
b
serves t o demonstrate t h e usefulness of three-di-
mensional frozen-stress techniques in the investiga-
tion of stress distrihutio s a n d stress concenLrations
in nut-bolt conil,inationb.
.An rurly attelnpt a t a purely analytical solution
~f stress distril~utionsin holts and n u t s was given
Frozen Stress
I
A hrief description cjf t h e frozen-stress method
I,y Strumeyer: ancl another was undertaken by
Den Harrog.' These analyses are interesting and
provitle 3x1 insight into t h e loading of threarled parts
nomcAnon.
in t l ~ a rtliry :lccount in a qualitative way for t h e
increasc in tlirei~tiIoi~dingfrom the top to the hot-
tom of' the nut. Both I)al)ers lack something in
~ o n l p l e t ~ n e s1)t~c;iusc
s. t l ~ ec ~ l c ~ t l a t i o arc
n s Imsed on
:I thre;+tl elasticit>- which is c:rlcul:ttetl for a two-
i i i n I ~ I nntl I must necessmily he in
t.rn,r Ir is true. i~~,n-cver. t l ~ a tsince the problem
is essvntially el;~stic.: u,waver. at elrv;~terl teni-
is unr in rlaoticir>-. t h r sh:il)tb of thc lo;rtl-distril)u-
~ ) e r ; ~ t u w sits
, viscr~sity is gre;~tlyretlit(wI and i t
tion ci1rl.r should I I Y the. s;Ilne. ; ~ n donly the scale of
magnituiir \\.oul(l Iv clinngetl I)y (:onsiritiring t h e
rnorc corrwt tl1rt.i-i!itn<,nsioni~ltlirc;~tl.
Ty!ric.ri cnrly rsiwrimc.nt;rl investigations used
two-rli~nrr.iionaiphotoel;~sticmodels; descriptions
of thesr rsperimrntnl investigations are given in
the r of Solakian,? Hall,' anrl Heywood."
Gootlier 'nnalyzrtl thread loarls using tlie unique
rr])erinirilt;~l~ e c l i n i ( ~ uofe measuring the external
(lisl>l:r\.r~lirnrs of n cylindrical n u t and relating these
tlisp1:rccnlcnts to the thread loatls and stresses.
Tile rr5ults of all these investignlivris show es-
sentially the satne thing, t h a t , in standard nuts, t h e
first thrr:ltls carry the IargesL portion of the load
ancl t h e r e l y impose large stress concentrations i n
the I~~oltin this region. T h e two-dimensional
photncl;~sti\~ studies indi~,ated t h a t the area of
Iiigheat stress concentrntion was located in the
root arc:r of tlie bolt threads, but there was dis-
itgrrenwnt ;IS to the magnitude and even some un-
threatls.
certainty ns to rsnctly which bolt t h e a d carries
t l ~ eIwa\ irsr loi~d.
Failure of two-dimensional photoelastic methods Scope of l n ~ e s t i ~ a t i o l
to yield itsefitl data can be attributed to two causes:
1 the rlifficulty involved in accurately machining
the two-cli~nensiondscrew threads, and (2) t h e
h s i c inability of the two-dimensional model t o
~luplicatethe three-dimensional stress distribution
existing in screw fasteners.
One of the firsr reports of three-cliniensional
stress an;\lysis of tlirenclecl fasteners in given by
Horger and Bucl;walter7 in a p a r w which also gives
results of fatigue tests on several bolt--nut comhina-
Experimental Progkam
Prepuration of Specimens
Model nuts and bolts were prepared fvtin pre-
cast Hysol CP5-4290 Oirefringent plastk. Care
was exercised in machining the models from the
plastic stock to insure conformance with thread-
profile specificdtions and surface finish, and ro insure
t h a t the models were free of locked-in stresses some-
times caused hy heat generated during the ma-
chining operations. T h e machinist who per-
formed the machinihg operations on the niodels
is experienced in machining Hysol plastic m d is
aware of the special precautions which must be
taken in machining it. T h e quality of his work
on the nut and holt niurlels was generally high, a s
can he seen in t h r photogr,\phs in this report
Polurisope
All fringe photographs and all fringe-order counts
were taken a n a diffuped-light polariscopt.. Light
source is a bank of 17 15-w fluorescent tubes be-
hind a frosted Plesigllas diffuser. T h e polarizer,
analyzer and the two quarter-waves plates .Ire 10
in. in (lianwter nntl are inclcpenclently rotatable. tioning. T h e method of determining fringe order
Green fluorescent tuk)cs were usetl for illumina- in the unsectioned holt is described below.
tion for the black-and-while photographs. T h e Stress tlistril~uti~)n
in a cross section of the shank
grwn tuhes d o not provirle monot 11rom;ilic light, portion of a holt is essentially uniforrn; conse-
I ~ u their
t output covers n rrlntively narrow spectral quently, b y plotting the fringes in the photographs
Ijantl antl they are a satisf.~ctorylight source, pro- of the unsectionetl shank on 3 cross-section view of
vided the proper film is ustd. Korlax Co~nniercial the bolt, i t was possihle by interpolation to deter-
Protess Ortho film was usetl for the bldck-and- mine the fringe order in a slice c u t from this portion
\vhite photographs and the film was developed and of the holt. Calculations indicated t h a t the fringe
printed for contrast. Commercial Process Ortho level in the shank of the oversize holt would be
film is highly sensitive t o green light, so, the com- about 1.1 fringe'and t h a t in the standard bolt shank
hination provided good fringe photographs. Cool- would be about 1.4 fringe for a n 8-in.-thick section.
u h i t e fluorescent tuhes were used for niahing t h e Largest bending moment was found in the aver-
color photographs and for illun~inatingthe models size holt; however, the maximum bending stress
for the telescopr eunmination. Koclak Ektacolor was less t h a n 5 percent of the tensile stress. T h i s
Professional T y l ~ e"S" him was used for the color was cmisirlered to he satisfactory; so, the speci-
photographs mens were prepared for sectioning.
either from the end of 111~. 11~1lts. or f r l ~ ma n ;irljn- e;l(.h setting of tlie telescope. Errors in fringe
cent unloarlerl t h r r x l \vii~w,t l ~ fringe
, n ~ u n h e ris count c;lnsrd by aligning t h e tc.les~.o!x~\\-it11 the
zero. I n the area of ~ n : ~ s i i i ~ isit~ri ~i wconctsntril- Iwlis angle art> negligil~lc,since the ht~iix:~ngle$ is
tion, t h e fringes c o i w qiiit<~clc~st. together, hmv- ;ilioul 2.5 tleg am1 the errors go ;Is 1 - cws i l l , or
ever, and it \VHS f n u n ~ lto IN, iii111ossiI11~' to o l ~ t a i n allnLit 0.001.
tlie masiln~um fringe ~ ~ ~ fro111 u n l the I ~ l x k - i l n t l - Most of the fringe-order ~ ~ ~ i i xofi ~inrerest n ; ~ liere
white photographs. AIII<.II 11c1tc.rresults coultl I,(. occ~lron traction-frw surfilctts of lht. 11olt; con-
obtained from full-~.olor~!liotograpl~s takvn of 111~. s e q ~ ~ e n tthe
l ~ ~frirry?
. ortlrrs ilre ~ ~ r o l ~ ~ r t i oton :the
il
sectioned n~odels,Iiut evvn t l i ~ wresults wcre not ~ u x s i m u ~strcwras
n at L I I O S ~ points. Fringe order
conil~letelysatisfactory. TIN.Iiest results were 011- is propwtionnl to thc difference in the principal
tained by counting the fri11gc.s directly by nleans of stresses :md, on a tract.ion-free surface. the princi-
a short-focus telescope \\-it11 tlw models in thr. pal stresses art, normal and tangent to the surface,
polariscope. Using this n~t.tliotl. fringes could I x t h c normal vnml)rlnent being zero. Hence, for
counted quite accur~ttt%ly in !lie w r y root of' the locations of' intrresl, points of rn;lxirllr~n~frinyc
threads. I t was foilncl 1hit1 i( was necessxy to ortler are points of m;lsimum strew : ~ n dt l w fringe
line up t h e optical :>xis of tlw telescope with tllc order is proportion;rl to the stxrss :lt there points.
helix angle of t h e tlire:1<1root in order to rwtl thl. One point of n r ; ~ x i ~ ~ ~ slress
u l n nor f:~llingin the
highest fringe orders. 'I'l~is align~nent\vns c r i ~ i c a l , ;\l~o\.ecl;~ssiiic.:$tion that is used in later cirlcul:%tions
so a nlnsiniunl of t\vo thrtwtls c o i ~ l dbe read \vith in this p i l ~ e ris Ioc;ttr~l:tt Lhe cent~hrof' thc shank.
I STANDARD
xOVERSIZE
SPECIAL NUT
i
\rill he noted that the results lie very close t o each T h e inauiniun~frin e orders recorded for bolt
t~rlirrantl the cur\.es are drawn in t o "guide the threads loaded by the pecial nuts are all quite low.
c>-e through tlir points." I t can I)e seen iin- They are only slightly larger t h a n the fringe orders
nlecliately Lhat the special n u t offers a reduction in recorded for the threa -runout area. For e w n ~ p l e ,
n l n x i n ~ ~ ~stress
rn compared t o tlie stantlard nut. tlie four maxima in mlt threads lo,ided hy t h e
T h e reduction ainounts to approxi~iu~tely one- special nuts are 3.8, 3.8, 4.2 and 4.5 \.ihicli can be
third of the m a s i n ~ u mstress encuiinterrd with t h e conlpared to fringe ord r s of 3.2, 3.7. 3.8 and 2.4 i n
stantlard nut. This is acc:omplishcrl by provid- the runout areas of 111 overs&-shank Iwlt. T h i s
I
ing relirf in tlw root of the n u t thread which im- means t h a t t h e stress concentrations clue t o the
~)arLsa certain amount of flcxihility to the n u t reduction in area com ined with those due t o t h e
thread antl permits some of the upper threads t o presence of a notch t h e thread in the runout
s1l;lrc the load-carrying funclion. area give rise t o stress s of t h e same magnitude a s
I t would he wrong, on the basis of these results, those due t o the inte action of tlie I~olrand the
to say t h a t the special thread permits more threads
to carry tlie load, since i t will l ~ enoted t h a t t h e
first two "eng:~ged" thretids in the bolt ends
special nut.
1
T h e low fringe orde of 2.4 in one of the thread
roots is something of asurprise. It is not known if