This research introduces a proposed model for predicting tilting angle and limit states of single-fastened cold-formed steel-to-steel shear connections. Predictions are validated through an experimental study considering ply configuration and a single Hex #10 -washer head fastener, centered in a 102 mm by 102 mm three boundary window. The fastener tilting angle is captured using an automated, optical non-contact measurement procedure. The results are used to identify cold-formed steel shear connection deformation as load progresses, including tilting, bearing, and combined tilting bearing at the plies and thread tension, shear and bearing fastener failure. Results shows that fastener tilting plays a kinematic affect for the connection. Fastener tilting is predicted in function of ply thickness and fastener pitch. Local ply bending deformation is reported to be the main deformation of the connection during fastener tilting. While fastener bending and shear failure occurred if the fastener does not tilt. / Master of Science

The assignment, which has been carried out on behalf of Troax AB was to develop suggestions on one sided fasteners that will be used to attach the anti-collapse system for pallet racks. The problem, as it is today, is that the installers of the mesh panels for the anti-collapse system find it difficult to reach behind and inside the pallet racking beam when they screw together the screw and the nut to hold up the anti-collapse system. Therefore, there is a desire to use a fastener which does not have to handle screws or bolts on the back of the beam. One design requirements is that it should fit most hole patterns and hole sizes available for pallet racks today. It also has the requirement that it must hold for a pendulum test. The energy is then converted into a force for easier calculations. When a safety factor is applied the force that the system is subjected to is approximately 10KN. SolidWorks was used to model and structurally analyze the various design proposals. The best design proposal was put into a simulations study to be analyzed. Then the proposal was compared with the screw which is currently in use. The results of the structural analysis of the current screw show that it withstands the applied loads. The proposed suggestion lacks credibility due to the fact that the stresses shown in the simulations are too high. Based on the results from the structural analysis, it is concluded that further studies are needed and also that the other design suggestions should be examined further in case they could be improved to make them meet the requirements. / Detta arbete är utfört på uppdrag av Troax AB där uppgiften var att ta fram förslag på ensidesfästade fästelement som ska användas till att fästa rasskydd till pallstallage. Problemet som det är idag är att montörerna av rasskyddet anser att det är svårt att komma åt bakom och innanför balken då man ska skruva dit skruv och mutter för att hålla upp rasskyddet. Därför finns det en önskan att kunna använda ett fästelement där man inte behöver hantera skruvar eller muttrar på baksidan av balken. Kravet som sattes på fästelementet är att den ska passa till de flesta hålbilder och hålstorlekar som finns på stallagebalkar idag. Den ska även hålla för ett pendeltest då en pendel med vikten 160kg och rörelseenergin 2500J slås in i ett gallernät. Energin räknas sedan om till en kraft för enklare beräkning och för att kunna föra in kraften i datorsimuleringar. Kraften som systemet utsätts för blir enligt uträkning ca 7100N och med en säkerhetsfaktor blir den resulterande kraften 10000N. SolidWorks används för modellering samt för analys av designförslagen. Först sätts hela systemet med alla balkar, konsoler, paneler och skruvar upp i SolidWorks och Simulation för att se hur allt hänger ihop. Därefter förenklas uppsättningen och ger resultatet att skruven utsätts för dragkraft och skjuvkraft där hela kraften appliceras. Det designförslag som bäst uppfyllde kraven sattes in i Simulation för att studeras. Där undersöks och jämförs förslaget med dagens skruv där båda utsätts för både dragkraft och skjuvkraft. Dagens skruv visar resultatet att den håller för de uppsatta krafterna. Förslagets resultat vid drag är dock opålitliga då uppsättningen av denna inte är optimal. Utifrån resultatet dras slutsatsen att det krävs ytterligare studier på förslaget och att man även bör titta på de övriga förslagen som togs fram för att se om det finns eventuella förbättringar på dessa som gör att de uppfyller kraven. / <p></p><p></p>

Bolted joints are often the most critical parts with respect to fatigue life of structures. Therefore, it is important to analyze these components and the forces they are subjected to. A one-dimensional nite element model of a bolted joint is created and implemented as a program module in the Saab software `DIM', together with a complete graphical user interface allowing the user to generate the structure freely, and to apply both mechanical and thermal loads. Available methods for calculating fastener exibility are reviewed. The ones derived by Grumman, Huth and Barrois are implemented in the module, and can thus be used when dening a geometry representing a bolted joint assembly. Investigations have shown that it cannot be said that either method is generally better than the other. Calculated properties of interest include the fastener forces, plate bearing and bypass loads, and - for simpler geometries without thermal loads - the load distribution between rows of fasteners. The program is fully functional and yields numerically accurate results for the most commonly used joints where fasteners connect two or three plates each. It has limited functionality on geometries with fasteners connecting four or more plates and for a certain loading combination also for three plates, due to the tilting of the fasteners not being accounted for in the model for these cases. Also, there is no explicit method available for nding an accurate value for the fastener exibility for these, less common, joint structures.

Over the past two decades, a major part of the manufacturing and assembly market has been driven by its customer requirements. Increasing customer demand for personalised products create the demand for smaller batch sizes, shorter production times, lower costs, and the flexibility to produce families of products - or different parts - with the same sets of equipment. Consequently, manufacturing companies have deployed various automation systems and production strategies to improve their resource efficiency and move towards right-first-time production. However, many of these automated systems, which are involved with robot-based, repeatable assembly automation, require component- specific fixtures for accurate positioning and extensive robot programming, to achieve flexibility in their production. Threaded fastening operations are widely used in assembly. In high-volume production, the fastening processes are commonly automated using jigs, fixtures, and semi-automated tools. This form of automation delivers reliable assembly results at the expense of flexibility and requires component variability to be adequately controlled. On the other hand, in low- volume, high- value manufacturing, fastening processes are typically carried out manually by skilled workers. This research is aimed at addressing the aforementioned issues by developing a freeform automated threaded fastener assembly system that uses 3D visual guidance. The proof-of-concept system developed focuses on picking up fasteners from clutter, identifying a hole feature in an imprecisely positioned target component and carry out torque-controlled fastening. This approach has achieved flexibility and adaptability without the use of dedicated fixtures and robot programming. This research also investigates and evaluates different 3D imaging technology to identify the suitable technology required for fastener assembly in a non-structured industrial environment. The proposed solution utilises the commercially available technologies to enhance the precision and speed of identification of components for assembly processes, thereby improving and validating the possibility of reliably implementing this solution for industrial applications. As a part of this research, a number of novel algorithms are developed to robustly identify assembly components located in a random environment by enhancing the existing methods and technologies within the domain of the fastening processes. A bolt identification algorithm was developed to identify bolts located in a random clutter by enhancing the existing surface-based matching algorithm. A novel hole feature identification algorithm was developed to detect threaded holes and identify its size and location in 3D. The developed bolt and feature identification algorithms are robust and has sub-millimetre accuracy required to perform successful fastener assembly in industrial conditions. In addition, the processing time required for these identification algorithms - to identify and localise bolts and hole features - is less than a second, thereby increasing the speed of fastener assembly.

Threaded fastener is one of the most common ways to join components. Having a method to test threaded fasteners is key when designing a joint and even more a nutrunner. A joint is often tightened by a torque applied on the head. The applied torque is equal to three quantities in the joint, the thread torque, the underhead torque and the clamp force. To measure these quantities are the propose of a friction test rig. A test rig was built last year to be able to do that in a flexible and effective way. But the test rig built last year does not have the possibility to measure the underhead torque. A new transducer is constructed to add that possibility. The transducer is constructed by using methods such as concept generation, strength calculations, FEM simulations and a comparison of sensors are made. An easy way to change the stiffness is also investigated but no possible solution could be found. Some modifications and trims are also done on the test rig and also a comparison with the older BLM rig. A validation is made of how good the rig perform is also done. The results shows in favour for the FTR but precise results is not possible to determine.

<p>This report investigates the feasibility and accuracy of determining fastener flexibility with 3D FE and representing fasteners in FE load distribution models with simple elements such as springs or beams. A detailed study of 3D models compared to experimental data is followed by a parametric study of different shell modelling techniques. These are evaluated and compared with industry semi-empirical equations.</p><p>The evaluated 3D models were found to match the experimental values with good precision. Simulations based on these types of 3D models may replace experimental tests. Two different modelling techniques were also evaluated for use in load distribution models. Both were verified to work very well with representing fastener installations in lap-joints using the ABAQUS/Standard solver. Further improvement of one of the models was made through a modification scale factor. Finally, the same modelling technique was verified using the NASTRAN solver.</p><p>To summarize, it is concluded that:</p><p>• Detailed 3D-models with material properties defined from stress-strain curves correspond well to experiments and simulations may replace actual flexibility tests.</p><p>• At mid-surface modelling of the connecting parts, beam elements with a circular cross section as a connector between shell elements is an easy and accurate modelling technique, with the only data input of bolt material and dimension.</p><p>• Using connector elements is accurate only if the connecting parts are modelled in the same plane, i.e. with no offset. Secondary bending due to offset should only be accounted for once and only once throughout the analysis, and it is already included in the flexibility input.</p>

This thesis provides much needed representative sample data for reuse life of fully seated and torqued locknuts. Most national requirements for prevailing torque locking fasteners only specify unseated reuse life. This could create a potentially dangerous situation if unseated is misinterpreted for seated. This thesis provides comparative data for seated verses unseated configuration. Six aerospace, 3 all-metal and 3 nylon insert, and one non-aerospace locknuts were tested at preloads levels of unseated, 66%, 75%, and 85% of yield of bolt. The locknuts tested are MS21043-4, NAS1291-4, NAS1805-4, MS17825-4, MS21044D4, NAS1021N4, and Grade 8. A fixture was created in order to allow for the simultaneous data collection of the applied preload and torque, along with the removal of preload without loosening the locknut. The results from testing indicate the number of reuse cycles is greater for nylon locknuts than the all-metal locknuts. Large losses, on the order of 20-50%, in prevailing torque occur between the first and second cycle of each locknut under all preloads. Tightening Torque required to achieve a certain preload was found to increase with reuse. Application of lubrication to nylon locknuts had a significant effect, reducing the reuse life and prevailing torque performance. The testing indicated the effect of preload reduced the number of reuse cycles to failure, failure occurs when the prevailing torque is measured outside the range of 3.5 to 30 in-lb. All locknuts survived unseated and 66% Y preload testing, except MS21043 which lasted about 14.5 reuse cycles at 66% Y and NAS1805 which survived 8 reuse cycles for unseated and 12.67 reuse cycles at 66% Y. NAS1805's loss of reuse life is due to hardness and material compatibility issues. The scatter of the torque measurements was low for the first three to five cycles, then as the coatings and lubrications are worn the scatter increases. The data collected from testing agrees with the torque friction equation.

This report investigates the feasibility and accuracy of determining fastener flexibility with 3D FE and representing fasteners in FE load distribution models with simple elements such as springs or beams. A detailed study of 3D models compared to experimental data is followed by a parametric study of different shell modelling techniques. These are evaluated and compared with industry semi-empirical equations. The evaluated 3D models were found to match the experimental values with good precision. Simulations based on these types of 3D models may replace experimental tests. Two different modelling techniques were also evaluated for use in load distribution models. Both were verified to work very well with representing fastener installations in lap-joints using the ABAQUS/Standard solver. Further improvement of one of the models was made through a modification scale factor. Finally, the same modelling technique was verified using the NASTRAN solver. To summarize, it is concluded that: • Detailed 3D-models with material properties defined from stress-strain curves correspond well to experiments and simulations may replace actual flexibility tests. • At mid-surface modelling of the connecting parts, beam elements with a circular cross section as a connector between shell elements is an easy and accurate modelling technique, with the only data input of bolt material and dimension. • Using connector elements is accurate only if the connecting parts are modelled in the same plane, i.e. with no offset. Secondary bending due to offset should only be accounted for once and only once throughout the analysis, and it is already included in the flexibility input.

No description available.

At the calculations group in Sigma Industry East North, the traditional method for evaluating fasteners has been by use of the VDI2230 manual. As the complexity of a model increases the evaluation also becomes harder. The goal of this thesis is to set a robust evaluation method by combining the VDI2230 with the Finite Element (FE) method. Varied topics such as fastener and plate compliance, embedding effect, forces through the fastener and plate, minimum thread engagement length, service loads and the fatigue effect in fasteners is discussed. The flowchart discusses the process flow, as in, where to use the VDI2230 and where the FE method comes into use. The thesis also helps to understand designing of bolts like selection of the bolt diameter of varied applications and is user friendly to handle. The focus is also on reducing the time taken for fastener evaluation and setting up of an in-house technique for the evaluation. The evaluation method is verified using a test case. / På beräkningsgruppen på Sigma Industry East North har den traditionella metoden för utvärdering av fästelement varit att använda sig av manualen VDI 2230. Ökad komplexitet gör utvärderingen svårare att genomföra. Målet med detta examensarbete är att föreslå en robust utvärderingsmetod som kombinerar VDI 2230 med Finita Element-Analys (FEA). Olika ämnen såsom vekhet för fästelement och plåtar, sättningar, kraftvägar genom fästelement eller plåtar, minsta ingreppslängd, laster och utmattningseffekter diskuteras. Flödesdiagrammet avhandlar processflödet, det vill säga var man ska använda VDI2230 och när FE-metoden bör användas. Examensarbetet är också till för att skapa förståelse för hur man konstruerar skruvar, såsom val av skruvdiameter vid olika tillämpningar. Fokus har också varit att minska tidsåtgången för utvärdering av fästelement och att sätta upp tekniker för utvärdering att användas i den dagliga verksamheten. Utvärderingsmetoden verifieras med hjälp av ett provfall.