An easy and reliable way to join two or more components is to use a bolted joint. When torque is applied on the bolt head, a clamp force is achieved. However about 90% of this torque will be used just to overcome the friction in the interfaces. To be able to fasten these in an ecient and precise manner the friction in the bolt threads and underhead area is important to understand. This is currently investigated at Atlas Copco by using a friction test rig, FTR, which measures the clamp force, the total torque and the shank torque. To evaluate the test rig and also to be able to evaluate dierent friction models, a parameterised simulation model of a bolted joint is built. This is a 3D-model of the joint containing a bolt, a nut and a test specimen. The stiness and frictional behaviour of the FTR is used in the model to get a good comparison between these two. Dierent contact formulations and settings are tested to achieve a good model. Also, mesh size, step size and material models are evaluated to see the eect of these. The results show a good correlation between the FTR data and the simulation model. For the total torque to clamp force ratio a dierence of about 1% is achieved. The average dierence in shank torque and underhead torque is at 3.1% and -1.6% respectively. The pressure distribution for this model is shown to be unevenly distributed along the threads. This is minimized by softening the contact, but this instead increases the error between the FTR data and the simulation model. For the evaluation of friction models that are based on the contact pressure this needs to be investigated further to nd a good compromise between the contact pressure and the frictional behaviour.

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No description available.

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.

The subject of this diploma thesis is the theoretical basis of the screw connection theory and the subsequent application to the specific screw connection problem. Mentioned connection is part of the turbo charged combustion engine, specifically directly between the cylinder head and the turbocharger. The diploma thesis is divided into several parts. The first part dealing with selected chapters of the screw connections and the combustion engines theory, whose knowledge is important for further chapters of this diploma thesis. The next part shows method of creating the geometric and computational model, on which were performed the appropriate sensory analyses with respect to determine the cause of the nut and bolt loose in the given connection. On the basis of the gained knowledge and their evaluation has been created a separate calculation methodology in the last part of this thesis, which describing parameters that have an impact on this undesirable phenomenon, and which should be included in analyses for similar issues. The diploma thesis was realized in cooperation with ŠKODA Auto a.s., tř. Václav Klementa 869, Mladá Boleslav, and AUDI AG, Union-Straße 1, Ingolstadt.

Submitted by RAFAEL AGUERA REZENO DA SILVA null (aguera.feg@gmail.com) on 2016-04-10T23:05:59Z No. of bitstreams: 1 Dissertação_Aguera.pdf: 5287076 bytes, checksum: 018a793b7d2956814528ec0cb549cc66 (MD5) / Approved for entry into archive by Ana Paula Grisoto (grisotoana@reitoria.unesp.br) on 2016-04-12T17:53:04Z (GMT) No. of bitstreams: 1 silva_rar_me_guara.pdf: 5287076 bytes, checksum: 018a793b7d2956814528ec0cb549cc66 (MD5) / Made available in DSpace on 2016-04-12T17:53:04Z (GMT). No. of bitstreams: 1 silva_rar_me_guara.pdf: 5287076 bytes, checksum: 018a793b7d2956814528ec0cb549cc66 (MD5) Previous issue date: 2016-02-16 / Em bielas automotivas, os parafusos atuam de maneira a manter a união entre capa e haste, suportando as cargas trativas, compressivas e transversais originadas no olhal maior. Para tais componentes, o dimensionamento de juntas aparafusadas torna-se complexo, visto que a disposição dos parafusos e a geometria do mancal conduzem ao surgimento de esforços excêntricos à face de fratura, elevando a criticidade do projeto. Em vista disso, e do reduzido número de publicações sobre o assunto, o presente trabalho propôs uma “abordagem híbrida” para a análise de juntas aparafusadas em bielas anguladas, utilizando resultados obtidos a partir de um modelo de elementos finitos simplificado e as ferramentas contidas no roteiro VDI 2230 parte 1. Além disso, foi avaliada a influência do fenômeno de abertura unilateral sobre a vida em fadiga dos fixadores utilizados em bielas anguladas, analisando os resultados obtidos de modo a desenvolver um critério de avaliação para a fadiga desses componentes. A despeito das restrições, a abordagem numérico-analítica desenvolvida demostrou-se atraente, tanto pelo baixo custo computacional associado, quanto por sua precisão, principalmente na determinação da força tensora residual mínima para a prevenção de abertura, mostrando-se adequado para processos de otimização multiparamétricos, selecionando designs promissores passíveis de posterior avaliação através de modelos refinados. Já as análises de influência do fenômeno abertura não apresentaram alterações sensíveis nos níveis de força adicional dos fixadores, fato esse relacionado com a posição dos pontos de abertura em relação ao parafuso e ao mancal. Apesar disso, as simulações realizadas demonstraram que as condições de carregamento avaliadas não influenciaram no diagrama de Haigh local dos nós críticos de cada fixador, o que sugere o uso de resultados extraídos de ensaios de fadiga como variáveis de entrada para simulações em juntas de bielas, incluindo assim as influências benéficas do processo de manufatura. / Connecting rods screws maintain the connection between cap and shank supporting the tensile, compressive and transversal loads applied on the big end. In this case, the design of bolted joints become complex since the screw’s position and bearing geometry lead to eccentric forces acting on the joint split line. Due to that and the reduced number of publications on the subject, this dissertation aims to develop a "hybrid approach" for the analysis of bolted joints in angled connecting rods, using results from a simplified finite element model as input for the VDI 2230 part 1 guideline. In addition to that, this study evaluates the influence of unilateral opening phenomenon on fasteners fatigue life, analyzing the results in order to develop a criterion for fatigue analysis of connecting rod bolts. Despite the restrictions, the “hybrid approach” proved to be attractive due to the low computational cost and accuracy, especially for the calculation of minimal residual tensile force to prevent opening, being suitable for multiparametric optimization during project early phases. The opening phenomenon showed no significant changes in fastener’s additional forces, fact related to the position of joint opening points. Nevertheless, the simulations showed that the loading conditions did not influence on the local Haigh diagram of critical nodes, which suggests the use of fasters fatigue tests as input variables for fatigue simulations, thus including the beneficial influences of the manufacturing process.

No description available.

A self-sensing and self-healing bolted joint has been developed. This concept encompasses the areas of health monitoring, joint dynamics and smart materials. In order to detect looseness in a joint the impedance health monitoring method is used. A new method of making impedance measurements for health monitoring that greatly reduces the equipment cost and equipment size was developed. This facilitates implementation of the impedance technique in real-life field applications. Several proof of concept experiments are presented and compared to the traditional method of making impedance measurements. Investigations of bolted joint dynamics were conducted. A literature review of bolted joints and their diagnostics is presented. The application of the transfer impedance method is compared to standard modal tests on various bolt tensions. An investigation of damping in bolted joints was also made comparing a bolted and monolithic beam. Practical issues in adaptive bolted joints are investigated. This includes issues on activating/heating SMA actuators, connecting the actuators to the power source, size selection of SMA actuators and insulations. These issues are examined both experimentally and theoretically. / Master of Science

La dissipation dans les systèmes mécaniques joue un rôle important dans la limitation des niveaux de vibrations qui peuvent causer des difficultés allant de l'inconfort jusqu'à la ruine des structures. L'amortissement intrinsèque des matériaux utilisés pour la fabrication de structures aéronautiques étant très faible, les jonctions représentent une des sources principales de dissipation. Dans le cadre du projet FUI MAIAS (Maitrise des Amortissements Induits dans les ASsemblages), les travaux présentés ici portent sur la maximisation de l'amortissement induit. Une grande partie des travaux de littérature s'intéressent à l'étude de jonctions élémentaires. On cherche donc ici à étudier la conception de jonctions dissipatives intégrées dans une structure globale. Pour limiter les applications, on se restreint plus particulièrement aux jonctions boulonnées rencontrées en construction aéronautique et à l'utilisation de matériaux viscoélastiques pour générer la dissipation.Une notion de couplage pour la mesure de la capacité des liaisons à dissiper est introduite pour s'assurer de leurs contributions au comportement vibratoire. En utilisant le couplage en tant que mesure de sensibilité des jonctions aux propriétés des matériaux viscoélastiques, en plus de l'étude de la tenue fonctionnelle d'une liaison boulonnée, une approche de conception de jonction boulonnée dissipative est alors développée. Une étude expérimentale est ensuite effectuée pour la valider. Lors de la compagne d‘essais, des défauts de forme ont été détectés dans la structure. L'influence de ces défauts, susceptibles d'exister dans les structures réelles, sur l'amortissement est alors décrite. L'intégration pour un grand nombre de modèles physiques, détaillés au voisinage des jonctions, dans un modèle d'ensemble est généralement une problématique. Une représentation simplifiée s'avère être alors nécessaire. Une réduction de modèle peut être alors appliquée sur la partie linéaire du système. Cependant, pour les non-linéarités localisées au niveau des jonctions, une construction de méta-modèle caractérisant les efforts transmis dans les liaisons est alors proposée. Différentes stratégies de construction de méta-modèle, reproduisant les déformations et les efforts principaux de liaisons, sont proposées et étudiées en supposant des liaisons à comportement viscoélastique. Un modèle cylindrique à dix jonctions boulonnées, plus représentatif de l'architecture réelle des structures aéronautiques est étudié pour illustrer le cas des liaisons répétées dont le chargement réel de chacune est beaucoup plus complexe que les structures simples couramment étudiées. / Dissipation in mechanical systems plays an important role in limiting vibrationlevels. The present work deals with maximizing damping induced by junctions and treatsjunctions integrated into an overall structure. After introducing the physical models used inrepresenting viscoelastic behavior, a first example introduces the concept of coupling. Coupling,estimated by preliminary calculations of elastic natural frequencies sensitivity, ensures thatjunctions sufficiently contribute to the global behavior to induce damping. To study this couplingas well as obtain accurate damping predictions by complex modes calculation, model reductionmethods, adapted to parameterized problems, are needed and different strategies are detailedand validated. A structure representing aeronautic construction is then used to illustrate theproposed damping design process. The study highlights the functional importance of thecohesive zone under the bolt and the possibility of using the residual flexibility of the joint tointroduce a viscoelastic layer enabling high damping. Experimental modal tests confirm thevalidity of the design and the predicted trends, but also show the influence of manufacturingdefects which limit the induced damping. The manuscript finally addresses the need forrepresentative models of detailed joints in overall models. Although model reduction is possibleand desirable, the construction of meta-models representing the main forces transmitted by thejoints is useful in modeling and necessary for the operation of elementary tests. Generalstrategies for defining principal deformations and loads are introduced and their validity isillustrated.

As a valuable asset in human augmentation and medical rehabilitation, exoskeletons have become a major area for research and development. They have shown themselves to be effective tools for training and rehabilitation of individuals suffering from limited mobility. However, most exoskeletons are not capable of balancing without the assistance of crutches from the user. Leveraging technology and techniques developed for force controlled humanoid robots, a project was undertaken to develop a fully self-balancing, compliant lower-body robotic exoskeleton. Due to their many beneficial features, series elastic actuators were utilized to power the joints on the exoskeleton. This thesis details the development of four linear series elastic actuators (LSEA) as part of this project. All 12-degrees of freedom will be powered by one of these four LSEA's. Actuator requirements were developed by examining human gait data and three robot-walking simulations. These four walking scenarios were synthesized into one set of power requirements for actuator development. Using these requirements, analytical models were developed to perform component trade studies and predict the performance of the actuator. These actuators utilize high-efficacy components, parallel electric motors, and liquid cooling to attain high power-to-weight ratios, while maintaining a small lightweight design. These analyses and trade studies have resulted in the design of a dual-motor liquid-cooled actuator capable of producing a peak force 8500N with a maximum travel speed of 0.267m/s, and three different single-motor actuators capable of producing forces up to 2450N continuously, with a maximum travel speeds up to 0.767m/s. / Master of Science