有限大层板承载孔的孔边应力分析

含圆孔的复合材料层合板, 在孔内轴销加载下的孔边应力分析, 是一个比较复杂的弹性接触问题, 板与轴销均处于十分复杂的受力状态。在文献中, 作者曾提出一个计及轴销变形与接触区摩擦效应的弹性轴销模型。本文在上述工作的基础上, 采用解析-有限元混合解法, 研究了有限大层合板承载销孔的孔边应力。分析表明, 讨算结果与实验相符。      

Stress distribution modeling for interference-fit area of each individual layer around composite laminates joint

The discussion about nonuniform stress distribution around interference-fit joint is particular significance in the design of composite laminates structures. In order to investigate the stress distribution of interference-fit area around composite laminates joint, an analytical model is developed for stress distribution based on the Lekhnitskii's complex potential theory. The normal and tangential stresses of contact are achieved by the relationship of deformation between pin and hole. The effects of ply orientation and interference percentage on stress components distributions of each individual layer around symmetrical laminates joint are discussed. In order to verify the validity of the analytical model, extensive 3D finite element models are established to simulate the stress components of laminates interference-fit joint. The results show that the analytical model is valid, and the laminate property and ply orientation have a significant effect on stress distribution trend while interference percentage mainly affects stress magnitude.     

多孔复合材料机械连接件弹性接触内力和应力分析

本文用有限元混合法给出了多孔复合材料机械连接件弹性接触内力和应力分析。文中详细讨论了销钉弹性、层合板铺设方式和摩擦对各孔钉载分配及孔边应力的影响,并给出了多孔连接件向单孔连接件简化的条件。      

Modelling considerations for stress intensity factor solutions at pin‐loaded holes

This work summarizes investigations into stress intensity factor solutions for straight, through cracks at pin‐loaded holes in thin sheets. As shown in this work, several assumptions contribute to the fidelity of a stress intensity factor solution that includes the distribution of contact pressure on the pin‐hole interface, the friction coefficient at the pin‐hole interface, the crack initiation angle, and stiffness mismatch. These assumptions lead to higher or lower stress intensity factor solutions as demonstrated by results generated from advanced finite element analyses of the relevant geometries. Results shown here contribute to the development of a realistic and conservative set of assumptions for stress intensity factor solutions. Conclusions drawn from this work are applicable to cracks originating at pin‐loaded holes in plates and lugs.     

STRESS INTENSITY FACTORS FOR CRACKS AT FASTENER HOLES

Abstract— Transmission and reflection photoelasticity has been used to determine the stress intensity factors for artificial cracks emanating from a hole in two-dimensional tensile plates. Three geometries were investigated, namely a free hole, a pin-loaded hole and a hole with an interference-fit pin. All these cases relate to situations commonly found in aircraft structures. The results have been compared where possible with analytical data and a good correlation was found for these cases.     

Analytical stress intensity solution for the stable Poisson loaded specimen

An analytical calibration of the Stable Poisson Loaded (SPL) specimen is presented. The specimen configuration is similar to the ASTM E-561 compact-tension specimen with displacement controlled wedge loading used for R-curve determination. The crack mouth opening displacements (CMOD's) are produced by the diametral expansion of an axially compressed cylindrical pin located in the wake of a machined notch. Due to the unusual loading configuration, a three-dimensional finite element analysis was performed with gap elements simulating the contact between the pin and specimen. In this report, stress intensity factors, CMOD's, and crack displacement profiles, are reported for different crack lengths and different contacting conditions. It was concluded that the computed stress intensity factor decreases sharply with increasing crack length thus making the SPL specimen configuration attractive for fracture testing of brittle, high modulus materials.     

Failure Analysis of a Cyclic Contact Testing Machine Pin

The goal of this paper is to investigate the failure of a mandrel pin mounted on a rolling contact test bench. For this purpose, different methods of analysis were conducted, including metallography and stress analysis. The stress values in the failed pin were determined by Finite Elements. The high notch effect and the incorrect mounting of the specimens were identified as the failure causes. A pin design change is proposed to reduce the maximum stress even in the case of incorrect specimen mounting.     

Stress and strength analysis of pin joints in laminated anisotropic plates

Mechanical joints in composites can be tailored to achieve improved performance and better life by appropriately selecting the laminate parameters. In order to gain the best advantage of this possibility of tailoring the laminate, it is necessary to understand the influence of laminate parameters on the behaviour of joints in composites. Most of the earlier studies in this direction were based on simplified assumptions regarding load transfer at the pin-plate interface and such studies were only carried out on orthotropic and quasi-isotropic laminates. In the present study, a more rigorous analysis is carried out to study pin joints in laminates with anisotropic properties. Two types of laminates with (0/ + ₄/90)_s and (0/ ± ₂/90)_s layups made out of graphite epoxy T300/5208 material system are considered. The analysis mainly concentrates on clearance fit in which the pin is of smaller diameter compared to the hole. The main aspect of the analysis of pin joints is the changing contact between the pin and the plate with increasing load levels. The analysis is carried out by an iterative finite element technique and a computationally efficient routine is developed for this purpose. Numerical studies indicate that the location and magnitude of the peak stresses along the hole boundary are functions of fibre angle and the overall anisotropic properties. It is also shown that the conventional assumption of cosine distribution for the contact pressure between pin and the plate in the analysis lead to underestimation of bearing failure load and overestimation of shear and tensile failure loads in typical (0/90₅)_s cross-ply laminates.     

销孔螺栓断裂分析

销孔螺栓在服役期限内发生断裂。借助扫描电子显微镜对断口形貌及显微组织进行观察分析。结果表明,由于销孔螺栓的热处理工艺不当,使其显微组织成为珠光体＋沿晶界分布的网状铁素体及魏氏体组织,造成晶界弱化,使得销孔螺栓强度降低,在应力的作用下发生疲劳断裂。     

A novel method of cold expansion which creates near-uniform compressive tangential residual stress around a fastener hole

A recognized way of improving the fatigue resistance of a fastener hole is to introduce compressive tangential residual stress around it. This can be achieved by using a cold expansion method in which an oversized pin or ball is forced through the hole to produce a local plastic region surrounded by an elastic one. Once the pin or ball is removed allowing the elastic region to spring back it results in compressive tangential residual stress around the hole. In practise, however, it is found that such a cold expansion method creates a non‐uniform residual stress distribution through the plate thickness and even tensile residual stress can be created at the entrance and exit faces. In this paper a new method of cold expansion is proposed. It uses a tapered pin with a mating tapered split sleeve and creates an almost uniform compressive residual stress around the hole as shown by FE method. Also, fatigue tests were carried out to verify that the method does significantly improve fatigue life. Finally the tangential residual stress distribution and fatigue life improvement of this new method were compared with those of a well‐established cold expansion method and it was shown that the new method is more efficient in improving fatigue life.     

On the Bearing Failure of Laminated Composite Pin‐Loaded Joints: Exploitation of Semi‐Analytical Solutions for the Determination of the Stress State

Abstract: The present work deals with the development and verification of a set of analytical solutions for the bearing failure of single lap composite joints, which are applied on a composite joint tested experimentally. The stress field originating from the solution is calculated and progressive failure criteria are applied, verifying their applicability as a fast way of calculating bearing failure of a joint. Additionally, the extracted stress field from the results is introduced as a load to the finite element model of the joint under evaluation, and the equivalency of this method is compared and proven against typical implicit non‐linear contact analysis. The major advantage of the proposed methodology is that the highly non‐linear contact problem is circumvented using the stress distribution at the hole boundary as an actual load and thus transforming the analysis to a linear one, providing considerable agreement to the exact high‐cost numerical solution.     

A finite element calculation of stress intensity factors by a modified crack closure integral

An efficient technique for evaluating stress intensity factors is presented. The method, based on the crack closure integral, can be used with a constant strain finite element stress analysis and a coarse grid. The technique also permits evaluation of both Mode I and Mode II stress intensity factors from the results of a single analysis. Example computations are performed for a double cantilever beam test specimen, a finite width strip with a central crack, and a pin loaded circular hole with radial cracks. Close agreement between numerical results given by this approach and reference solutions were found in all cases.     

DBEM and FEM analysis on non-linear multiple crack propagation in an aeronautic doubler-skin assembly

The performance of a riveted patch repair, applied on a cracked panel, is simulated by using both a commercially available boundary element code (BEASY) and a finite element code (ANSYS). A two-dimensional stress analysis on a single-sided repaired configuration is performed by both methodologies; consequently, the occurrence of out-of-plane bending and its effect on the through-thickness stress intensity factor (SIF) variation is neglected. The connection between the two layers (patch and panel) is realised by 32 rivets, with through-cracks initiated on the most loaded holes. Special elements are used to model the crack: discontinuous elements in the dual boundary element method (DBEM) approach or quarter point elements in the finite element method (FEM) approach. Different loading configurations are considered depending on the presence of a biaxial or uniaxial remote load and the non-linear hole/rivet contact is simulated by gap elements. The most stressed skin holes are highlighted, and the effect of a through crack from such holes is analysed in terms of SIFs and stress redistribution. The accuracy in SIFs assessment by DBEM and FEM and the respective computational and pre-processing efforts are determined. Such a two-dimensional analysis allows us a straightforward pre-processing phase, and very short run times are needed. A peculiar arrangement of the pin configuration in the DBEM analysis allows us to take into account the real in-plane plate stiffness and the transversal pin stiffness, even in a 2D analysis (this is straightforward by using FEM).     

Fretting fatigue of a shrink-fit pin subjected to rotating bending: Experiments and simulations

Fretting fatigue initiation was studied for a shrink-fit pin at rotating bending. Eight assemblies with four different grips were manufactured from soft normalized steel and tested at loads well below bending endurance. All pins displayed rust-red fretting oxides deep into the contact and black oxidised fretting scars with fretting fatigue cracks at the rim. The slip evolution was simulated in a three-dimensional FE model including assembly, bending and sufficiently many rotations to reach a steady-state. The extension of cyclic slip agreed with the black oxidised scar. Deeper into the contact a monotonic slip developed to the positions with rust-red oxides. Asymmetric slip and traction on the interface sides together with a slight twist of the pin in the hub and the slip development process, illustrated that a three-dimensional analysis was required for the interface. Both the stress amplitude and the Findley multi-axial criterion predicted fretting fatigue of the pin although the rotating bend stress was well below the endurance limit.     

Analysis of a finite composite plate with smooth rigid pin

A continuum method of analysis is presented in this paper for the problem of a smooth rigid pin in a finite composite plate subjected to uniaxial loading. The pin could be of interference, push or clearance fit. The plate is idealized to an orthotropic sheet. As the load on the plate is progressively increased, the contact along the pin-hole interface is partial above certain load levels in all three types of fit. In misfit pins (interference or clearance), such situations result in mixed boundary value problems with moving boundaries and in all of them the arc of contact and the stress and displacement fields vary nonlinearly with the applied load. In infinite domains similar problems were analysed earlier by ‘inverse formulation’ and, now, the same approach is selected for finite plates. Finite outer domains introduce analytical complexities in the satisfaction of boundary conditions. These problems are circumvented by adopting a method in which the successive integrals of boundary error functions are equated to zero. Numerical results are presented which bring out the effects of the rectangular geometry and the orthotropic property of the plate. The present solutions are the first step towards the development of special finite elements for fastener joints.     

Stress analysis of a pinned wood joint by grey-field photoelasticity

Pinned (bolted) joints/connections are a widely used, but difficult to analyze, component. Their bolt/hole interface stresses are typically unknown a priori. Structural failures often initiate at connections and their contact stresses can be the “Achilles’ heel”. Although such connections are extremely prevalent in wood structures, ability to determine the individual stresses in mechanical wood joints is aggravated by the material’s orthotropy. Solutions to such non-linear problems that account for finite geometry, pin/hole friction and clearance are non-trivial. Many mechanical-joint analyses ignore friction for simplicity, but some contact friction is virtually always present. By applying a thin birefringent coating to the wood, the individual stresses and strains in the coating (and hence in the wood) are determined by synergizing grey-field photoelasticity, a stress function and boundary information. Full-field individual stresses are obtained in the wood, including at the contact boundary. Predicted strength based on the determined stresses is compatible with the connection failure.     

VLF-RRIM复合材料多螺栓连接承载分布研究

为提高VLF-RRIM增强PU基复合材料多螺栓连接时承载分配比例的均匀性,在综合考虑接触状态非线性和累计损伤过程非线性的影响情况下,运用ABAQUS建立了可变长纤维增强聚氨酯基复合材料制件在多螺栓3行3列单搭接状态的三维有限元仿真模型,并采用试验和数值模拟相结合的方法分析了复合材料连接板的开孔位置尺寸(包括边距、行距、列距、端距等)对承载分配比例的影响.结果表明:该模型可有效模拟大范围损伤发生之前的承载特性;连接模型承载时,螺栓孔离边界越近,所受的载荷就越大,即外部螺栓孔受力大于内部的螺栓孔受力;大的列距、小的行距对载荷分配有明显改善作用;当边距Sw=3.5D、行距P=4D、列距S=5D、端距E=5D时,各螺栓孔承载分配比例最为均匀.     

Nonlinear elastic mechanics of the ball-loaded blister test

The nonlinear elastic mechanics of spherically capped shaft or ball-loaded blister tests is presented. In the test model, a thin film is attached to a substrate with a circular hole running through the thickness of the substrate. A central load is applied to the film through the hole by a spherically capped shaft or a ball with a finite radius. The deformed blister is divided into two parts: a circular region in contact with the sphere of the cap or ball and an outer noncontact annulus. The Reissner’s plate theory is employed to describe the deformation of the contact part and the von Kármán plate theory for the noncontact annulus. A constitutive equation of coupled linear springs is obtained to quantify the effect of the substrate deformation on the blister deflection. For small deflection, the analytical solution of load-deflection is derived. For large deflection, an iteration approach is adopted to predict numerically the load-deflection curve. Finite-element analysis is conducted to verify the analytical and numerical solutions. The influence of the substrate deformation, residual stress, radius of the spherical cap or ball and the friction between the film and ball on the load-deflection relation is investigated.     

S135钻杆内螺纹接头胀扣失效分析

本文对某油井发生的Ф127mmS135钻杆内螺纹接头胀扣失效事故进行了调研，并对其胀扣失效原因进行分析。结果表明，钻杆接头的材质符合行业标准要求；钻杆内螺纹接头胀扣失效的原因是外螺纹接头密封台肩面倒角直径过小，井下钻柱扭矩过大。内螺纹接头密封台肩面承受的接触压力超过材料屈服强度，导致内螺纹接头密封台肩面下陷，外螺纹接头密封台肩面进入内螺纹接头镗孔段，致使内螺纹接头发生胀扣失效。     

A finite element method for contact problems related to fracture mechanics

A finite element method for contact problems in crack mechanics is developed on the basis of the penalty function method. The method is successfully applied to three important problems in fracture mechanics: a crack propagated from a pin hole, a two-point supported specimen with an edge crack loaded by a stamp, and a thick plate with a through-wall crack under bending force.