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Structural shear joints: Analysis, properties and design for repeated loading

G T Hahn, C A Rubin, Vanderbilt University and K A Iyer, US Army Research Centre, USA

Woodhead Publishing Series in Metals and Surface Engineering No. 16

 - understand how to optimise the design and reliability of shear joints
 - places into context the results of over 150 detailed, 2D and 3D finite element analysis of aluminium and steel sheer connections

Engineers employ shear connections - riveted and bolted butt and lap joints - in a wide range of structures and machines. Ordinary stress analysis of joints are unable to define the features that ultimately govern fatigue and fretting and provide bases for design. Detailed analysis has only become possible recently with advances in finite element methods and computing capabilities. This text places into context the results of over 150 detailed 2D and 3D finite element analyses of aluminum and steel shear connections so that engineers can optimise the design and reliability of shear joints.

ISBN 1 84569 119 9
ISBN-13: 978 1 84569 119 6
December 2005
280 pages  247 x 174mm  hardback  
£115.00 / US$195.00 / €140.00

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About the authors

George T Hahn (ScD, MIT, 1959) is Professor Emeritus of Mechanical Engineering and Materials Science at Vanderbilt University, Nashville, TN. Prior to that he was Manager of the Metal Science Section at Batelle Laboratories in Columbus, OH. He is a Fellow in the American Society of Metals and has published well over 150 papers in the fields of fracture mechanics, rolling contact, and riveted connections.

Carol A Rubin, PE (PhD, Kansas State University, 1966) is a Member, ASME, Applied Mechanics and Computers in Engineering Divisions. Dr. Rubin is Professor in the Department of Mechanical Engineering at Vanderbilt University. Her areas of expertise are finite element analysis and solid mechanics. She has published more than 80 papers in the areas of theoretical mechanics, numerical methods in applied mechanics, contact mechanics, and riveted connections.

Kaushik A Iyer (PhD, Vanderbilt University, 1997) is a Member, ASME, Design and Tribology Divisions. Dr Iyer is on the faculty of the Department of Mechanical Engineering at the University of Michigan. He works for the US Army Research Laboratory in Maryland. He has published nearly 20 papers on topics including riveted connections, contact fatigue, and quenching process modeling.

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Contents

PART 1 MECHANICAL BEHAVIOR OF SHEAR JOINTS AND DESIGN CONSIDERATIONS
PART 2 COMPILATION OF FINITE ELEMENT RESULTS

PART 1 MECHANICAL BEHAVIOR OF SHEAR JOINTS AND DESIGN CONSIDERATIONS

Basic features
 - Aspects of shear joints
 - Out-of-plane deformation, microslip and plasticity
 - Fasteners and the fastener load
 - The bearing, clamping and adhesive modes of load transfer
 - Stress descriptors for fatigue

Shear joints in the bearing mode
 - Stress descriptors for bearing mode
 - Butt joint
 - Doubler
 - Lap joint
 - Lap joints in the bearing-plus-adhesive mode
 - Multiple rows of fasteners
 - Biaxial loading and effects of the free edge
 - Fastener stresses

Clamping, interference, micro-slip and self-piercing rivets
 - The clamped, fictional or slip-resistant mode of butt and lap joints
 - Fasteners in the clamping mode
 - Hole expansion, squeeze and interference
 - Contact pressure, micro-slip and tangential stress
 - Self-piercing rivet

Fatigue of shear joints
 - Stages of the fatigue process
 - Failure modes and locations
 - Fatigue strength of panels
 - Fatigue strength of fasteners
 - Fretting wear and fatigue

Design considerations for repeated loading
 - Mechanical performance
 - Considerations for joint durability
 - Joint type and mode selection
 - NDI and fretting
 - Fail safe design
 - Generalizing finite element results

PART 2 COMPILATION OF FINITE ELEMENT RESULTS

Load transfer in single rivet-row lap joints (conventional and countersunk)
 - Summary of load transfer models
 - Load transfer calculations for single rivet-row lap joints
 - Summary and important points

Compilation of results for open hole panels and butt joints
 - Summary of calculational models for open hole panels
 - Summary of calculational models for butt joints
 - Summary of calculational results for open hole panels
 - Summary of calculational results for butt joints without interference
 - Effects of interference in butt joints

Compilation of results for lap joints
 - Summary of calculational models
 - Summary of calculation results
 - Summary of calculation results including interference and clamping

Single rivet-row lap joints under biaxial loading
 - Summary of calculational models for 2-D and 3-D lap joints under biaxial loading
 - Summary of calculation results for pinned connections under biaxial loading
 - Summary of calculation results for single rivet-row lap joints under biaxial loading

Compilation of results for lap joints with sealants and adhesives
 - Summary of calculational models for single rivet-row lap joints with sealants and adhesives
 - Summary of calculation results for pinned connections with sealants and adhesives

Compilation of results for rivets
 - Summary of calculational models for rivets
 - Summary of calculational results for rivets

Data tabulations
 - Summary calculation results for single rivet-row lap joints
 - Summary calculation results for double rivet-row lap joints
 - Summary calculation results for rivet installation residual stresses
 - Summary calculation results for single rivet-row joints under biaxial loading
 - Summary calculation results for single rivet-row joints with sealant
 - Summary calculation results for variation of panel thickness in wide single rivet-row joints
 - Summary calculation results for joint excess compliance and rivet tilt

PART 3 CALCULATIONAL MODELS AND VALIDATION

Finite element models
 - 2D models of butt joints, attachment joints and open hole panels
 - 3D models of single rivet-row lap and butt joints (standard and countersunk rivet heads)

Thin adhesive layer analysis (TALA) for modeling sealants and adhesives installed in joints
 - Development of a thin adhesive layer analysis (TALA)
 - Conversion of adhesive solid element to spring element for 2-D fem
 - Conversion of stress-strain relationship to force-displacement relationship for thin adhesive layer
 - Mechanical behavior of thin sealant layer
 - Shear spring dependence of contact pressure

Material models for finite element calculations

Validation of finite element calculations and TALA
 - Finite element model validation
 - Validation of the thin adhesive layer analysis (TALA)

Stress concentration factors in multiple – row joints
 - Analyses of multiple row joints
 - Estimating fastener loads in multiple row joints
 - Estimating fastener loads with 3D deformations
 - A superposition method for estimating SCFs
 - Validation

Analysis of fastener tension and clamping strain
 - Nomenclature
 - Clamping model
 - Fastener tension and clamping strain predictions
 - Summary of procedure