Modeling Pretensioned Bolts
Bolted joints are common in mechanical and civil engineering structures. If you are interested in analyzing the details of a bolted joint, the prestress in the bolt must be taken into account in order to correctly capture the behavior under service loads. The Bolt Pretension functionality in COMSOL Multiphysics is designed to simplify such analyses. You can model the bolts either using solid or beam elements.
During mounting, a bolt is tightened to a certain prestress. The mounting of the bolt is, in general, accompanied by deformations of the surrounding structure. In the subsequent service, the force in the bolt can then change due to external loads.
Sometimes the sequence in which the bolts are tightened is important. This will be the case if significant nonlinearities are induced by the tightening process. Modeling such a process is also fairly straightforward. This is, however, a less common case which adds some extra complexity to the modeling, so it will be discussed separately below.
Modeling the Bolts
You must use a specific modeling technique in order to use a bolt in a prestress analysis.
Using Solid Elements
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If you are using bolts from the Part Libraries, a slit boundary is predefined, and has the selection name Pretension cut. In order to make this boundary selection visible from the physics interface, select its Keep check box in the Boundary Selections section of the settings for the part instance (Figure 2-25).
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Add a Bolt Pretension node, in which the pretension force or stress is prescribed for a set of bolts sharing the same data.
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For each bolt having the same essential data, add a Bolt Selection subnode where its slit boundary is selected.
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The label of the bolt, which is an input in the Bolt Label section, is used to identify the bolts during result evaluation. A suggestion for the name is automatically generated, based on the base name given in the parent node.
When a bolt is located in a symmetry plane (so that only half the bolt is modeled), and Automatic symmetry detection is selected in the Bolt Selection node, the given pretension force is interpreted as the force in the whole bolt, and not as the force in the half-present bolt. This makes it possible to use the same Bolt Pretension node for a set of similar bolts where some of them are located in symmetry planes.
Figure 2-24: Example of a bolted joint with the bolt modeled as a solid.
Figure 2-25: Getting access to the slit boundary selection for a bolt from the Part Libraries.
Using Beam Elements
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When modeling with beam elements, you will typically use a Polygon with three points to model each bolt (Figure 2-26).
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You can connect the end of the beam to the edge of the bolt hole (the lower end in Figure 2-26). Then, use the Solid–Beam Connection multiphysics coupling, with Connection type set to Solid Edges to Beam Points. In this case, you select the edge of the bolt hole.
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You can create a circular boundary having the diameter of the bolt head on the surface of the component (the upper end in Figure 2-26). Then, use the Solid–Beam Connection multiphysics coupling, with Connection type set to Solid Boundaries to Beam Points. In this case, you select the annular solid boundary.
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Even without creating an extra boundary, you can use the Solid–Beam Connection multiphysics coupling, with Connection type set to Solid Boundaries to Beam Points, general. Then set Connected region to Distance (manual) and enter half the head diameter as Connection radius. In this case, you select the entire boundary on which the bolt head is residing. This method is convenient, but will often give more spurious stresses around the bolt hole, since partial element faces will be connected.
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All these techniques are shown in the Structural Mechanics Module Application Library example Modeling of Pretensioned Bolts.
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Add a Bolt Pretension node, in which the pretension force or stress is prescribed for a set of bolts with the same data.
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For each bolt having the same essential data, add a Bolt Selection subnode where its slit boundary is selected.
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The label of the bolt, which is an input in the Bolt Label section, is used to identify the bolts during result evaluation. A suggestion for the name is automatically generated, based on the base name given in the parent node.
Figure 2-26: A bolt modeled using the Beam interface.
The Predeformation Degree of Freedom
Each bolt defined in the Bolt Selection node has a single global degree of freedom called predeformation, d. At the slit boundary, the two sides of the bolt are disconnected so that the displacements over it can be discontinuous. The discontinuity is represented by:
Here the subscript u denotes the upside of the slit boundary, and d denotes the downside. n is the normal pointing out from the downside. The sign has been selected so that d gets a positive value when the bolt force is tensile. An optional relaxation r can also be included.
The axial force in the bolt is thus caused by a small overlap between the two sides of the slit boundary. It is computed as the reaction force belonging to the degree of freedom d.
It is only meaningful to introduce the relaxation in a later study step. If it is present all the time, then its only effect would be to increase the predeformation during the pretension analysis by r. Thus, the value of r is usually a function of the load history, which is initially zero.
Setting up the Study Steps
In an analysis of prestressed bolts, you have to use two or more separate study steps. They can be part of a single study or be placed in different studies. The first study step, in which the bolt prestress is prescribed, simulates the mounting process. If you would only use a force to load the bolt (for example, as an initial stress), the resulting stress in the bolt would be less than the intended, due to the compression of the material around the bolt. The prestress step ensures that the bolts have the intended prestress, irrespective of the flexibility of the surrounding structure and their interaction.
In the subsequent studies, the bolt force is allowed to change, while keeping the extension of the bolt, as caused by the first study, fixed. The procedure to do this is as follows:
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Run the study step for the mounting simulation. The predefined study type Bolt Pretension is designed for this. You may need to apply the pretension load in smaller steps, if there are nonlinearities in the system. Then, you select Auxiliary sweep in the Study Extensions section in the settings for the Bolt Pretension study step. Introduce a load ramping parameter, which is used to multiply the pretension forces.
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Sequential Tightening
If you need to take the order of the bolt tightening into account, then you must use an auxiliary sweep where the sweep parameter is used to control the tightening history.
You need to perform the following steps:
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In each Bolt Selection node representing a bolt that is not fully pretensioned from the beginning of the study step, select the Sequential tightening check box.
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A new text field, Pretensioning expression, is now shown. In this text field, you enter a Boolean expression, which evaluates to a nonzero value at the parameter values when the prestress is applied. It may happen more than once, if the bolt is not given its full pretension force at once. An example of such an expression is round(par)==3 || round(par)==11.
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If you want the bolt prestress (when applied) to have a value that differs from the value given in the parent Bolt Pretension node, change the setting of Pretension type from From parent to another option. Extending the example above, the expression for the pretension force could be 50[kN]*if(par>3.5, 1, 0.6). The only thing that matters here is the value of the force at the parameter values when the pretension force is set, in this example 3 and 11.
A sequential tightening precess may have a quite slow convergence rate until a certain number of bolts have been loaded. The reason is that it is common that two mating boundaries barely touch, so that many contact iterations are needed. It is advisable to start by giving all bolts a small prestress, maybe 1% of the final value, in order to stabilize the model.
If you use the Bolt Pretension study type for the pretension study step, and any other study type to analyze the service loads, the solvers are automatically set up to handle this. The Bolt Pretension study type is actually a special case of a Stationary study step, with the sole purpose of activating the predeformation degrees of freedom. These degrees of freedom are by default not solved for in any other study type.
You enable or disable the solution of individual degrees of freedom under the Dependent Variables node for a certain study step in the solver sequence. If required, begin by clicking Show Default Solver in the study node or in the Solver Configurations node of the study. Then move to the Dependent Variables node, and in the General section, set Defined by study step to User defined.
You can now go to the node for each predeformation degree of freedom below Dependent Variables and adjust the state of the Solve for this state check box.
For more information, see also Dependent Variables and Studies and Solvers in the COMSOL Multiphysics Reference Manual.
Results
The results in a bolt do not belong to any part of the geometry, but are global variables. To access the result from a certain bolt, a full scope of the type <interface>.<Bolt Pretension tag>.<Bolt Selection tag>.<variable> must be used. An example could be solid.pblt1.sblt1.F_bolt. The bolt results are summarized in the table below.
Table 2-15: Bolt Variables.
If you place a bolt in a symmetry plane, that only half of the bolt is modeled, this will automatically be detected. The results are reported for the whole bolt, not for the symmetric half.
When there are pretensioned bolts in a study, evaluation groups containing the bolt forces will automatically be generated.
Studies and Solvers in the COMSOL Multiphysics Reference Manual
Modeling of Pretensioned Bolts: Application Library path Structural_Mechanics_Module/Tutorials/bolt_pretension_tutorial
Prestressed Bolts in a Tube Connection: Application Library path Structural_Mechanics_Module/Contact_and_Friction/tube_connection