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AM-VPD09-006

Fastener Modeling for Joining Composite Parts


Alexander Rutman, Associate Technical Fellow, Spirit AeroSystems Chris Boshers, Stress Engineer, Spirit AeroSystems John Parady, Principal Application Engineer, MSC.Software Larry Pearce, Senior Lead Application Engineer, MSC.Software

References
Fastener Modeling for Joining Composite Parts, Alexander Rutman, Chris Boshers (Spirit AeroSystems), Larry Pearce, John Parady (MSC.Software Corporation), To Be Presented at the 2009 Americas Virtual Product Development Conference, April 21-22, 2009, Phoenix, AZ Fastener Modeling for Joining Parts Modeled by Shell and Solid Elements, Alexander Rutman, Chris Boshers (Spirit AeroSystems), Larry Pearce, John Parady (MSC.Software Corporation), 2007 Americas Virtual Product Development Conference, October 11-12, 2007, Detroit, MI Fastener Modeling for MSC.Nastran Finite Element Analysis, Alexander Rutman, Adrian Viisoreanu (Boeing), John Parady (MSC.Software Corporation), 2000 World Aviation Conference, October 10-12, 2000, AIAA-2000-01-5585

Objective
Develop an FEM representation of a fastener installed through multiple metal and composite plates.
Accurately represent fastener behavior Rapid model preparation of each fastener Can be used with parts modeled by shell elements with isotropic or orthotropic material properties, parts modeled by solid elements with isotropic properties, or any combination of these parts Accounts for the effects of variable bearing stiffness of a fastener composite plate interface

Representation of a Fastener Joint


Idealization of a plate-fastener system includes the following:
Elastic bearing stiffness of a plate and fastener at the contact surface Bending and shear stiffness of a fastener shank Compatibility of displacements of a fastener and connected plates in the joint

Compatibility of Joint Displacements

Modeling displacement assumptions


No interference of the plates under load The plates mid-planes remain parallel to each other under load Planes under the fastener head and nut remain parallel to the plate midplanes under load

Examples of Fastener Joint Models


RBAR DOF 1,5,6 5,6 1,4,5,6 1 DOF 2,3,5,6

RBE2

Interaction Between Fastener Shank and Joined Plates


Bearing stiffness between fastener shank and plate is represented by CBUSH element Each CBUSH element contains two non-zero axial and two non-zero rotational springs Translational and rotational bearing stiffnesses are defined in PBUSH cards
Solid Element 2nd plate

CBUSH Elements
1st plate

Shell Element

Solid Element

3rd plate

Stiffness of a Fastened Joint in a Metallic Plate


Combined plate and fastener translational bearing stiffness t

S xbt = S ybt =

1 1 + E Ecf
2

Fastener

t p1 t p2 t p3 t p4 df

1st plate 2nd plate 3rd plate 4th plate

Combined plate and fastener rotational bearing stiffness

S xbr = S ybr

tp 1 = 12 1 2 1 + E Ecf

E Ecf

- comp. modulus of plate i material - comp. modulus of fastener material

t p - thickness of the plate

Stiffness of a Fastened Joint Change from Previous Formulation


Comparison of Finite Element and Analytical Results for Translational Bearing Stiffness

Analysis Method Finite Element Analysis


Et

Translational Bearing Stiffness, lb/in 1,192,871 1,030,000 1,155,875

S analytical S FEM S FEM

100%

-13.65 -3.10

Et 1 2

Stiffness of a Fastened Joint in a Composite Plate - Extension


Combined plate and fastener translational bearing stiffness

S xbt =
i =1

ti 1 1 + ( Q11i ) Ecf

S ybt =
i =1

ti 1 1 + (i Q22) Ecf
mi = cos i ni = sin i
(i (i Q66) = G12)

Where,

( (i (i (i (i Q11i ) = Q11) mi4 + 2 Q12) + 2Q66) mi2 ni2 + Q22) ni4 ( (i Q22i ) = Q11) ni4
(i ) 11

( + 2(Q
(i ) 22

(i ) 12

(i + 2Q66)
( E 2i )

) )m n
2 i

2 i

(i + Q22) mi4

E1(i ) 1
(i ) 12 (i ) 21

(i (i 1 12) 21)

(i ) 12

(i ( (i 12) E 2i ) 21) E1(i ) = = (i (i (i (i 1 12) 21) 1 12) 21)

Ecf
( Q11i )

- compression modulus of fastener material - transformed reduced stiffness for ply i in the x-direction

(i Q22) - transformed reduced stiffness for ply i in the y-direction

Stiffness of a Fastened Joint in a Composite Plate - Rotation


Combined plate and fastener rotational bearing stiffness
S xbr 1 n (zi cx ) ( zi 1 cx ) = = 1 1 x 3 i =1 + ( Q11i ) Ecf Mx
3 3

S ybr =

My

1 n (zi c y ) (zi 1 c y ) = 1 1 3 i =1 + ( Q22i ) Ecf


3

Centroid Location

zi2 zi21 1 1 i =1 + (i ) Ecf Q11 1 cx = 2 S xbt


n

zi2 zi21 1 1 i =1 + (i ) Q22 Ecf 1 cy = S ybt 2


n

Analysis Procedure and Limitations

The bearing stiffness in the joint depends on the direction of the fastener reactions. Because these directions are not known prior to running the model, an iterative procedure is required to accurately determine fastener reactions. For composite plates with variable in-plane stiffnesses, the spring analogy used in this analysis does not take coupling between transverse displacements into account. The error induced by this approximation is expected to be small and will decrease with each iteration.

Procedure for Analysis of a Fastened Joint


Construct FEM, Determine Initial Properties

Run FEM

Determine Fastener Reactions Magnitude and Direction Summarize Reactions

Update Fastener Stiffnesses

No

Initial Run?
Not Converged

Yes

Converged

Compare Reactions to Previous Run

Example Composite Plate in Double Shear


Design Configuration Finite Element Model

100 lb Fasteners

FEM Isoview

FEM Upper Plate Removed

Example Bearing Stiffnesses as a Function of Resultant Fastener Direction

90

Example Fastener Reactions After Initial Run


Fastener ID 1 2 3 4 Rx -29.5 29.3 -49.9 50.1 Ry 46.9 46.9 3.13 3.02 122.2 58.0 176.4 3.4

100 lb

Example Fastener Reactions After 2nd Run


Fastener ID 1 2 3 4 Rx -25.8 25.6 -49.4 49.6 Ry 49.5 49.6 0.5 0.395 117.5 62.7 179.4 0.5

100 lb

Example Fastener Reactions After Final Run


Fastener ID 1 2 3 4 Rx -25.2 25.1 -49.5 49.6 Ry 49.7 49.8 0.3 0.2 116.9 63.3 179.7 0.2

100 lb

Example Summary of Analysis Results

Fastener Load Convergence


5 4 Change in Load (lb) Fastener 1, Px 3 2 Fastener 3, Px 1 0 1 2 Run # 3 4 Fastener 3, Py Fastener 1, Py
4 2 3 1

Patran Fastener Builder

MSC.Software is currently developing a PCL procedure consisting of two parts:


The first part shall quickly and easily create fasteners in Patran for models containing plates with composite and optionally metal material properties. The second part is needed for updating bearing stiffnesses in the composite plate-fastener interface.

An MSC.Nastran procedure for automatically iterating the process is very desirable to increase the speed of the analysis.

Patran Iterative Analysis Panel Patran Fastener Builder Panel

Conclusions

The fastener modeling technique developed for isotropic materials has been extended to models containing composite plates. The previous formulae for computing bearing stiffnesses for fasteners in a metal plate has been modified to better account for plate behavior. Due to the variation of in-plane stiffnesses of a composite material, an iterative procedure is necessary to accurately determine fastener loads. An automated PCL procedure is under development to quickly and easily create fastener representations in MSC Patran.

Contact Details :

For further information please contact Alexander Rutman 316-523-7048 alexander.rutman@spiritaero.com Chris Boshers 316-523-0374 chris.boshers@spiritaero.com Spirit AeroSystems P.O. Box 780008 Mail Zone K78-20 Wichita KS, 67230 USA John Parady 817-481-4812, ext. 15 john.parady@mscsoftware.com Larry Pearce 770-252-6560 larry.pearce@mscsoftware.com MSC.Software 2 MacArthur Place Santa Ana, CA 92707 USA

13/05/2009

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