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INFLUENCE OF WASHER SIZE AND TIGHTENING TORQUE ON THE STRENGTH

OF BOLTED JOINTS IN [0/± ±45/90] S GFRE COMPOSITES

Conference Paper · December 2004

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 8th International Conference on Production
Engineering Design and Control,
PEDAC’2004
December 2004, Alexandria, Egypt

INFLUENCE OF WASHER SIZE AND TIGHTENING TORQUE ON THE

± 45/90]S GFRE COMPOSITES
STRENGTH OF BOLTED JOINTS IN [0/±

U.A. Khashaba*1, H.E.M. Sallam2, A.E. Al-Shorbagy 1, M.A. Seif 3

1
Mechanical Design and Production Engineering Department
2
Materials Engineering Department,
Faculty of Engineering, Zagazig University, P.O. Box 44519, Zagazig, Egypt
3
Mechanical Engineering Department, Alabama A&M University, Normal, AL 35762, USA

ABSTRACT
The weight and fuel savings offered by composite materials make the m attractive not only to
the military, but also to the civilian aircraft, space, and automobile industries. In these
industries, bolting and riveting are extensively used as a primary method of forming structural
joints. Therefore, the main objective of the present paper is to investigate the influence of
certain factors on the strength of bolted joints in [0/±45/90]s glass fiber reinforced epoxy
(GFRE) composites. These factors include the tightening torque (T = 0, 5, 10 & 15 Nm) and
the washer outer diameter size (Dwo = 14, 18, 22 & 27 mm). The mechanical properties
(tensile, compressive, and in-plane shear) of GFRE laminates have been determined
experimentally and theoretically.
The experimental results show that under the same tightening torque, the slope of load-
displacement diagrams of bolted joints (stiffness) increases with decreasing washer size.
Bolted joint with 18 mm washer size and 15 Nm tightening torque has the maximum strength.
In the range of the investigated tightening torques, the bearing strength of bolted joint with 18
mm washer size increases with increasing tightening torque. The load-displacement curve of
bolted joint specimen with finger tight, T=0 Nm, has the lowest slope/stiffness with several
knees, which may indicate an unstable development of internal damage. Most of the test
specimens failed in the following sequence: (a) delamination between the 0o , ± 45o, and 90o
layers due to their different strains under the compressive bearing load, (b) net tension failure
mode for 90o layers, (c) shear-out failure modes for 0o layers, and (d) the final failure was
nearly catastrophic due to the bearing failure of ±45o layers.

KEY WORDS: Angle-ply composites, glass fiber, epoxy, bolted joint, washer size,
tightening torque.

1. INTRODUCTION
Polymeric composite materials are widely used in weight sensitive applications due to the
following advantageous : high specific strength and stiffness, high wear resistance, excellent
corrosion and chemical resistance, high dimensional stability, its viscoelastic properties that
reduce the noise, and the flexibility in designing complex shapes. Fasteners have been the
primary method of joining and assembly of composite structures in the automotive and

* Corresponding author, E-mail: khashabu@hotmail.com

aerospace applications. Design techniques for faste ned joints have received considerable
attention due to the complex nature of the stress fields in the vicinity of the joint, the variety
of failure modes that can occur, and the complexity of stress relieving mechanisms such as
matrix cracking [1]. It is well known that stress concentrations near the fastener holes could
initiate delamination or other types of damage modes, which severely reduce the strength of
the structure and lead to final failure [2,3].
A major goal of bolted joint research has been to determine the effect of various bolting
parameters on the bearing strength of the joint [4-10]. These parameters include: (a) joint
geometry (specimen width, end distance, and hole diameter), (b) joint configuration (single
over lap, double lap, single bolt, single bolt row, or multi-bolt row), (c) loading condition
(tension, compression or combined static and/or fatigue loading), (d) fastening parameters
(bolt/hole clearance, bolt/washer clearance, tightening torque or clamping force, washer size,
and presence of countersink), and (e) material parameters (stacking sequence, fiber shape,
matrix type, fiber volume fraction).
Currently, there is no distinct failure criteria for the experimentally tested mechanical fastened
composite joints. The bearing load is defined in ASTM D 1602 as the maximum load
obtained during a test, while the pin travels 6.4 mm toward the end of the specimen. The static
ultimate bearing strength is defined in ASTM D953 as the stress that causes elongation
(deformation) = 4% of the original hole diameter (D). Maikuma and Kubomura [11] reported
in their review two failure criteria for calculating the bearing strength of FRP composites. The
first criterion was based on the half of the maximum bearing load, while the second criterion
was based on the first peak load, using the load-pin displacement curve. Herrington and
Sabbaghian [12] and Khashaba [13] showed that, the load-pin displacement curve of bolted
joint specimens had a linear behavior up to a point, followed by an unstable nonlinear
behavior. They defined the bearing failure as the maximum load just prior to unstable,
nonlinear behavior. The bolt bearing strength calculated by Hollmann [14] was based on the
ultimate failure loads. Theoretically, the load at which the stresses ha ve exceeded a prescribed
limit in any of the plies along an approximately chosen curve (denoted as the characteristic
curve) considered as a failure criterion by many investigators [15].
Many investigators used finite element analysis for studying composite bolted joints [1-
3,6,16]. Sallam [6] investigated the behavior of notched and finger tight bolted joint in
unidirectional carbon fiber reinforced epoxy composites with different diameter/width ratios.
He found that, based on the net cross-section area, the composite materials were insensitive to
the notch size under static and fatigue loads. The failure mode of the used bolted joint was
shear out, where the strength of the bolted joint mainly depends on the size of the contact area
between the hole and the bolt.

The principal failure modes of bolted joints have been studied by many investigators [6,13,16-
18]. These modes are: (a) bearing failure of the material, (b) net-tension failure of the material
in the reduced cross-section through the bolt hole, (c) wedge-type splitting, (d) shear-out
failure of the material, and (e) bolt failure (mainly shear failures). Combinations of these
failure modes do occur.
In the present work, the effects of tightening torque and washer outer diameter size on the
strength of bolted joint in composite materials are investigated experimentally. Angle -ply
[0/±45/90] s glass fiber reinforced epoxy composites are manufactured using hand lay-up
technique. The mechanical properties of the composite laminate (tension, compressio n, and
shear) are determined experimentally.
2. EXPERIMENTAL WORK

2.1. Specimen Preparation

The angle -ply [0/±45/90] s glass fiber reinforced epoxy (GFRE) composite laminates with
5.2±0.1 mm thickness were fabricated using hand lay-up technique. The constituent materials
of the composite laminates are illustrated in Table 1. The details about the manufacturing
technique are illustrated elsewhere, Khashaba [19]. Fiber volume fraction (Vf) was
determined experimentally by physical removing the matrix using the ignition technique
according to ASTM D3171-99. The average value of Vf was 47.8%.

Table 1. Composition of GFRP composite laminates.

Material Type

Matrix Epoxy: Araldite LY5138-2 (100 part by weight)

Hardener HY5138(23 part by weight)
Reinforcement E-Roving glass; Linear density =1150 g/Km.

2.2. The Mechanical Properties

A series of ASTM tests were carried out on the angle -ply [0/±45/90] s GFRE composites using
universal testing machine. The crosshead speed of the loading member in tension,
compression, in-plane shear, and bolted joint tests was 2 mm/min. Three specimens were
tested for each test condition and the average values were used for drawing the different
relationships. One of these specimens was used in measuring the strains in tension and in-
plane shear tests using Digital Strain Meter Tc -21K model 232.

2.2.1. Tension Test

Tensile properties of angle-ply [0/±45/90]s composites were determined experimentally
according to ASTM D3039/D3039M-00. The ultimate tensile strength was determined from
the load-displacement curve of the testing machine, while Young’s modulus was measured
using the strain gage that bonded at the center of the test specimen. The dimensions of the test
specimen are illustrated in Fig.1.

70 110 70

25

Strain Gage

5
2.5

Fig.1. Dimensions of tension test specimen.

 2.2.2. Compression Test
The compression properties of the composite laminates were determined experimentally using
Boeing Modified ASTM D695 Compression Test Fixture. Details about the test fixture are
illustrated elsewhere, Khashaba [20]. The dimensions of the compression test specimens were
illustrated in Fig. 2.

2.2.3. In-Plane Shear Test

The in-plane shear properties of the composite laminate were determined using the V-notch
beam method according to ASTM D5379. Modified Iosipescu test fixture was used for this
purpose. Details about the test fixture, test procedure, and shear force and bending moment
distributions are illustrated elsewhere, Khashaba [19]. The dimensions of the test specimens
were illustrated in Fig.3.

2.2.4. Bolted Joint Test

The strength of bolted joints with various values of tightening torque (T = 0, 5, 10 & 15 Nm)
and washer sizes (outer diameter of washers, Dw = 14, 18, 22 & 27 mm) was determined
experimentally according to ASTM D5961. The bolted joint test fixture is shown in Fig. 4.
Standard spe cimens, Fig.5, were chosen to ensure that the failure would occur in bearing
mode, not in net tension or shear-out. The washer inner diameter (Dwi) = 1.04 bolt diameter
(i.e. = 1.04x6 = 6.24 mm [21]). The hole-bolt clearance was 0.1 mm (as being typical of
aircraft joints [4,21].

3.1. Strength Properties

The experimental results of tension, compression, and in-plane shear tests are illustrated in
Table 2. The in-plane shear strength was calculated from the following equation:

P
τ xy = (1)
w.t

Where P is the maximum load just prior to the first knee on the curve, Fig.6, t is the specimen
thickens, and w is the specimen width between the roots of two V-notches.

θ 90°

80 10

w =11 Strain gages 19

5.2
17 75
Specimen dimensions
Fig.2. Dimensions of compression Fig.3. Dimensions of Iosipescu Shear test specimen
test specimen.
 8

To Machine Grip

6.5
φ10
Bolt

L
D
Bearing Bolt, Clamping force (provided
D = 6 mm by bolt torque)
Washer E
Composite Specimen
5.2 W

L = 135 mm
W = 36 mm
E = 18 mm
Applied Load From D = 6 mm
Testsing machine

Fig.4 Bolted joint fixture Fig.5. Dimensions of bolted joint specimen.

3. RESULTS AND DISCU SSIONS

3.2. Elastic Properties

Table 2 illustrates the experimental and theoretical results of the tensile elastic modulus (Exx)
of GFRE composites. The experimental values were determined from the stress -strain
diagram, Fig.7. The strain values in this figure are measured from the longitudinal strain gage
that bonded on the test specimen, Fig.1. The predicted values of the tensile modulus of
elasticity were calculated using the classical lamination theory (CLT). Details about the
calculation procedure and the equations are illustrated elsewhere, Khashaba [19]. The results
in Table 2 show excellent agreement between the experimental and the theoretical results.

Fig. 8 shows the relationship between the shear stress and the strains measured from +45o and
–45o strain gages on the V-notch specimen. The values of shear strain (γxy) related to each
shear stress value were calculated from the following equation [19,22];

γ xy = ε- 45 - ε +45 (2)

Table 2. Experimental results of the mechanical properties

Strength Elastic Properties (GPa)

Test
(MPa)
Experimental Theoretical (CLT)
Tension 316.97 18.519 17.887
Compression 390.27 ---- ----
In-plane shear 112.02 7.98 6.704
 8 100
Slope of the tangent =
Ex x = 17.86 GPa
P 80
6

Tensile stress (MPa)

60
Load (KN)

4
40
P

2
20
Experimental data
P 0
0
0 0.2 0.4 0.6 0.8
0 2 4 6 8
Displacement (mm) Tensile strain (%)

Fig.6. Load-displacement diagram of V-notch shear specimen Fig.7. Tensile stress-strain diagram

Since ε-45 is tensile and ε +45 is compression, the shear strain is positive. Hence, the
relationship between the shear stress (τxy) and shear strain (γxy) can be constructed as
illustrated in Fig.9. The in -plane shear modulus has been determined from the slop of the
shear stress-strain curve, at 0.5% strain level as, Eq.3;

τ xy
G xy = (3)
γ xy

3.3. Bolted Joint Properties

3.3.1. Effect of Washer Size
Fig.10 shows load-displacement diagrams of bolted joint specimens tested at constant torque
(15 Nm) and various outer diameter washer sizes. The slope of these diagrams (stiffness of
the joint) increase with decreasing washer size. Note that at constant tightening torque (i.e.
constant bolt axial force), the contact pressure of the washer decreases with increasing the
contact area, A=(π/4)*(Dwo – Dwi)2 , and the latter increases by increasing the washer outer
diameter (D wo). Fig.10 shows that the failure load of bolted joints decreases with increasing
washer size from 18 to 27 mm. The load-displacement diagrams behave in a nonlinear fashion
with knees due to the failure sequence of the different layers as illustrated in failure mode
section.

Fig.11 illustrates the effect of washer outer diameter on the bearing strength of bolted joint
tested at constant tightening torque, T=15 Nm. The results in this figure show that the
maximum bearing strength was obtained at 18 mm washer size. Although bolted joint with 14
mm washer size has the minimum contact area, i.e. maximum contact pressure, its bearing
strength is less than the joint with 18 mm washer size. This behavior was due to the lateral
constrained area of 14 mm washer is less than that of 18 mm washer. Also increasing the
contact pressure, i.e. the lateral compressive stress under the washer in bolted joint with D wo=
14 mm may result in microcracks resulting in premature failure of the composite joint.
 1.5 120
o
SG1 (+45 )
1 SG2 (-45o) 100

Shear stress τxy (MPa)

0.5 80
Strain ε (%)

0 60

-0 .5 40

-1 20
γ xy = ε - 45 - ε + 45
-1 .5 0
0 20 40 60 80 100 120 0 1 2
Shear Stress, τxy (MPa) Shear strain γxy (%)
Fig.8. Shear stress-strains diagrams (from ±45 S.Gs) Fig.9. Shear stress-shear strain diagrams

This behavior indicates that the bolt bearing strength not only depends on the contact pressure
but also on the lateral constrained area of the washer. Although the lateral constrained areas of
bolted joint specimens with 22 and 27 mm washer sizes are higher than that of bolted joint
specimen with 18 mm washer size, their bearing strength is lower than the latter specimen.
This result is due to the decreasing of contact pressure with increasing washer sizes on these
specimens. Therefore, for the fabricated composite laminates, bolted joint specimen with 18
mm washer size and 15 Nm tightening torque has optimum contact pressure and lateral
constrained area that give maximum bearing strength. Hence, in the next sub-section the
influence of tightening torque on the bearing strength will be inve stigated at constant washer
size, D wo=18 mm.

3.3.2. Effect of Tightening Torque

Fig.12 shows the influence of tightening torque on the behavior of load-displacement
diagrams of bolted joint specimens with constant Dwo=18 mm. The curve of the finger tight
specimen, T=0 Nm, has the lowest slope (stiffness) with several knees, which may indicate an
unstable development of internal damage. As a result of increasing the contact pressure, the
slope of the load-displacement curve (stiffness) increases with increasing the tightening
torque. Similar behavior was observed by Tong [4]. It is clear that the ultimate loads increases
with increasing the applied torque from finger tight to 15 N m.

Fig.13 illustrates the relationship between tightening torque and the bearing strength of bolted
joint specimens with Dwo=18 mm. The results in this figure indicate that, in the range of the
investigated tightening torques, the bolt bearing strength increases with increasing the
tightening torque.
 20 600
T = 15 Nm
Dw= 22 Dw=27
16
Dw = 18 550

Bearing strength (MPa)

Bearing Load (KN)

12

500

450
4

• Experimental results
P
0 400
0 0.2 0.4 0.6 0.8 1 1.2 14 18 22 26 30

Displacement (mm) Washer size (mm)

Fig.10. Load-displacement diagrams of bolted Fig.11. Effect of washer size on

joint specimens with different washer sizes. bearing strength of bolted joint.

20 600
Dw = 18 mm
T=15 Nm
16
550
Bearing strength (MPa)
Bearing load (KN)

12
500
T=0
8 T=5

P 450
4
Dw = 18 mm • Experimental results
0 400
0 0.2 0.4 0.6 0.8 1 1.2 0 4 8 12 16

Displacement (mm) Tightening Torque (Nm)

Fig.12. Load-displacement diagrams of bolted joint Fig.13. Effect of tightening torque on

specimens with different tightening torque values. bearing strength of bolted joint.
3.4. Failure Modes
Figs.14-a & b show photographs of some failed bolted joint specimens. Most of the test
specimens failed in the same manner. Failures occurred on the following sequences:
- First, delamination between the layers occurred. This was attributed to the different strains
in the 0o , ±45o, and 90o layers.
- After delamination, the “net- tension” failure mode was observed for 90o layers, Fig.14-c.
These layers had the minimum strength compared with the other layers.
- This followed by “shear -out” failure mode for 00 layers, Fig.14-d.
- After the failure of the 90o and 0o layers, the load was transferred to ±45o layers resulting
in bearing failure mode. This final failure of bolted joints specimens was nearly
catastrophic, Figs. 10 and 13. The failure was associated with fiber splaying at the
hole/bolt contact area, Fig.14.

(a) (b)

T=15 T=15 T=15 T=15 T=0 T=5 T=10 T=15

D=14 D=18 D=22 D=27 D=18 D=18 D=18 D=18

Net -tension of 90 o layers (c) (d)

Delamination Shear-out of the

first layers, 0o

In-plane
shear.
Delaminated
zone

Delamination due to interlaminar shear

failure between 0, ± 45, & 90 o layers.

Fig.14. (a) Photograph illustrates the damage in bolted joint specimens: (a) specimens tested at
different washer sizes, (b) specimens tested at different tightening torques, (c) side views for some
damaged specimens, and (d) top view of damaged specimen with Dw =18 mm & T=15 Nm.
4. CONCLUSIONS

1. The mechanical properties such as tensile, compressive, and in-plane shear of GFRE
laminates were determined experimentally and theoretically. The predicted values of the
elastic properties, using classical lamination theory (CLT), agreed very well with the
experimental results.
2. The slope of the load-displacement diagrams (stiffness) increased with decreasing washer
size of bolted joint specimens tested at constant tightening torque (15 Nm).
3. For the fabricated composite laminates, bolted joint specimens with 18 mm washer size
and 15 Nm tightening torque had optimum contact pressure and lateral constrained area
that gave maximum bearing strength.
4. Although the contact pressure of bolted joint specimen with Dwo= 14 was higher than that
has D wo= 18 mm, tested at the same tightening torque, its bearing strength was the lowest.
This behavior was due to the lateral constrained area of 14 mm washer that was less than
the 18 mm washer. Also increasing the contact pressure, i.e. the lateral compressive stress
in the specimen under the washer, of bolted joint specimen with Dwo = 14 mm would result
in microcracks around the hole edge. These cracks contributed in premature failure of the
composite joint. On the other hand, although the constrained areas of bolted joint
specimens with Dwo=22 and 27 mm were higher than that of Dwo=18 mm, their bearing
strength were lower than the latter specimen because of their lower contact pressures.
5. The load-displacement curve of bolted joint specimen with finger tight, T=0 Nm, had the
lowest slope/stiffness with several knees that indicated an unstable development of
internal damage. In the range of the investigated tightening torques, the slope of the load-
displacement curve (stiffness) increased with increasing the tightening torque as a result of
increasing the contact pressure. The bolt bearing strength increased as the tightening
torque increased.
6. Most of the test specimens failed in the following sequences : (a) delamination started
between the 0o , ±45o, and 90 o layers due to their different strains under the compressive
bearing load, (b) net tension failure mode occurred at 90o layers, (c) shear-out failure
modes took place at 0o layers, and (d) the final failure was nearly catastrophic due the
bearing failure of ±45o layers.

ACKNOWLEDGMENT
The work reported herein is sponsored by the U.S.–Egypt Joint Science and Technology
Program. Profs. Khashaba and Seif would like to acknowledge the support of Dr. F. El-
Refaie, President of Academy of Scientific Research and Technology, Egypt, and Dr. O. A.
Shinaishin, Senior Program Manager, Office of International Science and Engineering at the
National Science Foundation.

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