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Presentation
Coefficient of friction on
threaded fasteners in the
automotive industry
Erik Galdames
Bach. of Eng., Chem.
Xativa, Spain
Contents
Introduction
Standards and specs
Symbols
Test of coefficient of friction
Formula of Kellermann-Klein
Origin of formula of coefficient of friction
Total coefficient of friction
Bearing surface under the head of the bolt
Influencing factors on coefficient of friction
Coating systems
ISO 16047
Standards and specs of coefficient of friction
Requirements of coefficient of friction
Introduction
Tightening process
10% ge ne rate s
clamping force
40% used in
overcoming
friction on the
thread
50% used in
overcoming
friction under
the head
Introduction
Coefficient of friction of bolted joints is determined measuring force and torque. It is a standardized
method that uses a formula in which F and T mainly and dimensional characteristics of the bolt/nut to
be studied
Mating surfaces and reference bolts/nuts are to be the same and agreed so that results are
reproducible and used for comparison
This test is not suitable to predict behaviour of assembly problems but can give some hints of how the
tightening will be
Variations of this test under real conditions in the automotive industry can be used in order to predict
behaviour at the assembly (e.g. VDA 235-203)
Bolt
Bearing plate
Reference nut
F
Measuring
cells
Nut holder
Tb
Tth = T Tb
Introduction
The method of calculation is the linear relationship between clamping force and torque
below the yield point of the bolt
An axial force is produced when a bolt is tightened against a bearing surface and a nut by
means of a pair of forces (torque). This force elongates the bolt and compresses the
bearing surfaces in contact, i.e. two opposite forces are produced
Not all torque is used to generate clamping; most of the torque applied is used to overcome
friction
50% of torque is used in overcoming friction under the head of the bolt, 40% on the thread
and only 10% is used to generate clamping force
Compression/Elongation
Equilibrium of forces
ISO 16047
Renault 01-50-005
VDI 2230
EN 14399-2
ISO 2320
Symbols
ISO 16047:2005
d
Nominal diameter
Fu
d2
Fy
d4
Torque
dh
Tth
Thread torque
Do
Tb
Dp
Pitch
Db
Rotating angle
LC
Clamp length
th
Lt
Clamping force
tot
FP
140
Torque/Ma [Nm]
120
100
80
60
40
20
0
0
10
20
30
40
50
60
Clamping Force/Fv [kN]
Ma/Fv-_001.PRB
ges_UL-_001.PRB
ges_LL-_001.PRB
Ma/Fv-_002.PRB
ges_UL-_002.PRB
ges_LL-_002.PRB
Ma/Fv-_003.PRB
ges_UL-_003.PRB
ges_LL-_003.PRB
70
80
Ma/Fv-_004.PRB
ges_UL-_004.PRB
ges_LL-_004.PRB
Ma/Fv-_005.PRB
ges_UL-_005.PRB
ges_LL-_005.PRB
Ma/Fv-_006.PRB
ges_UL-_006.PRB
ges_LL-_006.PRB
Ma/Fv-_007.PRB
ges_UL-_007.PRB
90
100
Formula of Kellermann-Klein
The formula for determination of
coefficient of friction is base on the work of
Kellermann-Klein
This formula of Kellermann-Klein was
published in 1956 by Rudolf Kellermann
and Hans Christof Klein in the essay
Bercksichtigung des Reibungszustandes
bei der Bemessung hochwertiger
Schraubenverbindungen
1 P 1,154 th d 2
Do d h
T F
b
(10)
2
P
4
1,154 th
d2
Tightening of a bolt
Pitch
Pitch
1/2xPitch
Unfolded helix
Helix
Pitch angle
10
tot
T P
F 2
Db
0,577 d 2
2
Uncertainty of 1% to 2%
To determine coefficient of friction it will be
necessary to know:
T, Tb, F, measured by equipment
Tth is calculated through T = Tb + Tth then, Tth = T Tb
P, d2 y Db Dimensional parameters of the bolt/nut
Target values of T and F are obtained through a table
for the different dimensions of bolts/nuts
(5)
Db
Hex bolt
Do d h
2
Do
Do
Do
dh
dh
dh
12
Values of coefficient of friction can be adjusted but these factors may influence
their predictible behaviour dramatically if out of control or when there is too much
variation
13
Lubricants based on emulsions in water can be applied such as waxes, oils and solid
lubricants in water mixes (e.g. PE, PTFE, PAK, molybdenum bisulfide). They are dried after
application and they provide a stable coefficient of friction
Solid lubricants or sealers with solid integrated lubricants provide less variation of
coefficient of friction than liquid or lubricants in water emulsions and provide better results
in automated assembly
Solid lubricants also provide better repeated assembly
Variation of coefficient of friction will be higher when working with > 0,14. The tend to
scatter more
Values under < 0,08 are difficult to adjust and are not desirable, since self-loosening
effect may appear
Values over 0,25 do not produce sufficient tightening, so there is a high risk of fatigue
fracture
Values under 0,06 can lead to ultimate clamping load. High risk of fracture.
There are some bolted unions that request coefficient of friction of 0,06 to 0,09
Uncontrolled lubrication such as oil spraying on the workshop could lead to lower
coefficient of friction and unsafe bolted unions. This may lead to ultimate clamping force
and thus, bolt fracture. This situation must be avoided
14
Coatings
Coatings and lubricants help improving friction behaviour and offer less variation
of values of coefficient of friction
Coatings for bolted joints in the automotive industry consist mainly on:
Phosphate + post-treatment
Electroplated Zn or Zn alloys (ZnNi, ZnFe) + post-treatment
Zinc flake coatings + post-treatment
15
ISO 16047
Uncertainty 2%
Room temperature, 10C to 35C, 24 h after coating application
Applied clamping force, 75% of proof load 0,75F P (see ISO 898-1, ISO 898-2)
Rotation speed = 10 a 40 rpm (M1,6 to M16), 5 to 15 rpm (M16 to M39)
Bearing plate or washer type HH or HL
Roughness Ra = 0,5 0,3 m (Ra < 1,6 m and Ra < 3,2 m washer type HL)
Tolerance of flatness acc. to ISO 4759-3, section 3.5.3
Surface
a) Blank and degreased
b) Zinc plating A1J acc. to ISO 4042 and degreased
Minimum thickness according to ISO 7093-1
Hardness 50 to 60 HRc (200 to 300 HV for washer type HL)
Hole diameter dh, acc. to ISO 273, medium series, without chamfering
Reference nuts for bolt testing
A) ISO 4032 and ISO 8673 class 10 uncoated nuts and degreased.
B) Zinc plated nuts A1J ISO 4042 and degreased
Reference bolts for testing nuts
Uncoated and degreased bolts ISO 4014, ISO 4017, ISO 4762, ISO 8765, ISO 15071, ISO 15072
Zinc plated bolts A1J acc. to ISO 4042 and degreased
16
tot
F
Temperature
Rpm
Uncertainty
Bearing surface
Roughness
Tolerance flatness
Dimensions
Reference nuts
Nut surface
ISO 16047
Ford WZ100
Ford WZ101
VOLVO STD
5511,72
BMW GS90003-1
GS90003-2
--
N/A
0,14 0,03
0,12 0,18
0,09 0,15
75% Fp
75% Fp
75% Fp
75% Fp
See tables on
GS9003-2
10C a 35C
RT
RT
10 35C
10C a 35C
10 a 40 rpm M<16
<30 rpm
10 25 rpm
10 25 RPM
2% F, T,
3% F, 2% T
2% F, T
2% F, T
2% F, T
Steel
500 600HV
Steel
200 250HV
8.8 200-250 HV
10.9 = 300 400 HV
12.9 = 350 450 HV
Type HH 50 60 HRC
Ra 1,6 3 mm; Ra
3,2 3 < h 6 mm
Ra 1,2 a 1,6 m
Ra 1,6 max
// 4%
// 4%
// 4%
Acc. to standard
Acc. to standard
Acc. to standard
Acc. to standard
Acc. to standard
ISO 4032 6H
ISO 4032 6H
S309
zinc plated passiv. lubr.
ISO 965/1 6g
ISO 4014 6g
ISO 965-2 6g
ISO 965-2 6G
S309
zinc plated passiv. lubr.
Uncoated
Reference bolt
Bolt surface
17
0,06
0,07
0,08
0,09
0,10
0,11
0,12
0,13
0,14
tot
0,15
0,16
VDA 235-101
th, b
th, b
VW 011 29
tot (*)
tot
tot (*)
BMW GS 90003-1
th, b
tot
th, b
tot
Ford WZ 101
tot
tot
tot
Renault 01-50-005C
PSA C10 00 54
18
0,17
0,18
English
French
German
Italian
Coeficiente de friccin
Coefficient of friction
Coefficient de frottement
Reibungszahl
Coefficiente dattrito
Tightening torque
Couple de srrage
Anziehdrehmoment
Coppia di serraggio,
momento di serraggio
Carga, tensin
Clamp force
Tension
Vorspannkraft
Precarico, tensione
Carga de prueba
Proof load
Tension dpreuve
Prfkraft
Carico di prova
Carga de rotura
Tension de rupture
Bruchkraft
Carico di rottura
Lmite elstico
Yield point
Limite dlasticit
Streckgrenze
Limite desnervamento
ngulo de giro
Rotating angle
Angle de rotation
Drehwinkel
Angulo di giro
Tornillo
Bolt, screw
Vis, boulon
Schraube
Vite, bullone
Tuerca
Nut
crou
Mutter
Dado
Arandela
Washer
Rondelle
Scheibe
Rosetta
Esprrago
Stud
Goujon
Stiftschraube
Prigioniero
Rosca
Screw thread
Filetage
Gewinde
Filetto, filettatura
Superficie de apoyo
Bearing surface
Surface dappui
Auflageflche
Superficie sottotesta
Agujero de paso
Clearance hole
Taraudage
Durchgangsloch
Foro de passo
Paso de rosca
Pitch
Pas
Steigung
Passo
19
THE END
20