Effects of countersunk hole geometry errors on the fatigue performance of CFRP bolted joints
Abstract
Due to good aerodynamic performance and reliability, countersunk bolt joint is one of the most commonly used connection methods for carbon fiber reinforced polymer (CFRP) components in the aircraft. However, the countersunk hole machining process is inevitably accompanied by geometric errors, which will directly affect the mechanical properties of the joint structure. This paper presents a numerical and experimental investigation on the effect of countersunk hole geometry errors on the fatigue performance of CFRP bolted joints. FE model of CFRP countersunk bolted joints with designed geometry errors are established, and the rationality of the FE analysis was verified by fatigue life and failure forms. The CFRP bolted structure failure mechanism under fatigue load and influence of hole-making geometry error (including countersunk fillets radius, countersunk depth, and countersunk angle) on the fatigue life are investigated. Based on the relationship between fatigue life and the geometry error, the corresponding tolerances for CFRP bolt joint countersunk hole are determined as well. The research results can provide a reference for establishing reasonable geometric accuracy requirements for CFRP joint hole machining.
Get full access to this article
View all access and purchase options for this article.
References
1. Nezhad HY, Egan M, Merwick F, et al. Bearing damage characteristics of fibre-reinforced countersunk composite bolted joints subjected to quasi-static shear loading. Compos Struct 2017; 166: 184–192.
2. Park CY, Grandt AF. Effect of load transfer on the cracking behavior at a countersunk fastener hole. Int J Fatigue 2007; 29: 146–57.
3. Park CY, Grandt AF, Suh JJ. Stress intensity factors for surface cracks at countersunk holes. Eng Fract Mech 2006; 73(13): 1878–1898.
4. Coman CD, Constantinescu DM. Temperature effects on joint strength and failure modes of hybrid aluminum–composite countersunk bolted joints. Proc IMechE, Part L: J Materials Design and Applications 2019; 233: 2204–2218.
5. Chishti M, Wang CH, Thomson RS, et al. Experimental investigation of damage progression and strength of countersunk composite joints. Compos Struct 2012; 94: 865–873.
6. Heimbs S, Schmeer S, Blaurock J, et al. Static and dynamic failure behaviour of bolted joints in carbon fibre composites. Compos Part A Appl Sci Manuf 2013; 47: 91–101.
7. Nixon-Pearson OJ, Hallett SR. An experimental investigation into quasi-static and fatigue damage development in bolted-hole specimens. Compos Part B Eng 2015; 77: 462–473.
8. Saleem M, Zitoune R, El Sawi I, et al. Role of the surface quality on the mechanical behavior of CFRP bolted composite joints. Int J Fatigue 2015; 80: 246–256.
9. Stocchi C, Robinson P, Pinho ST. A detailed finite element investigation of composite bolted joints with countersunk fasteners. Compos Part A Appl Sci Manuf 2013; 52: 143–150.
10. Hühne C, Zerbst AK, Kuhlmann G, et al. Progressive damage analysis of composite bolted joints with liquid shim layers using constant and continuous degradation models. Compos Struct 2010; 92(2): 189–200.
11. Egan B, McCarthy MA, Frizzell RM, et al. Modelling bearing failure in countersunk composite joints under quasi-static loading using 3D explicit finite element analysis. Compos Struct 2014; 108(1): 963–977.
12. Liu P, Cheng X, Wang S, et al. Numerical analysis of bearing failure in countersunk composite joints using 3D explicit simulation method. Compos Struct 2016; 138: 30–39.
13. Cao Y, Cao Z, Zuo Y, et al. Numerical and experimental investigation of fitting tolerance effects on damage and failure of CFRP/Ti double-lap single-bolt joints. Aerosp Sci Technol 2018; 78: 461–470.
14. Feyzi M, Hassanifard S, Varvani-Farahani A. Progressive fatigue behavior of single-lap bolted laminates under different tightening torque magnitudes. Proc IMechE, Part L: J Materials Design and Applications 2020; 234(10): 1303–1312.
15. Wu CQ, Gao GL, Li HN, et al. Effects of machining conditions on the hole wall delamination in both conventional and ultrasonic-assisted CFRP drilling. Int J Adv Manuf Technol 2019; 104: 2301–2315.
16. Qiu X, Li P, Li C, et al. Study on chisel edge drilling behavior and step drill structure on delamination in drilling CFRP. Compos Struct 2018; 203: 404–413.
17. Negarestani R, Sundar M, Sheikh MA, et al. Numerical simulation of laser machining of carbon-fibre-reinforced composites. Proc IMechE, Part B: J Engineering Manufacture 2010; 224(7): 1017–1027.
18. Faraz A, Biermann D. Subsequent drilling on pilot holes in woven carbon fibre reinforced plastic epoxy laminates: the effect of drill chisel edge on delamination. Proc IMechE, Part B: J Engineering Manufacture 2011; 225(9): 1493–1504.
19. Bayraktar S, Turgut Y. Determination of delamination in drilling of carbon fiber reinforced carbon matrix composites/Al 6013-T651 stacks. Measurement 2020; 154: 107493.
20. Kerrigan K, Scaife R. Wet vs dry CFRP drilling: influence of cutting fluid on tool performance. Compos Sci Technol 2018; 77: 315–319.
21. Fernández-Pérez J, Cantero JL, Díaz-Álvarez J, et al. Influence of cutting parameters on tool wear and hole quality in composite aerospace components drilling. Compos Struct 2017; 178: 157–161.
22. Ahmadi S, Zeinedini A. Experimental, theoretical and numerical investigation of the drilling effects on mode I delamination of laminated composites. Aerosp Sci Technol 2020; 104: 105992.
23. Amini S, Baraheni M, Hakimi E. Enhancing dimensional accuracy and surface integrity by helical milling of carbon fiber reinforced polymers. Int J Lightweight Mater Manuf 2019; 2(4): 362–372.
24. Zhang Y, Li H, Qin X, et al. Analysis of vibration response and machining quality of hybrid robot based UD-CFRP trimming. Proc IMechE, Part B: J Engineering Manufacture 2021; 235(6–7): 974–986.
25. Liu B, Yan C, Wang H. Effects of countersunk hole’s geometrical deviation on the strength of bolted carbon fiber–reinforced plastic/polymer metal joints under tensile loading. Proc IMechE, Part B: J Engineering Manufacture 2020; 234: 621–628.
26. Tian S, Li C, Dai W, et al. Effect of the countersunk hole depth on tensile-tensile fatigue behavior of riveted specimens of AA2024-T3 alloy. Eng Fail Anal 2020; 115: 104639.
27. ASTM D 5961/5961M-01, Standard test method for bearing response of polymer matrix composite laminates.
28. Aktas A, Dirikolu MH. An experimental and numerical investigation of strength characteristics of carbon-epoxy pinned-joint plates. Compos Sci Technol 2004; 64(10–11): 1605–1611.
29. Tserpes KI, Papanikos P, Labeas G, et al. Fatigue damage accumulation and residual strength assessment of CFRP laminates. Compos Struct 2004; 63(2): 219–230.
30. Wang Y. Bearing behavior of joints in pultruded composites. J Compos Mater 2002; 36(18): 2199–2216.
Cite article
Cite article
Cite article
OR
Download to reference manager
If you have citation software installed, you can download article citation data to the citation manager of your choice
Information, rights and permissions
Information
Published In
Article first published online: July 9, 2021
Issue published: March 2022
Keywords
Authors
Metrics and citations
Metrics
Journals metrics
This article was published in Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture.
VIEW ALL JOURNAL METRICSArticle usage*
Total views and downloads: 137
*Article usage tracking started in December 2016
Altmetric
See the impact this article is making through the number of times it’s been read, and the Altmetric Score.
Learn more about the Altmetric Scores
Articles citing this one
Receive email alerts when this article is cited
Web of Science: 7 view articles Opens in new tab
Crossref: 0
- Study of preload relaxation and optimization of wind turbine bolted co...
- Failure Behavior of Composite Bolted Joints: Review
- Experiment and simulation study on bonded, bolted and hybrid bolted/bo...
Figures and tables
Figures & Media
Tables
Get access
Get access
Get access
Access options
If you have access to journal content via a personal subscription, university, library, employer or society, select from the options below:
Access journal content via a university, library or employer subscription.
IOM3 members can access this journal content using society membership credentials.
Alternatively, view purchase options below:
Purchase 24 hour online access to view and download content.
Access journal content via a DeepDyve subscription or find out more about this option.
