BOLT

Determination of Factor of Safety of A Standard Automobile Door

OBJECTIVE

1) To determine the best type of bolt that were used at automobile door. 2) To do an analysis on the shear force, shear stress and the factor safety of the bolt. 3) To determine suitable material for automobile bolt.

DESIGN REQUIREMENT

a) The bolt installation must exceed the allowable factor of safety of an automobile part which is 1.10. b) The factor of safety must not be in the range of 1.10 to 1.25 in order to safe cost of manufacturing. c) The positioning of the bolt on the cars door must be suitable in order to increase the strength of the joint. d) The area of analysis must focus on the fillet area where the bolt experience concentrated stress. e) The bolt must be durable to withstand stresses under extreme condition such as road accident.

REAL APPLICATION

The joints of a cars body and a cars door mainly are made of bolt joints. It is because bolts are suitable due to its strong characteristic and simple design. Usually the factor of safety in aerospace and automobile industries are kept low (about 1.10 1.25) because the costs associated with structural weight are so high. This low safety factor is why automobile
24/5/12 Page 1

BOLT
parts and materials are subject to more stringent testing and quality control. Now computers are being used to provide more accurate simulation of stresses that occur in components, particularly in the case of high value products where safety and saving weight is essential

Based on the drawing that shown above, the hinge axis are mainly depends on clearance between the bolt and panel hole. Where A is the bolt clearance to door inner panel hole edge and B is the bolt clearance to hole edge of hinge body plate. Doors are flushness and parting gap in up and down direction. Dimensions bolts A was recommended between 20mm until 25mm based on the affect from the door. Due to the sequence on the body, the hinge were assembly is installed to the door panel by bolt A. While the door assembly with the door hinge are attached is installed to upper body by the bolt B. The clearance of bolt B are necessary to adjust and optimize door parting gap. Once bolt B is fastened in body shop, it will not be unfastened for retrofitting to the at plant. To ensure that the design is safety, the hinge axis was adjusted to assume at the worst case of gap and flush quality. The maximum of adjustment are depends on bolt clearance to hole edges of concerned parts.

24/5/12

Page 2

BOLT
BOLT ANALYSIS

Type of material : steel Type of bolt : Hex Head (upset) Mass : 45.36kg Area : 90 x 80 = 7200mm2 Angle = 600C = 1.047 rad Time, t = 2s K = 0.18 (lubricated) N = 4( total bolt) From table 8.8 (pg 130:shigleys) Poisson Ratio : 0.291 Elastic Modulus : 207 Gpa A : 0.78715 B : 0.62873 From table 8.9 (pg 433) *Psi = lbf/in2 *Sp ( minimum Proof Strength) SAE Grade No: 5 (material: Medium carbon, Q & T) Minimum Proof Strength : 85 kpsi = 586.05 MPa Minimun Tensile Strength : 120 kpsi = 827.37 MPa Minimum Yield Strength : 92 kpsi = 634.32 MPa By assumming Length of screw, L : 50mm
24/5/12 Page 3

BOLT
d : 12mm From table 8.7( pg 426) By assuming l : 35mm LT = 2d + 6mm, L 125mm, d 48mm Length of unthreaded portion in grip : ld = L -LT Length of threaded portion in grip: lt = l - ld Area of unthreaded portion : Ad = d/ 4 Area of thereaded portion : At from table 8.1 Fastener stiffness : kb= From table 8.1(pg 412) Nominal Major Diameter, D : 20mm Pitch, p : 2.5mm Tensile-stress Area, At : 272 mm2 Minor-Diameter Area, Ar : 259mm2 Equations that was used: (8.23) (pg 429) C= Fp = At Sp Fi = 0.90 Fp (permenent connection) i = Fi / At b = Fb/ At = (CP+ Fi) / At T = K Fi d
24/5/12 Page 4

(pg 436)

BOLT
nL = ( SP At Fi)/ C(Ptotal /N) nP = ( SP At)/ [C(Ptotal /N) + Fi] no = Fi /[ (Ptotal /N)(1-C)]

Calculations : LT = 2(12) + 6mm = 30 mm ld = 50 30 = 20mm lt = 35 20 = 15mm Ad = Bolt stiffness; kb = Members stiffness; km / (207x 106)(12) = (0.78715) exp [(0.62873)(12)/ 35)] km = 2.3588 x 109 Mpa Stiffness constant; C = (4.829 x 1011) / (4.829 x 1011 + 2.3588 x 109 ) = 0.9551 = 4.829 x 1011 Mpa = 113.097 mm2

Proof load; Fp = 272 (856.05 Nmm2) =232.85 kN Preload recommandation; Fi = 0.90 (232.85 kN) = 209.56 kN Preload stress;

24/5/12

Page 5

BOLT
i = Fi / At = 209.56 x103 / 272 = 770.44 N/mm2 Stress under the service ; b = Fb/ At = (CP+ Fi) / At Fp = ma, a = x/t2 X= r = 90 (1.047) = 94.23mm a = 94.23 / 22 = 23.56 mm/s Fp = 45.36 (23.56) = 1068.57 N P = Fp/A = 1068.57 / 7200 = 0.15 Pa b = [(0.9551)(0.15) + 209.56)/ 272] = 770.44N/mm2 Torque necessary to achieve preload; T = K Fi d = 0.18 (209.56x 103) (12) = 452.65 kNmm Load factor; nL = ( SP At Fi)/ C(Ptotal /N) nL = ( 856.05(272) 209.56x103) / 0.9551(0.15/4) = 650.14x103 Yielding factor safety; nP = ( SP At)/ [C(Ptotal /N) + Fi] nP = ( 856.05(272))/ [0.9551(0.15/4) + 209.56x103] = 1.11 Load factor guarding against join separation; no = Fi /[ (Ptotal /N)(1-C)] no = 209.56x103 / [(0.15/4)(1-0.9551)] = 124.46x106

24/5/12

Page 6

BOLT
CONCLUSION

For the conclusion, the value of the preload and service load stresses are respectively ten percent less then the proof strength. Therefore it is suitble for the bolt to apply in the automobile door. Torque that applied at the bolt is 425.65 kNmm. The yielding factor of safety that guarding against the static stress exceeding the proof strength is 1.11. based on the factor safety that being calculated, it is proved that it is suitable to applied this type of bolt.

24/5/12

Page 7