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The strength analysis of steel sunk screw connections in the rocket

Article  in  Acta Astronautica · April 2017

DOI: 10.1016/j.actaastro.2017.04.032

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 Acta Astronautica 137 (2017) 345–352

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Acta Astronautica
journal homepage: www.elsevier.com/locate/actaastro

The strength analysis of steel sunk screw connections in the rocket MARK
⁎
Xiaogang Li, Xiaotian Zhang
School of Astronautics, Beihang University, Beijing 100191 PR China

A R T I C L E I N F O A BS T RAC T

Keywords: A finite element model is established to investigate the strength and slip characteristic of sunk screw
Sunk screw connections in the rocket. A typical configuration is used as the basic model of parametric study to analyze
Strength analysis the influence of pretension, friction coefficient and the angle of sunk head. It is found that with the rise of
Slip characteristic pretension force, the maximum von Mises of sunk screw connection decreases before the optimal pretension
Pretension
force and then increases, and the optimal pretension force can be predicted by finite element method. The
Friction coefficient
Angle of sunk head
friction coefficient has positive influence on structural behavior. With the rise of angle of sunk head, the
maximum Von Mises increases and then decreases, and the position of stress concentration transfer from the
middle of sunk screw to the lower edge of sunk head.

1. Introduction [5,6] conducted some experimental, numerical and analytical studies

on thin-walled plates connected by a single bolt or multiple bolts to
Screw and bolted connections which are used extensively in mainly investigate the load-deflection relationship and developed a way
structure connections have the characteristics of easily to be installed to calculate the hole elongation. Fernandez et al. [7] proposed a method
and disassembled. In present studies, most authors concentrate on based on Finite Element Method and Data Mining to predict the
bolted connections, but few have a research on sunk screw connections. properties of bolted connections. Shamoto et al. [8] presented an
Currently, authors did a lot work on the failure modes, bearing analytical method to predict contact stiffness and utilized only the
resistances, deformation behaviors, slip behaviors and tighten beha- structural dimensions to predict damping coefficient. Yu et al. [9]
viors about bolted connections. What they most cared about is the proposed a modified bearing strength method for bolted connection
performance of the metal plates in bolted connections. with a gap which was absent in the existing provision in North
In the recent studies, Moze et al. [1,14,15] conducted a series American Specification for Cold-Formed Steel Structural Member.
experiments which were calibrated by parametric analysis on connec- Cai et al. [10] conducted a series tests to investigate single shear bolted
tions with one or several bolts. The authors proposed a modified design connection by using steady state test method in the temperature ranged
check about the bearing strength at bolt holes according to standard from 200 to 950 °C and found that the specifications are generally
EN 1993-1-8, which is simpler and more accurate. Salih et al. [2] conservative. Esmaeili et al. [11] investigated the effects of clamping
performed an investigation about the bearing behaviors of stainless force on fatigue life of double lap bolted joints and revealed that
steel connections between thick and thin plates. The influences of edge clamping force has positive effect on fatigue life. Ganeshmurthy et al.
distance, end distance and plate thickness on bearing strength were [12] provided a FEA model considering thread helix to simulate
discussed and the results of parametric studies have been used as different process control methods for bolt tightening in joints with
design criteria for bearing failure in stainless steel bolted connections. nonparallel contact. Some important variables such as thread, friction
Sallam et al. [3] firstly considered the effect of clamping force and coefficient and bolt hole clearance is investigated in the analysis.
friction coefficient on stress intensity factors (SIF) of a crack from Dusicka et al. [13] investigated the effects of undeveloped filler plates
lapped joints and came to a conclusion that high clamping force causes on high strength steel bolted connections using standard size holes,
a decrease in SIF which also means increase in fatigue life for cracked oversize holes and multiple fillers by experimentally methods. Kim
lapped joints. Draganic et al. [4] performed a research on the plastic et al. [16] investigated the ultimate strength and failure mechanism of
behavior of single bolt lap connections considering the elongation of single shear bolted joints by experiment. Some main variables such as
bolt hole and proposed an appropriate equations which can give better alloy type, plate thickness, end distance and bolt arrangement were
results in predicting ultimate and serviceability loads. He and Wang discussed and two fracture modes such as shear fracture and block

⁎
Corresponding author.
E-mail address: zhangxiaotian@buaa.edu.cn (X. Zhang).

http://dx.doi.org/10.1016/j.actaastro.2017.04.032
Received 8 August 2016; Accepted 8 April 2017
Available online 27 April 2017
0094-5765/ © 2017 IAA. Published by Elsevier Ltd. All rights reserved.
X. Li, X. Zhang Acta Astronautica 137 (2017) 345–352

shear fracture were observed. Cai et al. [19] investigated in a similar

way with the different material of stainless steel. Talja et al. [17]
conducted a series lap shear tests in different thickness, edge distance
and bolts arrangement to developing design guidance. In the study
done by Hoang et al. [18], a 3D finite elements model was established
to predict the global behavior of a bolted joint and the tightening
torque and clearance was considered in the analysis. In the study of
Yang et al. [20], a parameterized 3D finite element model of bolted
joints with real helical thread geometry is established to approach real
assembly conditions. Kim et al. [21] investigated the ultimate strength Fig. 2. The exploded-view of the connection.
and fracture mode of austenitic stainless steel single shear bolted
connections and the conditions of curling occurrence was discussed.
However, there is few attention to another frequently-used connec-
tions named sunk screw connections. Sunk screw connections have
significant advantage in space available that can guarantee the surface
continuity of the plates to be connected. Sunk screw connections are
more suitable or even the best in some occasions such as avoiding
interference and avoiding the changes in aerodynamic configuration.
Although sunk screw connections have the unique advantage in
space available, as the connector of thin plates, the diameter of sunk
screw is limited because the screw head should be totally embedded to
the plates, otherwise the plates will be totally penetrated. Therefore, the Fig. 3. The sectional view of the connection.
weakness of sunk screw connections is mostly the sunk screw.
Fig. 1 shows the bending moment distribution along the rocket
body. The sunk screw connection between two cabins where body
coordinate x=2.87 m sustain the load that bending moment is
8510 N.m, which make the sunk screw connection the weakest of the
rocket body. Fig. 2 shows the exploded-view of the sunk screw
connection including part of two cabins, the connecting piece, 24 sunk
crews and 24 bolts. Fig. 3 shows the sectional view of the connection
and the magnified detail of the sunk screw and the bolt.
The connection sustain the bending moment M=8510 N m and the
extra axial force F=13,000 N. The max shear force sustained by one of Fig. 4. The sectional dimension of sunk screw connection.
the 24 sunk screws can be approximately evaluated by engineering
method as follows, 2. Finite element model

F 4M
J= + 2.1. Geometry of sunk screw connections
n nD (1)
The single sunk screw connection is simplified as a double shear
where n=24 is the amount of the sunk screws, D=0.324 m is the
connection to investigate the behavior of the sunk screw under shear
diameter of bearing circle. The result of the calculation is J=4919.2 N.
force. Fig. 4 shows the sectional dimension of sunk screw connection.
There is no engineering algorithm for sunk screw connections to
The width of the specimens is 44 mm. The left ends of top plate and the
examine the strength. Because of the particularity of sunk screw, its
bottom plate are fixed and the shear force is applied to the right ends of
structural performance under shear force is between ordinary bolted
middle plate. Fig. 5 shows the dimension of sunk screw.
connections and fitting bolted connections which both have the
The values of parameters in Figs. 4 and 5 are defined as:
universal engineering checking algorithm. But the performance of that
two kinds of connections is too wide-range to make an accurate
R1 = 8.2 mm
judgment of whether the sunk screw connections are strong enough. R2 = 8 mm
Because of the structure symmetry of sunk screw connections R3 = 4.2 mm
between two cabins along the circumference, the most dangerous R = 4 mm
single sunk screw connection which bearing the maximum load is H = 4 mm
chosen to be the research object. This paper will present a parametric h = 6 mm
study of sunk screw connections about the pretension force, friction θ = 90°
coefficient and the angle of sunk head using the commercial finite
element modeling software ANSYS.

Fig. 1. The bending moment distribution along the rocket body. Fig. 5. The dimension of sunk screw.

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X. Li, X. Zhang Acta Astronautica 137 (2017) 345–352

Fig. 6. Simulation model for sunk screw connection.

2.2. Finite element modeling

A coordinate system is set up for finite element model. The origin of

coordinates locates on the center of a circle whose radius is R1 in the
countersunk, and the direction of three axes are showed in Fig. 6.
There are four parts in double shear sunk screw connection namely
top plate, bottom plate, loaded plate and sunk screw in which the Fig. 8. The partial enlarged von Mises stress distribution.
thread is ignored. The dimension of the FE model is described as
Chapter 2.1, but a clearance of 0.01 mm is applied to the screw and the
screw holes in the loaded plate and the bottom plate. The nut is
simplified as a cylinder and combined together with screw. The
material of sunk screw and plates are all high-strengh steel with the
following material properties: yield stress fy = 900 MPa and tensile
strengh fu = 1000 MPa. Figs. 6 and 7 show the FE model in which
eight-node solid elements SOLID185 with the capabilities of plasticity,
hyperelasticity, stress stiffening, creep, large deflection and large strain
are employed to model all the components.
Contact interfaces between the top plate, the bottom plate, the
loaded plate, the sunk screw and the nut are modelled by contact
elements CONTA174 and target elements TARGE170. A few key
parameters which have significant effect on contact pairs are adjusted
to form the standard set-up where penalty stiffness coefficient
FKN=0.5, friction coefficient μ = 0.2 , contact mode KEYOPT(12)=0
that is standard contact mode. The clamping force F=500 N is applied
by creating and meshing a pretension section. The shear force is
applied by setting the nodal forces Jn = 16.7 N on the 299 nodes that
located in the right end of loaded plate. The nodal forces Jn is calculated Fig. 9. The von Mises stress distribution of sunk screw.
as follows,
Jround 5000N
Jn = = = 16.7 N
nnode 299

where Jround is the result of slight enlargement of J=4919.2 N, nnode is

the amount of the nodes that located in the right end of loaded plate.

2.3. The analysis and computation of the typical configuration

The typical configuration is described in Chapter 2.1 and 2.2. Fig. 8

shows the partial enlarged von Mises stress distribution in the section
that located in x-y plane of sunk screw connection. Fig. 9 shows the von

Fig. 10. The sketch map of two paths.

Mises stress distribution of the sunk screw.

Defining two paths as shown in Fig. 10 to intuitively show the stress
distribution of sunk screw by extracting data in two paths and also to
make a contrastive analysis of different configuration.
There are two paths as shown in Fig. 10 namely path 1(A-B-C) and
path 2(D-E-F). The coordinate of these points are A(8,0,0.2),
Fig. 7. Simulation model of sunk screw. B(4,0,4.2), C(4,0,18), D(−8,0,0.2), E(−4,0,4.2), F(−4,0,18). The data

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X. Li, X. Zhang Acta Astronautica 137 (2017) 345–352

Fig. 11. The data in path1. (a)SX, SZ, SXZ and SEQV, (b) UX, UZ and USUM.
Fig. 12. The data in path2. (a)SX, SZ, SXZ and SEQV, (b) UX, UZ and USUM.

obtained from the paths are the coordinate values(XG,YG,ZG), the von
Mises stress(SEQV), the stress along the X axis(SX), the stress along
the Y axis(SY), the stress along the Z axis(SZ), the shear stress in plane
X-Z(SXZ), the deformation along the X axis(UX), the deformation
along the Y axis(UY) the deformation along the Z axis(UZ) and the total
deformation(USUM). Figs. 11 and 12 show the SX, SZ, SEQV, SXZ,
UX, UZ and USUM in two paths.
In path 1, as shown in Fig. 11(a), the maximum stress points in all
configurations in this paper, appear around the lower edge of the sunk
screw where ZG=4.2 mm or the middle of the shank where
ZG=7.65 mm. The performance of the sunk screw depends on the
stress value of these two points. As shown in Fig. 12(a), the dangerous
part in path 2 is the middle of screw, where ZG range from 6 mm to
12 mm. Comparing the stress in path 1 and path 2, the SEQV in path 2
is less than that in path 1, so caring the data in path 1 is enough for
consideration of the strengh of sunk screw. The deformation curves in
Fig. 11(b) and Fig. 12(b) present the phenomenon of screw bending.
The deformation along Z axis is caused by asymmetry. Fig. 13. The MXSEQV of sunk screw in different pretension force.

3. Parametric study
is obtained from the data of a node which always located in path1 and
3.1. Pretension force the coordinate ranging from ZG=7.65 mm to ZG=8.6357 mm with the
rise of pretension.
Analyzing the effects of pretension force on sunk crew connections As shown in Fig. 13, the MXSEQV of sunk screw decreased first and
by changing the pretension force from P=0 N to P=3000 N while the then increased with the increase of pretension force, and the minimum
external force and friction coefficient is the same as the typical of MXSEQV appears when P=2250 N. As shown in Fig. 14, because of
configuration. The max von-Mises stress of sunk screw(MXSEQV), the increase of friction force that leading by the increase pretension
the max contact sliding(MXSLID) and the max force, the MXSLID and the MXUSUM decreases almost by linear,
deformation(MXUSUM) are shown in Figs. 13 and 14. The MXSEQV which indicate that the stiffness increased.

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X. Li, X. Zhang Acta Astronautica 137 (2017) 345–352

Fig. 14. The MXSLID and MXUSUM in different pretension force.

Table 1
The stress state of middle plate in different pretension force.

P/N F1/N F2/N N1/N F1/F2 (F1+F2)/N1 (%)

0 237.2 181.5 4574.7 1.307 9.15

500 247.1 210.6 4535.6 1.173 10.09
1000 265.7 242.1 4485.5 1.097 11.32
1500 309.7 288.6 4395.0 1.073 13.61
2000 362.0 356.8 4274.6 1.015 16.81
2250 394.8 429.6 4168.9 0.919 19.78
2500 430.5 439.3 4123.5 0.980 21.09
3000 514.1 498.5 3980.8 1.031 25.43

The stress state in different pretension force of sunk screw and

three plates are summarized for a deeper analysis of the phenomenon
appears in Figs. 13 and 14. The forces act on middle plate including the
friction force between top plate and middle plate (F1), the friction force
between bottom plate and middle plate (F2) and the pressure between Fig. 15. The MXSEQV of sunk screw in different friction coefficient.
bolt shank and middle plate (N1). The stress state of middle plate is
listed in Table 1. along Z axis increase, namely the N increases. But still lead to a
As shown in Table 1, because of the asymmetry of sunk screw decrease in f, indicates that the degree of decrease in μ is bigger than
connection, the F1 and F2 still exist when the pretension force is zero. the increase in N. In a word, the bigger friction coefficient leads to a
Under the shear force applied on the middle plate, the relative better performance of the joint.
displacement along Z axis occurs between the top plate and the bottom
plate, and the middle plate is pressed even without pretension force. 3.3. The angle of sunk head
With the increase of pretension force, F1 and F2 increase, which
lead to a decrease in N1, and the gradient of decrease raises. The value 3.3.1. Change the value of R1
of the ratio F1/F2 indicates that with the increase of pretension force, As shown in Figs. 4 and 5, R1, R2 are the radius of the up end of
the symmetry of stress state of sunk screw connection is better. In the sunk hole and sunk head. H is the height of sunk head. θ is the angle of
other hand, the overlarge pretension force is harmful to the connection, sunk head. Ensure the sunk head sinks into sunk hole for 0.2 mm and
so a proper bolt pretension is necessary. the height of sunk hole is 4.2 mm. The relational expression of R1, R2
and H is shown as follows:
3.2. Friction coefficient
R1 − 4.2 R2 − 4 R2 − 4.2
= =
4 H 3.8 (2)
Change the friction coefficient from MU=0 to MU=0.3 to analysis
the effects on property of sunk screw connection. The max von-Mises By calculating, 8 sets of data are shown as Table 3.
stress of sunk screw (MXSEQV), the max contact sliding (MXSLID) In standard set-up, R1=8.2 mm, R2=8 mm, H=4, θ=90°. Change
and the max deformation(MXUSUM) are shown in Fig. 15 and 16. the value of θ as Table 3. The MXSEQV, MXSLID and MXUSUM of
The stress state of middle plate is describe the same as Chapter 3.1 sunk screw connection are shown as Figs. 17 and 18.
and is listed as Table 2. As shown in Figs. 17 and 18, with the increase of θ, the stress
As shown in Table 2, the friction force and its contributory shearing concentration, the slippage and the deformation of sunk screw
force increase with the increased friction coefficient. The change of connection increase. The position of max von Mises point move from
ratio F1/F2 is tiny with different friction coefficient in the same the middle of sunk screw, namely ZG=8.2485 mm, to the lower edge of
pretension force, which indicates that the pretension force determines sunk head, namely ZG=4.6330, the variation happens when θ=90°. The
the force symmetry of the sunk screw connection. reason of this variation is the change of support mode that top plate
As the expression of friction force f=μN shows, the friction force and bottom plate to sunk screw. When a small angle of sunk head, the
determined by friction coefficient μ and positive pressure N. In the sunk screw is much closer to a cylinder. So the sunk screw can be
connection, when the μ decreases, the displacement of the connection simplified to a simply supported beam that receiving load in the middle

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X. Li, X. Zhang Acta Astronautica 137 (2017) 345–352

Fig. 16. The MXSLID and MXUSUM in different friction coefficient.

Table 2
The stress state of middle plate in different friction coefficient.

MU F1/N F2/N N1/N F1/F2 (F1+F2)/N1 (%)

0 0 0 4993.2 – 0
0.05 85.0 71.2 4837.1 1.194 3.23
0.10 152.3 128.0 4713.0 1.190 5.95
0.15 204.8 174.6 4614.0 1.173 8.22
0.20 247.1 210.6 4535.6 1.173 10.09
0.25 283.1 236.3 4474.0 1.198 11.61
0.30 308.6 260.7 4424.0 1.184 12.87

where also the max von Mises point. On the other hand, when a great
angle of sunk head, the sunk screw can also be simplified to a simply
supported beam. But the details of sunk head is highly significant.
Because of the rapid change of dimension and force that top plate to
sunk head along Z axis, the stress concentration at the lower edge of
sunk head is extremely serious. Fig. 17. The MXSEQV in different θ.

The MXSLID increase with the rise of the angle of sunk head. That
because with the rise of θ , the supporting effect by the conical surface of
sunk hole to sunk head decreases. The slip between sunk head and As shown in Table 5, the MXSLID and MXUSUM increase with the
sunk hole is easily produced, relevantly, the sliding between plates is rise of θ, while the MXSEQV increases and then decreases. The max
greater. von Mises point locates around the lower edge of sunk head in Path 1
As shown in Table 4, with the rise of θ, the friction force increase. where ZG=4.69. As shown in Table 6, the friction force increases and
The greater angle of sunk head leads to the asymmetry of connection then decreases with the rise of θ. The reason for strength weaken while
which cause an intense extrusion between plates and finally results in friction force increase is explained as Chapter 3.3.1. When θ is great
an increase in friction force. Accordingly, the force that middle plate enough, the extrusion between plates diminish and result in a decrease
acts on sunk screw decreases. in friction force. Although the shear force that middle plate acts on
sunk screw augment, the strength of sunk screw connection is
enhanced because of the decrease of extrusion force between sunk
3.3.2. Change the edge height ‘m’ of sunk head
head and sunk hole.
The method by changing the value of R1 to change the angle of sunk
When m=0.5, 1.5 and 2.5 mm, change the value of pretension force
head is improper when θ is oversize that will make the sunk screw
and the results of MXSEQV is shown in Fig. 20.
abnormal. Another method is applied to change θ by changing the edge
As shown in Fig. 20, with the rise of pretension force, the MXSEQV
height of sunk head.
increases and then decreases when m=0, 0.5, and 1.5 mm. In fact,
Fig. 19 presents the dimension of blunt-edged sunk screw. Keep the
when m=2.5 mm and pretension force F=3500 N, the
height of sunk head H=4 mm. By changing the value of m, the angle of
MXSEQV=353.07 MPa, which is larger than that when F=3000 N. It
sunk head change from 90° to 180°. Make sure R1=8.2 mm, and other
is interesting to note that the turning points are pushed back with the
dimension of sunk hole fit the sunk head.
increase of θ. The optimal pretension force is exist in every angle of
Table 5 presents the angle of sunk head, MXSEQV, MXSLID and
sunk head.
MXUSUM in different edge height.

Table 3
The dimension value of different angle of sunk head.

R1/mm 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0

R2/mm 6.385 6.86 7.335 7.81 8.285 8.76 9.235 9.71
H/mm 4.14783 4.08571 4.0424 4.01053 3.98605 3.96667 3.95094 3.93793
θ/° 59.8 70.0 79.0 87.1 94.1 100.4 105.9 110.8

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X. Li, X. Zhang Acta Astronautica 137 (2017) 345–352

Fig. 18. The MXSLID and MXUSUM in different θ.

Table 4 Table 6
The stress state of middle platE in different angle of sunk head. The stress state of middle plate in different θ.

θ/° F1/N F2/N N1/N F1/F2 (F1+F2)/N1 (%) θ/° F1/N F2/N N1/N F1/F2 (F1+F2)/N1 (%)

59.8 167.2 154.6 4671.5 1.082 6.89 97.6 269.2 228.6 4495 1.178 11.07
70.0 194.1 173.9 4625.3 1.116 7.96 101.0 276.6 231.5 4485.1 1.195 11.33
79.0 219.3 191.8 4582.3 1.143 8.97 104.4 283.8 235.4 4474.1 1.206 11.60
87.1 240.2 206.1 4547.1 1.165 9.81 106.3 286.6 237.7 4469.0 1.206 11.73
90.0 247.1 210.6 4535.6 1.173 10.09 116.0 303.7 244.2 4445.4 1.244 12.33
94.1 255.8 215.5 4522.0 1.187 10.42 126.9 317.6 243.9 4431.8 1.302 12.67
100.4 275.5 219.0 4499.0 1.258 10.99 138.9 325.4 227.5 4440.4 1.430 12.45
105.9 284.5 227.6 4481.2 1.250 11.43 151.9 315.0 191.4 4487.0 1.648 11.29
110.8 293.6 232.8 4467.0 1.261 11.78 165.8 278.0 131.2 4584.1 2.119 8.93
171.4 253.3 109.1 4630.9 2.322 7.83

Fig. 19. The dimension of blunt-edged sunk screw.

Fig. 20. MXSEQV-pretension curves in different angle of sunk head.

4. Conclusions

A finite element model is established to investigate the structural point which is named the optimal pretension force can be calculated
behavior of sunk screw connection and draw the following conclusions: by finite element methods.
2. The friction coefficient has positive influence on structural behavior.
1. Pretension force have effect on the behavior of sunk screw connec- In actual engineering, some strategies can be used to improve
tion. With the rise of pretension force, the maximum von Mises of friction coefficient such as increasing the surface roughness of plates
sunk screw connection decreases and then increases. The turning or surface treatment.
3. The angle of sunk head influence the structural behavior. With the

Table 5
The angle of sunk head and analysis data in different m.

m/mm 0.5 0.7 0.9 1.0 1.5 2.0 2.5 3.0 3.5 3.7
θ/° 97.6 101.0 104.4 106.3 116.0 126.9 138.9 151.9 165.8 171.4
SEQV/MPa 283.3 287.8 293.3 297.0 336.5 378.3 389.4 392.5 381.3 351.4
SLID/μm 30.1 31.6 32.6 33.2 36.3 40.4 45.8 53.1 62.0 65.7
USUM/mm 0.228 0.239 0.250 0.256 0.289 0.332 0.388 0.460 0.542 0.573

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X. Li, X. Zhang Acta Astronautica 137 (2017) 345–352

rise of θ, the maximum von mises increases and then decreases, and [8] E. Shamoto, et al., Analytical prediction of contact stiffness and friction damping in
bolted connection, CIRP Ann.-Manuf. Technol. 63 (1) (2014) 353–356.
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Foundation of China (11502010) and the Fundamental Research (p.021018).
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