Dynamic Behavior of Ti/Ti Single-Lap Laminated Structure with a Large-Diameter Bolt-Based Electromagnetic Force: Numerical Simulation and Experimental Verification
Highlights
- This study focuses on solving the installation problem of large-diameter high-lock bolts and provides important reference value for solving the installation of large-diameter bolts in modern aircraft bearing structures and the possible application of building and vehicle connection problems. Through numerical simulation and experimental validation, a systematic and comprehensive analysis of the installation process of TC4 joints under different interference-fit levels using electromagnetic loading technology was conducted. The study directly verifies that electromagnetic force loading provides excellent installation quality for large-diameter bolts under a certain level of interference, indirectly confirming the potential of dynamic installation technology under electromagnetic force loading to improve installation efficiency and connection strength.
- To study the mechanical performance of joints during dynamic installation, an analysis was conducted in four aspects: deformation and displacement of the hole wall, stress magnitude and distribution, changes in installation force, and the evolution of cross-sectional temperature. This ensured the accuracy and reliability of the analysis results. On this basis, the concepts of softening effects and elastic–plastic effects were introduced to systematically explain the mechanism behind the performance changes in the joints.
- To ensure the authenticity of the simulation results, the method of treating the installation process as a uniform speed process was discarded. Instead, the variable acceleration process during installation was considered, and bolt position was controlled through amplitude modulation in the simulation software to simulate the real installation process. The results showed a high degree of fit between the simulation and experimental data.
Abstract
:1. Introduction
2. Experimental Study and Numerical Simulation
2.1. Experimental Design
2.2. Model Establishment
3. Simulation Results and Analysis
3.1. Deformation and Stress Analysis
3.1.1. Radial Deformation and Stress of Bore Wall
3.1.2. Axial Stress and Deformation of the Bore Wall
3.2. Installation Force Analysis
3.3. Temperature Analysis
3.4. Experimental Validation
4. Conclusions
- The variance in radial deformation displacement at the inlet of joints with different interference-fit levels is less than 21.1 μm2, approximating 0, indicating uniform radial deformation of the bore wall. Additionally, at interference-fit levels of 1% and 1.5%, the axial stress distribution on the bore wall is more uniform compared to other interference amounts, demonstrating that dynamic installation under electromagnetic loading provides high installation quality for large-diameter bolts within a specific range of interference.
- The stress at the inlet of the bore wall is generally higher than at the outlet. For large interference-fit installation, plastic deformation of the bore wall is primarily concentrated at the inlet of the upper and lower plates. Furthermore, the maximum stress increment in the bore wall (ranging from 217.8 MPa to 23.4 MPa) gradually decreases, and installation force is slightly dropped during the initial stage. This indicates that the softening effect induced by large interference fit is a critical factor affecting the dynamic installation process.
- The critical interference-fit threshold at which bore wall stress states attain yield strength equivalence is quantitatively established at approximately 1%. Below this critical threshold, the material response is predominantly characterized by elastic deformation mechanisms, whereas beyond this magnitude, plastic deformation modes become the governing mechanical behavior. This elastoplastic transition behavior fundamentally defines the optimal installation interference magnitude as 1% for joint integrity preservation. Furthermore, a high correlation is identified between bore wall inlet deformation characteristics and cross-sectional temperature fluctuation patterns.
- At interference-fit amounts of 1% and 1.5%, the installation time in Stage 1 is 1.45 to 2.8 times and 2.29 to 2.67 times longer compared to other stages, respectively. This indicates that a significant amount of energy is required to overcome the installation resistance of the bore wall during the initial stage. The high degree of fit between experimental and simulation results, with errors not exceeding 3.71% and below the engineering requirement of 5%, confirms the reliability of the simulation model and the accuracy of its results.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
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Material | A/MPa | B/MPa | n | m | C | Tmelt/°C | Troom/°C |
---|---|---|---|---|---|---|---|
TC4 | 862.4 | 901.7 | 0.341 | 0.767 | 0.018 | 1652 | 25 |
Material | Young’s modulus /GPa | Poisson’s ratio | Density /g∙cm−3 | Specific heat/J∙(kg∙K)−1 | |||
TC4 | 114 | 0.33 | 4.45 | 678 |
Interference Quantity/% | 0.5 | 1 | 1.5 | 2 |
---|---|---|---|---|
Variance/μm2 | 0.005 | 0.478 | 4.131 | 21.1 |
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Zuo, D.; Jin, S.; Xu, T.; Zhang, M.; Cui, M.; Ding, H.; Fu, Y. Dynamic Behavior of Ti/Ti Single-Lap Laminated Structure with a Large-Diameter Bolt-Based Electromagnetic Force: Numerical Simulation and Experimental Verification. Materials 2025, 18, 1473. https://doi.org/10.3390/ma18071473
Zuo D, Jin S, Xu T, Zhang M, Cui M, Ding H, Fu Y. Dynamic Behavior of Ti/Ti Single-Lap Laminated Structure with a Large-Diameter Bolt-Based Electromagnetic Force: Numerical Simulation and Experimental Verification. Materials. 2025; 18(7):1473. https://doi.org/10.3390/ma18071473
Chicago/Turabian StyleZuo, Duquan, Shaoqing Jin, Tianyu Xu, Minghao Zhang, Mengyang Cui, Haolin Ding, and Yaoming Fu. 2025. "Dynamic Behavior of Ti/Ti Single-Lap Laminated Structure with a Large-Diameter Bolt-Based Electromagnetic Force: Numerical Simulation and Experimental Verification" Materials 18, no. 7: 1473. https://doi.org/10.3390/ma18071473
APA StyleZuo, D., Jin, S., Xu, T., Zhang, M., Cui, M., Ding, H., & Fu, Y. (2025). Dynamic Behavior of Ti/Ti Single-Lap Laminated Structure with a Large-Diameter Bolt-Based Electromagnetic Force: Numerical Simulation and Experimental Verification. Materials, 18(7), 1473. https://doi.org/10.3390/ma18071473