UNCLASSIFIED UNCLASSIFIED Elasto–Plastic 3D Finite Element Contact Analysis of a Hole Containing a Circular Insert in a Fatigue Test Coupon Witold Waldman Aerospace Division Defence Science and Technology Group DST-Group-TR-3140 ABSTRACT Aircraft structures typically contain large numbers of circular holes that are fitted with fasteners such as bolts or rivets. During the service life of aircraft, fatigue damage often occurs at such holes. The analysis of the stress distributions occurring around the boundaries of holes in the presence of fasteners is therefore of importance in fatigue life studies, particularly at higher load levels where the effects of material plastic deformation become significant. This report is primarily concerned with the results of a three-dimensional elasto– plastic finite element contact analysis of a typical aluminium fatigue test coupon containing a hole that is fitted with a zero-clearance titanium fastener. The response to separate tension and compression loading was considered. The peak levels of stress concentration and their locations in the presence of varying amounts of material plasticity were determined. The elasto–plastic study was augmented by a 3D linear-elastic investigation of the stress concentration behaviour when the hole is fitted with low-tolerance fasteners that have varying levels of clearance. The linear-elastic and elasto–plastic results presented here are relevant for use in test interpretation and validation activities in relation to the full-scale fatigue test of the BAE Systems Lead-In Fighter Hawk jet trainer aircraft in service with the Royal Australian Air Force. RELEASE LIMITATION Approved for public release
Elasto–Plastic 3D Finite Element Contact Analysis of a Hole Containing a Circular Insert in a Fatigue Test Coupon
Jun 12, 2023
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