TransverseVibration Loosening Characteristics of High-StrengthFastened Joints using Direct TensionIndicators (DTIs)

July 1998 SPSContractResearch Jenkintown,PA

Transverse Vibration Testing of M16 Class10.9 FastenerSets

Comparisonof fastenersetswith and without

Direct TensionIndicators(DTIs)

Introduction: In recentyears, Direct TensionIndicators for usewith hexheadcapscrews and @TIs) designed otherfasteners in the automotive, off-highway,andindustrial equipment marketshavebeen introduced.AlthoughDTIs havebeenusedon structural boltsfor over 35 yearsin dynamically loadedstructural applications suchasbridges,buildings, power-plants, andcranes, research is waranted for evaluation of service-related performance characteristics of the specific DTI types usedin thesenew markets. The"Junker's"transverse vibration-loosening testprovidesa simplified methodfor broadscale testingandinspection of the transverse vibration(loosening) properties Thetest of fasteners. machine is ableto generate relativemotionin the clamped partsperpendicular to the a:risof the fasteners. The Junkers methodprovides quantitative results relatingthe variables of clamp-load, numberof cycles, andamplitude.Figure l. depicts for the Junker's a standard configuration transverse vibration-loosening apparatus.

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Figure1. Junker'sTransverse Vibration-Loosening Apparatus

The Junkers testis considered a 'severe'testof the loosening characteristics of fasteners, particularly whencompared to previously introduced testmethods which rely on axialdynamic loadingto induceloosening.Junkerlargelyestablished the viabilityof the currentmethodin a paperentitled,'Investigations of the Mechanism of Self-Loosening andOptimalLocking of BoltedConnections'.

Background: This test programwasundertaken, in part,to address questions raised by OriginalEquipment (OEMs)of over-the-road Manufacturers trucks,who haveexpressed interest in research data joints aboutthe potentialfor vibrationloosening of fastened with andwithoutDTIs. A comparison vibrationtest is designed transverse to expose two or morefastener setsto the same test parameters to determine the effects of the differences. The present research compared nut-bolt-washer assemblies with nut-bolt-DTl assemblies. To betterunderstand vibrationloosening, Junker'sprovides us with models of boltedjoints understaticconditions andunder transverse vibration. (SeeFigure2a and2b.)

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Figure2a BoltedJointunderstaticconditions

Figure2b vibration BoltedJointundertransverse

Resultsof transverse vibrationJoosening testsareusefulfor deployment of bolting strategies which reduceor prevent the risk of vibrationloosening in service, or mitigateits effectswhereit cannot be avoided entirely. According to Gerhard H. Junker,originatorof this test,"(I)t is well joint failsin mostcases established loaded that a dynamically eitherby fatiguefailureor by rotationloosening of the fastener.Eventhe fatiguefailureis ofteninitiatedby partialloosening."r

TestProcedure: Specimens of plainfinishM16-2.0X 85mmClass10.9Hex HeadCapScrews with matching zinc platedClass10Nylon InsertLock Nuts, andanclyellowplatedHardened Washers wereprovided by a majormanufacturer of over-the-road trucks. All testswere conducted on fastener setsin the 'as-received' condition, without the useof supplemental lubricants.MatchingplainfinishClass 10.9Ml6 DirectTension Indicators wereprovided by J&M Turner,Inc.oflanghorne, PA. All testswere conducted at SPSContract Research Laboratories in Jenkintown, PA. Each fastener setwastestedon the 1" capacity SPSTranverse VibrationMachine,whichis capable of recording clamp-loads (133kN). of up to 30,000lbs. Steelcoupons were fabricated andusedto ensure a consistent bearingsurface for eachof the 'nut up', with a hardened tests.Tests wereconducted (or washer theDTI, whenonewasused,) placed underthe nut. The effective grip lengthof the fastener setswas- 54mm. Clamping forcewas generated for each testby turningof the nut until eachfastener setwas preloaded (104 to 23,400]bs., tll), irrespective of the torquerequiredto tightenthe standard sets or the flatness of the DTI sets. For information purposes, sometorquereadings wererecorded in orderto quantifyvariationin the nut factor 'K' of the fastener sets. The preloadat whichthe testingstartedrepresents the OEM's stated targettension, equalto 80Yo of proof load. The amplitude of the transverse displacement was setat 10Yo. (i 0.063") of nominal fastener diameter at a no-loadcondition. Eachfastener setwastestedat a speed of 750 CPM for 80 seconds in orderto complete1,000transverse-vibration cycles. A chartrecorderis usedto plot clamp-load vs. vibrationcyclesduringeachtest,thereby permittingmoredetailed analysis ofthe results. Chartsof the clamp-load vs. vibrationcurves "Appendix from the subject test programareattached to this reportas A". Cycles areplotted alongthe X-axis andthe clamploadof the fastener setis plottedalongthe Y-axis.

Results: Vibrationloosening of the fastener which did not include sets DTIs was clearlyevident.Retained clamp loadafter 1,000 cycles ranged from a highof 21,000 lbs.to a low of 4,200lbs.Expressed asa percent, clamploadlosswasbetween l}oh and82Yo, 630/o.Themeanclampload averaging after 1,000cycleswas 8,660lbs.,or almosta third of the initial preload. Only onesample from the groupwithout DTIs retained morethan 50% of its initial clampload after 1,000cycles. Exclusive of this one specimen, the remaining fastener (mean) sets requiredan average of 473 cycles to reduce clamp forceby 50%.

Vibrationloosening of the fasteners setswhichdid include DTIs was noticeably lessthanthose without. The difference is clearlynotable whenonecompares portrayed the resultsgraphically by the chartrecorder. Retained clampload after 1,000cyclesranged from a hrghof 22,750lbs.to a low of 20,900lbs. Expressed asa percent, clamploadlosswasbetween3o/o andllo/o, averaging 8%. Themean clamploadafter1,000 cycles was21,590lbs.All of the samples from thisgroup retained morethan(88%)of initialclamploadafter1,000 cycles.

Conclusion: Underthe conditions of the subject test,therewasa significant in the lossof clampload difference between fastener setswith andwithout DTIs. Fastener setswithout DTIs lost an average of 63% of their initial clampforce after 1,000cycles, contrasted with an average lossof only 8% in the fastener setsin whichDTIs were present.Underthe test parameters andconditions of the study, DTIs appear to provideimprovedresistance to vibrationJoosening. The primaryfunctionofDTIs is, of course, in bolted to ensure that properclampforce is attained connections. The scope of this studydid not include mechanism whereby determining the precise the DTI connections aisoappeared to demonstrate vibration-loosening superior characteristics.

1 Nerv Criteria for Self-Loosening of Fasteners Under Vibration, GerhardH. Jurker, EuropeanResearch & Engineering.Standard PressSteelCo., UnbrakoKoblenz 1973

Summary of Datafrom Transverse VibrationTests

Testson setswith no DTI number of clampload cyclesto starting after 50%original clamoload 1000cvcles clampload 23,400 4.200 615 23,400 5.000 u5 23.400 5,000 255 23,400 2 1 ,OOO NotAoplic. 23,400 8.1 00 475 23,400
8,660

sample# 1

2 3
4

total clampload lost(%) 82% 79% 79% 10%

65o/o

5 mean=

473

63%

Testson setswith DTI number of clampload cycles to starting after 50%original clampload 1000cvcles clampload 23.400 21.400 Not Applic. 23,400 22,750 Not Applic. 23.400 21,400 NotAoolic. 23,400 20.900 Not Applic. 23,400 21.500 NotApplic 23,400 21,590
Not Applic.

sample # 1 2 3
4

total clampload lost(%)

8o/o 3o/o 8o/o

11o/o
8o/o 8o/o

5 mean=

sP5
TO:

ITECHNOLOGIES

Test Certification
Date: July23, 1998 CERTTFICATION NO.980301 P.O. NO: 21 Page1 of3

SPSLaboratories

J&MTurnerlnc. 340 E. MapleAvenue Suite303 Langhorne, PA 19047 Attn:DavidSharo

Transverse vibration tests of ttli-6-2.0 x g5mm, crass l_0.9, plain finish hex head cap screws with zinc-plated Class 1O nylon--insert locknuts and zinc-plated washers suppried by pACCAR. Ftain finish, Class L0.9, size M16 Direct Tension fnd.icators and plain finish nonlocking hex nuts were provided by customer. Test Parameters: Junkers under nut

Test Machine: one inch diameter, 30,ooo lbs. capacity, test machine rfNut-up", washer (or DTr) located Joint orientation: Grip Length: 45 mm Bearing Surface under Bolt head: rnild steel Machine frequency: 750 cycles per minute Seating Torque: various as specifed Test Duration: 1000 cycles Test Anplitude: various as specified rras-receivedrt Lubricant: Parts tested Test Program:

The folLowing tests were performed based on authorization of David sharp. clampload vs. test cycle plots furnistred under separate cover.

Mr.

Subscribed and sworn

HighlandAvenue Jenkintown P e n n s y l v a n i a1 9 0 4 6

( 2 1 55 ) 72-3000 Fax 1215\ 572-3193 Telex: 83-4254

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