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This Technical Brief is intended to provide lessons learned from materials, structure and equipment failures,
prevent costly failures, and maintain equipment reliability and integrity.
Head-to-Shank Radius
First Engaged
Thread
10 mm
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Most materials and structure have a fatigue endurance limit. That is, if the
stress is below the fatigue endurance limit, failure will not occur, even with
many load cycles. Figure 4 illustrates a Stress vs. Cycles curve for a low alloy
steel with a 150,000 pounds per square inch ultimate tensile strength and a
stress concentration factor Kt=3.3. If a bolt is subjected to reverse bending
(stress ratio (R) = Maximum Stress/Minimum Stress) R = -1) and the stress is
below 30,000 pounds per square
100
inch, then a fatigue crack should
90
R=0
not initiate. To keep the stress
below the fatigue endurance
80
limit, bolts are tightened with a
70
pre-determined torque value
60
based upon the yield strength of
R = -1
50
the bolt and diameter.
This
clamp load, also called pre-load,
40
is a percentage of the bolt yield
ENDURANCE LIMIT
30
stress. In a cyclic condition, if
20
the cyclic stress does not exceed
the pre-load stress, then the
10
mean fatigue stress is reduced
0
and the probability for a fatigue
10
10
10
10
10
10
failure is also reduced. However,
FATIGUE LIFE, CYCLES
if the preload is not adequate,
Figure 4. Stress vs. Cycles Curves for an Alloy then the bolt could fail in a low
number of cycles.
Steel Bolt at a Stress Ratio of R=0 and R= -1
MAXIMUM STRESS, KSI
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Consultants, Inc. is one of the
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testing services to government
agencies and private companies
involved with dangerous, highly
hazardous, reactive, or explosive
materials.
For more information on material
engineering services, failure analyses,
or lab testing, contact:
Daniel J. Benac, P.E.
(210) 824-5960
DBenac@BakerRisk.com
www.BakerRisk.com
The initial pre-load torque value for the bolt is too low
The pre-load torque value is above the yield stress of the bolt
The yield stress of the bolt material is too low
Elevated temperatures, causing bolt relaxation
Equipment vibrations, causing the bolt to loosen
Higher stress amplitudes above the endurance limit
To reduce the probability of a bolt fatigue failure, each bolted-joint design should be
individually evaluated and the following should be considered:
Verify that engineering drawing torque value is appropriate for the specific bolt alloy
and diameter
Select the proper strength and toughness material for the bolt
Fatigue failures of bolts and fasteners can be avoided through good design practices,
proper installation, and routine inspection practices.