Bolt Thread Simulation
This example problem demonstrates a simplified modeling technique for bolt thread simulation via the
bolt section method. This method delivers approximate results with the near accuracy of the true
threaded bolt model, but without the need for detailed thread geometry and refined mesh discretization.
The bolt section method also offers a significant savings in simulation time.
The following features and capabilities are highlighted:
• Modeling of 2-D/3-D bolt thread by assigning the bolt section to contact elements.
• Use of pretension loading.
Topics related to this example problem follow:
1. Introduction
2. Problem Description
3. Modeling
4. Material Properties
5. Boundary Conditions and Loading
6. Analysis and Solution Controls
7. Results and Discussion
8. Recommendations
9. Input Files
1. Introduction
A bolted joint is used to hold two or more parts together to form an assembly of a mechanical structure.
In order to achieve expected physical behaviors of a bolted joint structure, a detailed three-dimensional
bolt model, which fully includes the bolt pretension effect and the frictional behavior at contact interfaces,
is desirable. However, for a large, complex structure, detailed modeling of bolted joints is difficult because
of problem size restrictions and computational costs associated with analyzing the entire structure.
The bolt thread modeling technique available for 2-D and 3-D contact elements offers simplified mod-
eling with accuracy close to that of a true threaded bolt model. Bolt threads can be simulated by assign-
ing a bolt section (defined by the SECTYPE command) to contact elements that are overlaid on a
smooth cylindrical bolt surface. To approximate the behavior of the bolt, calculations are performed
internally based on the user-specified thread geometry data and the end points of the bolt axis (input
via the SECDATA command).
The bolt thread modeling technique is useful for system level modeling where the primary bolt function
is to transfer a load. The absence of geometric details and refined mesh discretization in the thread
region also makes it a computationally inexpensive method. This technique can be applied to 3-D
models and 2-D axisymmetric models
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Bolt Thread Simulation
2. Problem Description
The two primary characteristics in a bolted joint are pretension and mating part contact. To simulate
the bolt configuration, a stud M120 bolt is modeled with a cover and a base plate. The bolt is subjected
to a pretension load of 256446 N to simulate the actual bolt phenomenon. Three frictional contact pairs
(FCP) are defined: one in the thread region, another between the bolt head and the cover plate, and
the third between the cover plate and the base plate.
A pressure load of 50 MPa (which is less than the equivalent pretension load) is applied to the upper
surface of the cover plate after applying pretension to the bolt. The resulting bolt shank stress (stress
in the region between the bolt head and the bolt thread) due to the pretension load and the inclusion
of frictional contact behavior are the major concerns during the bolt simulation.
The objective of this problem is to show that the bolt section method simplifies the modeling of this
bolt joint and produces approximate thread behavior and shank stress that are comparable to the true
threaded bolt model.
Figure 1: 3-D Half Model of a Bolted Joint
This problem is simulated by three methods:
1. True thread simulation
This method is the most accurate bolt simulation. The detailed modeling of threads provides accurate
thread behavior in the model. Very refined mesh discretization is required in the thread region,
which makes this method computationally expensive.
2. Bolt section method (simplified bolt thread modeling technique)
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Modeling
In this method, the bolt thread is simulated by assigning a bolt section to the contact elements
overlaid on the smooth cylindrical bolt surface. (No detailed thread geometry is required.) Calculations
are performed internally based on the thread parameters given by the SECDATA command to ap-
proximate the behavior of the bolt. This method is computationally inexpensive.
3. MPC method (bonded behavior in thread region)
In this method, MPC bonded behavior is defined in the thread region. (No detailed thread geometry
is required.) This method is very fast computationally, but thread behavior can be lost.
Both 2-D axisymmetric and 3-D models are used to compare these three methods. The 2-D model setup
for all three methods is shown in the figure below.
Figure 2: 2-D Axisymmetric Problem Setup for (a) True Thread, (b) Bolt Section, (c) MPC Bonded
Method
3. Modeling
An M120 structural steel bolt with standard thread dimensions is modeled with a cover plate and a
base plate of reasonable dimensions. Both 2-D and 3-D bolt thread modeling is performed. A bilinear
isotropic plastic material model is used for the bolt and the plates.
Modeling of this problem is done through the following steps:
3.1. Model the Bolt with Cover Plate and Base Plate
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Bolt Thread Simulation
3.2. Model the Pretension Section
3.3. Model the Contact Pairs
3.1. Model the Bolt with Cover Plate and Base Plate
Two models, one with a threaded bolt surface and another with a smooth bolt surface, are created to
demonstrate the simplicity and advantage of the bolt section method over the true thread simulation
method.
3.1.1. Model the True Threaded Bolt with Cover Plate and Base Plate
The 3-D threaded bolt model represents a single start M120 bolt with a cover plate and a base plate.
The bolt has a maximum diameter of 120 mm, a pitch diameter of 116 mm, a 6 mm pitch, and a half
thread angle of 30 degrees (according to the standard thread profile).
Figure 3: 3-D Model of a Threaded M120 Bolt
The model is meshed with SOLID186 and SOLID187 elements. Mesh refinement is performed in the
thread region.
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Modeling
Figure 4: 3-D Half Model of a Threaded Bolt Joint with Mesh Details
The 2-D surface geometry is extracted from the 3-D thread geometry. The 2-D model is meshed with
PLANE183 axisymmetric elements (KEYOPT(3) = 1).
Figure 5: 2-D Axisymmetric Model of a True Threaded Bolt Joint with Mesh Details
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Bolt Thread Simulation
3.1.2. Model the Simplified Bolt with Cover Plate and Base Plate
Instead of modeling a true threaded bolt, smooth cylindrical surfaces are created for both the bolt and
base plate.
Figure 6: Simplified 3-D Model of an M120 Bolt
A 2-D axisymmetric model is created and meshed with PLANE183 axisymmetric elements (KEYOPT(3)
= 1).
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Modeling
Figure 7: 2-D Axisymmetric Model of a Simplified Bolt Joint with Mesh Details
The 3-D model is generated with SOLID186 elements by extruding the 2-D axisymmetric model about
the Y-axis with the EEXTRUDE command.
eextrude,,30,,,360 !creates 3-D model by rotating 2-D axisymmetric model about y-axis
Figure 8: 3-D Half Model of a Simplified Bolt Joint with Mesh Details
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Bolt Thread Simulation
3.2. Model the Pretension Section
Pretension is the most important aspect of the simulation of the bolted structure. It transfers the load
in the model while sustaining only a small part of the external load on the bolt. The preload on the
bolt is caused by the tightening of the bolt to fasten the cover plate to the base plate. Pretension in
the bolt is modeled by cutting the bolt into two segments and pulling each segment toward the other.
The following steps and commands illustrate the procedure to simulate pretension in the bolt:
1. Mesh the bolt, then cut the mesh and insert PRETS179 elements to form the pretension section. The PSMESH
command is used to create pretension elements in the bolt at y = 260 mm.
ESEL,S,TYPE,,<type number> !selection of bolt elements by element type number
PSMESH,,,,ALL,,,y,260,,,,ECOMP,NCOMP !automatically generate the pretension elements @ y = 260
Figure 9: Pretension Section in the Bolt Model at y = 260 mm
2. The SLOAD command is used to apply the pretension load. In the first load step, the pretension load is
applied as a force to node K. In the second load step the force locks, allowing additional loads. The effect
of the initial load is preserved as a displacement after it is locked.
SLOAD,1,PL01,lock,FORC,2544690,1,2
3.3. Model the Contact Pairs
Three frictional contact pairs are defined to simulate the contact interfaces in the model. The coefficient
of friction in the contact region is 0.15. Contact regions are meshed with CONTA174 elements for the
3-D case and with CONTA172 elements for the 2-D axisymmetric case. The augmented Lagrange algorithm
is used (KEYOPT(2) = 0). Target surfaces are meshed with TARGE170 elements for the 3-D case and
TARGE169 elements for the 2-D axisymmetric case.
Contact pairs are modeled in the following regions:
3.3.1. Contact in the Thread Region
3.3.2. Contact Between the Bolt Head and the Cover Plate
3.3.3. Contact Between the Cover Plate and the Base Plate
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Modeling
3.3.1. Contact in the Thread Region
A surface-to-surface contact pair is defined between the bolt and the base plate. Contact in the thread
region is modeled differently for each of the three simulation methods.
[Link]. Contact in the Thread Region for the True Thread Simulation Method
A frictional contact pair is defined between the bolt thread surface (the contact surface) and the base
plate thread surface (target surface). The surface projection contact detection method (KEYOPT(4) = 3)
is used because it provides more accurate contact tractions and stresses for underlying elements com-
pared with other contact detection methods.
Figure 10: Contact and Target Surfaces at the Bolt Thread and the Base Plate Thread
[Link]. Contact in the Thread Region for Bolt Section Simulation Method
Contact elements (CONTA174 for the 3-D case, CONTA172 for the 2-D case) are generated on the smooth
cylindrical bolt surface. A bolt section is assigned to the contact elements to simulate the thread. The
contact region is computed internally based on the user-specified thread geometry data and the two
end points of the bolt axis. Target elements (TARGE170 for the 3-D case, TARGE169 for the 2-D case)
are overlaid on the smooth cylindrical hole of the base plate.
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Bolt Thread Simulation
Figure 11: Contact and Target Surfaces at the Bolt Surface and Base Plate
The SECTYPE and SECDATA section commands are used to define the bolt section for contact elements.
The format for these commands is shown below.
SECTYPE,SECID,CONTACT,BOLT
SECDATA,Dm,P,ALPHA,N,X1,Y1,Z1,X2,Y2,Z2
where
Dm = Mean pitch diameter, dm
P = Pitch distance, p
ALPHA = Half-thread angle, a
N = Number of starts (defaults to 1)
X1, Y1, Z1, X2, Y2, Z2 = Two end points of the bolt axis in global Cartesian coordinates
The following commands illustrate the procedure for bolt thread modeling using the bolt section
commands:
et,100,174 ! Define contact element type
keyopt,100,4,3 ! Define surface projection based contact detection method
keyopt,100,10,2 ! Update stiffness at each iteration
mp,mu,100,.15 ! Frictional co-efficient
sectype,5,contact,bolt
secdata,116,6,30,,0,0,0,0,162,0
et,101,170 ! Define target element type
r,100,
cmsel,s,bolt_thread,node
type,100
mat,100
real,100
secn,5 ! Assign the section to contact elements
esurf
cmsel,s,bottomplate_thread,node
type,101
mat,100
real,100
secn,0
esurf
allsel,all
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Modeling
[Link]. Contact in the Thread Region for the MPC Simulation Method
In this method, MPC bonded contact behavior is defined between the smooth cylindrical bolt surface
and the smooth base plate. There is no thread behavior defined. To define MPC contact, the following
contact elements KEYOPT settings are used:
KEYOPT(2) = 2 - MPC algorithm
KEYOPT(4) = 2 - Nodal contact detection
KEYOPT(12) = 5 - Always bonded behavior
3.3.2. Contact Between the Bolt Head and the Cover Plate
A frictional contact pair is defined between the bolt head (the contact surface) and the cover plate (the
target surface). The surface projection contact detection method (KEYOPT(4) = 3) is used for this contact
pair.
Figure 12: Contact and Target Surfaces at the Bolt Head and Cover Plate
3.3.3. Contact Between the Cover Plate and the Base Plate
A frictional contact pair is defined between the cover plate (the contact surface) and the base plate
(the target surface). The surface projection contact detection method (KEYOPT(4) = 3) is used for this
contact pair.
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Bolt Thread Simulation
Figure 13: Contact and Target Surfaces at the Cover Plate and Base Plate
4. Material Properties
Structural steel with the bilinear isotropic hardening model (TB,BISO) is used to model the bolt and
plates.
Table 1: Material Properties of Bolt
Elastic Material Properties
Young's Modulus 2.00E5 MPa
Poisson's Ratio 0.3
Density 7.85E-9 tonne/mm3
Bilinear Isotropic Hardening Constants (TB,BISO)
Yield stress 450 MPa
Tangent modulus 2.00E4 MPa
Table 2: Material Properties of Cover Plate and Base Plate
Elastic Material Properties
Young's Modulus 2.00E5 MPa
Poisson's Ratio 0.3
Density 7.85E-9 tonne/mm3
Bilinear Isotropic Hardening Constants (TB,BISO)
Yield stress 280 MPa
Tangent modulus 2.00E4 MPa
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Results and Discussion
5. Boundary Conditions and Loading
The bottom surface of the base plate is constrained in all directions. A pressure load is applied to the
upper surface of the cover plate after preloading the bolt.
• In the first load step, pretension loading of 2544690 N is applied to the pretension section through the
SLOAD command.
sload,1,p101,lock,forc,2544690,1,2 ! pretension load of 2544690 N
• In the second load step, a pressure load of 50 MPa (which is less than the equivalent pretension load) is
applied to the upper surface of the cover plate.
sf,sfload_nn,pres,-50 ! pressure load of 50 MPa on upper surface of cover plate
Figure 14: Boundary Conditins and Loading on the 3-D Model
6. Analysis and Solution Controls
A nonlinear static analysis is performed in two load steps. Large-deflection effects (NLGEOM) are included
in the analysis.
antype,static !selecting analysis
nlgeom,on !including geometric nonlinearity
7. Results and Discussion
A comparative study of all three methods shows the effectiveness and simplicity of the bolt section
method.
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Bolt Thread Simulation
7.1. Results for 2-D Models
Axial (UY) Displacement
The pretension effects can be observed in the following figure in which two segments of the bolt are
pulling against each other.
Figure 15: UY Displacement in the 2-D Axisymmetric Model for all Three Methods
von Mises Stress
The von Mises stress plots below show that shank stress is similar in all three methods. User-specified
contour values are used for the purpose of comparison. Variations are observed only in the local areas
such as the thread region or near the bolt head and cover plate contact region.
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Results and Discussion
Figure 16: von Mises Stress in the 2-D Axisymmetric Model for all Three Methods
The stress plot of the thread region for the bolt section method closely matches the stress plot for the
true thread simulation, and the MPC method plot varies. The comparison between stress plots
demonstrates that accurate simulation of thread behavior and shank stress in the bolt can be achieved
by using the bolt section method.
Linearized Stress Along a Path
Linearized stress in the bolt shank along the path at y = 280 is similar for all three methods. The values
are 329.2 MPa for the true thread simulation, 329.7 MPa for the bolt section method, and 330.10 MPa
for the MPC method.
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Bolt Thread Simulation
Figure 17: Linearized Stress in the Bolt Shank Along a Path at y = 280 for all Three Methods.
7.2. Results for 3-D Models
Contact Status
A helix pattern can be observed in the contact status plot of the bolt section method. If the mesh is
sufficiently refined in the thread region, a more accurate helix pattern can be obtained.
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Results and Discussion
Figure 18: Contact Status in the Thread Region for all Three Methods
Axial (UY) Displacement
The pretension effects can be observed in the following figure in which two segments of the bolt are
pulling against each other.
Figure 19: UY Displacement in the 3-D Half Model for all Three Methods
von Mises Stress
Similar to the 2-D case, the von Mises plots for the 3-D models show that shank stress is similar in all
three methods, and variations are observed only in the local areas.
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Bolt Thread Simulation
Figure 20: von Mises Stress in the 3-D Half Model for all Three Methods
Figure 21: von Mises Stress in the Bolt for all Three Methods
The stress plot of the thread region for the bolt section method closely matches the stress plot for the
true thread simulation, and the MPC method plot varies. This validates the conclusion that the bolt
section method achieves accuracy near to that of the true thread simulation.
von Mises Stress at Section
Average von Mises stress in the bolt shank at section y = 280 is similar for all three methods. The values
are 330.63 MPa for the true thread simulation, 330.10 MPa for the bolt section method, and 330.44 MPa
for the MPC method.
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Results and Discussion
Figure 22: von Mises Stress in the Bolt Shank at Section y = 280 for all Three Methods
7.3. Comparison of Computation Time
From the tables below it is clear that the bolt section method is less computationally expensive than
the true thread simulation. The MPC method is the least computationally expensive, but thread effects
are lost.
Table 3: Simulation Time and Cumulative Iterations for 2-D Models
Computation Elapsed Cumulative Number of
time time iterations Elements
True thread 182.942 186 31 12642
simulation
Bolt section method 38.439 41 28 2297
MPC method 35.646 38 28 2297
Table 4: Simulation Time and Cumulative Iterations for 3-D Models
Computation Elapsed Cumulative Number of
time time iterations Elements
True thread 731625.968 415326 29 1111133
simulation
Bolt section method 44451.254 45912 25 69061
MPC method 41255.852 41948 25 69061
Comparisons of von Mises stress and computation time demonstrate that accurate simulation of thread
behavior and shank stress results in the bolt can be achieved by the bolt section method, with the added
benefit of significant savings of simulation time.
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Bolt Thread Simulation
8. Recommendations
The following points are important for bolt thread modeling:
• The bolt cylindrical surface should be the contact surface, and the bolt section should be assigned to the
contact elements.
• Coordinates of the axis data points (required for SECDATA) should be on the bolt axis and defined in the
global coordinate system.
• In order to achieve better accuracy, the mesh size in the thread region should be less than the pitch distance.
• We recommend you use of a nodal contact detection method (KEYOPT(4) = 1 or 3).
• This technique is valid only for standard, straight threads. It is not applicable for nonstandard threads such
as tapered threads or buttress threads.
• The maximum stress in the thread region may vary with mesh density. However, the overall stress distribution
remains similar in pattern.
9. Input Files
The following files were used in this problem:
• boltSimulation_2-D — Input file for 2-D axisymmetric analysis of bolt thread simulation for all three
methods.
• boltSimulation_3-D — Input file for 3-D full model analysis of bolt thread simulation for all three
methods.
• [Link] — Common database of true threaded 2-D model.
• [Link] — Common database of non-threaded 2-D model.
• truethread_3-[Link] — Common database of true threaded 3-D model.
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