Paper received: 2012-04-20, paper accepted: 2012-08-21 © 2012 Journal of Mechanical Engineering. All rights reserved. An Improved Torque Method for Preload Control in Precision Assembly of Miniature Bolt Joints Xiwen Zhang - Xiaodong Wang* - Yi Luo Key Laboratory for Micro/Nano Technology and System of Liaoning Province, Dalian University of Technology, China In this work, the improved torque method based on a mathematical model is proposed for preload control in the precision assembly of miniature bolt joints. The mathematical model was used for predicting the friction-compensated control torque. The predicted control torque is a function of preload and torque gradient which is determined by the friction of contact surfaces. Thus, the effect of friction on preload error was reduced, and the bolts preload scatter due to frictional variables of the bolts was decreased. Experiments were carried out to verify the proposed method using the bolts with a thread of M1.6, and the results show that the scatters of preload were less than ±13.0% in the elastic range, which is more consistent than the conventional torque method. The preload control error for most bolts was less than 10%. Keyword: preload control, precision assembly, miniature bolt joints, torque gradient, friction-compensation 0 INTRODUCTION Threaded connection is a popular joining method in modern industries making up nearly 70% of all mechanical connections in industries worldwide [1]. The preload in threaded connections is an important factor affecting the joint performance and reliability. Improper preload can degrade the behavior and life span of the joint and lead to joint problems, such as material failure, fastener loosening, joint separation, leakage, rattle, and fatigue failure [2] to [4]. It has been reported that up to 90% of bolted joint failures are caused by incorrect initial bolt tightening [5]. In the assembly of miniature precision equipment, performance degradation can be attributed to nonuniform stress, which is caused by the scatter of bolts preload. Thus, it is important to achieve an accurate preload during the assembly process for a specific bolt joint [6]. Several methods have been developed to control the preload of a bolt joint, for example, torque control tightening method, angle control tightening method, tension indicating method, ultrasonic method etc. Among these methods, the most common way of tightening a bolt or a nut is the torque control method where the preload is predicted according to the torque-preload relationship. However, the torque-preload relationship is highly sensitive to the friction properties which may cause large scatter to about ±50% of the preload [7]. Even the most precise torque measurement can rarely predict the resulting bolt preload in a reliable way. The method of angle control tightening is supposed to be applicable to both sophisticated assembly tools and simple torque wrenches, the torque required to reach the yield point of bolt is very uncertain due to variations in geometry, bolt strength, and friction. However, applying a specific angle after an initial torque leads to more consistent preload levels. Tightening over the yield point results in the preload less affected by friction than in the case of elastic tightening. The yield characteristic of bolt determines the preload and its scatter, which is often less than ±10%. Nevertheless, since the rotation angle in the elastic region is small, there is a risk of over-tightening the miniature bolts [8]. The tension indicating method includes the use of tension indicating devices to measure the preload indirectly, such as the load indicating washers. An obvious disadvantage of this method is poor precision, which is due to the bolt preload being estimated by measuring the gap between the bolt head and the washer. The ultrasonic method is used in industries where the bolted joints are critical. The method can successfully measure the bolts with large diameters under favorable conditions. However, when the bolts are smaller, environmental disturbances or even the operator induced error may exceed the instrument resolution [9] to [11]. Recently, some new tightening control methods have been developed to increase the preload accuracy. New approaches using shape memory alloy (SMA) [12] to [13] or electronic speckle pattern interferometry (ESPI) technique [14] have been applied to the monitoring of the preload. However, the former is costly and the latter demands very stringent environmental stability and hence cannot be employed in a manufacturing environment [15]. Optical digital imaging correlation (DIC) method [16] was proposed to measure compressive strain in a washer, and the bolt preload is subsequently determined from the measured strain. The strain measurement is limited to only one angular location on the washer, thus it is not suitable for small washers in miniature bolt joints. The digital speckle pattern interferometry (DSPI) system [17] was developed to measure and monitor the out-of-plane deformation on the surface of clamped joints in real-time. In the study, M1.5 miniature bolt joint applications were investigated, yet the control accuracy of bolt preload was not evaluated since load cells and strain-gauged bolts were not suitable for miniature bolts. As a final summary, most of the existing tightening methods are limited in the precise control of tightening miniature bolt joints. It is particularly challenging to find an effective tightening control method for miniature bolt joints due to their small size and low preload level. In this paper, the improved torque method based on the mathematical model for preload precise control is proposed, and the effects of the friction under the head and in the threads were compensated in the model. The proposed method does not require any special equipment and is not restricted by the space, thus it is suitable for precision assembly of a miniature bolt joint. An introduction to the application of the improved method in M1.6 bolt tightening experiments is presented in detail. The effectiveness of the proposed model is demonstrated by the experiments. 1 PRINCIPLE FOR THE IMPROVED TORQUE METHOD 1.1 Theoretical Model One of the major problems with the use of bolt joints is the accuracy of preload. With the conventional torque control method, the control torque for the target preload is determined by the torque-preload relationship. The tightening torque has a significant dependence on the friction at contact surfaces and the majority of the torque is used to overcome friction (usually between 85 and 95% of the applied torque), so small variation in the frictional conditions can lead to large changes in the bolt preload [18]. However, if the effects of friction for a certain bolt are compensated, the preload scatter for these bolts will be decreased, and the tolerance of the bolt for critical application can be lowered. When tightening bolt joints, as the nut rotation, part of the torque and preload is applied to close the gaps, and this situation is referred to as 'snug torque'. Then, the torque Tf and the preload Ff both increase in proportion to the nut rotation angle 6, the relationship between Tf /Ff and 6 are linear and the gradient of Tf/ Ff is almost constant. At last, the preload Ff stretching the bolt over its yield point until the bolt fails and the relationship between Tf /Ff and 6 are nonlinear. In the elastic range, the equation relating preload Ff and nut rotation angle 6 is expressed as follows [19]: Ff = P0C, PmtC, In In where P is the thread pitch, a> and t are the rotation speed of nut and rotation time of nut, respectively. Cs is the system spring constant or system stiffness of bolt joint in the elastic range. In the tightening procedure of the bolt joints, the relationship between the applied torque Tf on nut (or bolt head) and bolt preload Ff can be expressed as [20]: Tf = Ffd jdkan (p + p) + 2d J. (2) In Eq. (2), d2 and d are basic pitch diameter of the thread and nominal thread diameter, p and ft are friction angles relating to friction coefficients and lead angle of threads, dn and fin represent the equivalent friction diameter and coefficient of friction at the bearing surface of nut, respectively. Usually, Eq. (2) is denoted by a simple form using torque coefficient K. Tf = FfdK. (3) Taking the derivative of Tf and Ff with respect to nut rotation time t, the gradient of Tf and Ff can be expressed as: dT, dF,dK Lf dt f dt = dK dFf dt dFf dt , PmtC d-- In dt Pm 2n C = K. dCS dt (4) (5) Combining Eqs. (4) and (5), the torque coefficient K is deduced from the torque gradient Kt using the following relation: K = 2nK, Pdffll CS + ^ ' S dt (6) Substituting for torque coefficient K from Eq (6) into Eq (3) yields: 2nKF (7) Tf = FfdK = ^ f Pffll Cç + d