Safely Secure Fasteners in Critical Mining Applications

"INTRODUCTION It can be vital that bolted joints holding subassemblies together remain secure. Bolts should resist the loosening effects of vibrations and dynamic loads yet need to be easily removable during maintenance. When a threaded fastener is subjected to vibration, the rapid movement causes a lowering of friction against the threads and a subsequent loss of preload. The loss of preload allows the fastener to vibrate loose and possibly fall out. As the diameter of fasteners increase desired preload becomes increasingly more difficult to achieve. Input torque requirements for achieving proper bolt preload is exponentially related to any given fasteners diameter. This means that specialized tooling or bolting practices are usually required to attempt the tightening of fasteners to reach their required preload. Traditional methods can cause problems with joint integrity and do not provide consistent bolt load across the bolted surface. BOLTED CONNECTIONS A failed critical bolted joint can lead to high maintenance costs, machine downtime, and risk to worker safety. Control of the clamp load in a bolted joint is vital. However, when faced with a problem joint, it is not surprising that the design engineer will not have an answer if asked about the clamp load. Torque calculations must always be based on the existing conditions that often are vague. Unless all parameters are correct, the calculation will be unreliable. Examples of parameters are: • Thread condition of the fasteners • Hardness of contact surface • Material (steel, aluminium, copper, etc.) • Extra friction from a locking fastener • Extra friction from an adhesive • Lubricant on the thread • Type of bolt head (flanged, regular or serrated) • Surface coating of the bolt • New or reused fastener During tightening, bolts are subjected to both tensile and torsional stress. The total stress in a bolt can be calculated using the formula: Total stress = vsx2 + 3txy2 In order to maximize the desired tensile stress (sx) it is vital to minimize the torsional stress (txy). Tensile stress (clamp load) is achieved when the bolt is axially elongated. Unwanted torsional stress (twisting) in bolts arises during tightening due to thread friction. High thread friction increases torsional stress and causes yielding at lower clamp load levels than normal. A lubricant is necessary to minimize the malign torsional stress. However, many commonly used bolt-locking systems are based on increased thread friction (deformed nuts, adhesives, etc). To minimize thread friction and concurrently safely secure the joint has often incorrectly been considered impossible. The use of locking systems that increase thread friction is the single most common reason why the full capacity of bolted joints is not utilized. The following example illustrates the problem."