| Three-dimensional elastic-plastic finite element models of single and double rivet-row lap joints have been developed to evaluate local distortions and the mechanics of airframe-type 7075-T6 aluminum alloy riveted assemblies. Loading induced distortion features such as the excess assembly compliance, rivet tilt, local in- and out-of-plane slips and stress concentration factors are evaluated as functions of rivet countersinking, rivet material and friction coefficient. Computed features are examined to identify alterations in the proportions of in-plane and out-of-plane load transmission across rivet-panel interfaces and isolate global and lower-order effects present in the complex response of these multi-body assemblies. Analytical procedures are validated by comparing calculated and measured values of excess assembly compliance and local panel bending. Direct out-of-plane load transmission between the rivet heads and panels affects global deformation features such as remote panel bending and local features such as the panel stress concentration factor. The increase in stress concentration due to panel bending is self-limiting owing to decreasing in-plane load bearing with increasing rivet tilt, which is a composite reflection of the basic rivet deformation modes of shear and rotation.; Calculations have also been performed to define approximate steady-state fretting fatigue conditions that lead to crack initiation at a panel hole surface in single and double rivet-row assemblies for countersunk and non-countersunk rivets. These account for and isolate effects of interference and clamping forces on fatigue performance by comparing computed circumferential variations of bulk residual stresses, cyclic stress range and mean stress. With interference, a non-countersunk assembly is shown to be as prone to crack initiation as a countersunk assembly. Frictional work due to fretting is evaluated and the physical location of fretting fatigue crack initiation is predicted by interpreting combined effects of primary fretting fatigue parameters such as contact pressure and slip amplitude. Angular shifts in the peaks of conventional fatigue and fretting fatigue parameters caused by interference may be exploited to optimize the residual life of aging airframes. |
