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Numerical study on the ForceMate bushing cold expansion of composite holes using a novel assisting sleeve

Wuzhu Yan, Zhen Li, Shujing Liang, Yuchang Guo, Xifeng Chen, Xing Wang, Jun Liu, Xiaoliang Geng and Xu Long

Vol. 19 (2024), No. 5, 747–762
Abstract

Cold expansion technology has been one of the most common anti-fatigue strengthening technologies for fastening holes. In this paper, a newly developed assisting sleeve is employed to install the ForceMate bushing, and the resulting deformation, rebound, drawing force, contact pressure, residual stress and damage are compared to those resulting from traditional ForceMate bushing process. The 3D Hashin failure criterion was implemented into finite element simulation via a specially written user subroutine to simulate the deformation and failure of cold expanded composite holes. The results show that a more uniform distribution of residual contact pressure and residual circumferential stress is achieved by introducing the assisting sleeve, and less damage around the composite hole is induced under the same interference level. In comparison with the traditional ForceMate bushing process, a better anti-fatigue performance of cold expanded composite holes can be expected by using the assisting sleeve.

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Keywords
fiber reinforced composite, cold expansion, bushing, composite holes, residual stress, finite element simulation
Milestones
Received: 12 March 2024
Revised: 14 July 2024
Accepted: 28 August 2024
Published: 30 October 2024
Authors
Wuzhu Yan
Department of Engineering Mechanics, School of Mechanics, Civil Engineering and Architecture
Northwestern Polytechnical University
Xi’an, 710129
China
Zhen Li
Department of Structure Design
AVIC The First Aircraft Institute
Xi’an, 710087
China
Shujing Liang
Aero Engine Technology Blade Branch
Aecc Aero Science and Technology Co., LTD
Chengdu, 610041
China
Yuchang Guo
Department of Engineering Mechanics, School of Mechanics, Civil Engineering and Architecture
Northwestern Polytechnical University
Xi’an, 710129
China
Xifeng Chen
Department of Structure Design
AVIC The First Aircraft Institute
Xi’an, 710087
China
Xing Wang
Innovation Research Institute of Shenyang Aircraft Industry Group Co., LTD
Shenyang, 110031
China
Jun Liu
Department of Engineering Mechanics, School of Mechanics, Civil Engineering and Architecture
Northwestern Polytechnical University
Xi’an, 710129
China
Xiaoliang Geng
Department of Engineering Mechanics, School of Mechanics, Civil Engineering and Architecture
Northwestern Polytechnical University
Xi’an, 710129
China
Xu Long
Department of Engineering Mechanics, School of Mechanics, Civil Engineering and Architecture
Northwestern Polytechnical University
Xi’an, 710129
China