2020 Steel
2020 Steel
2020 Steel
a r t i c l e i n f o a b s t r a c t
Article history: Hot-riveted connections have been widely used in the past for metallic bridges, of which a large part is still in ser-
Received 23 November 2019 vice, making relevant the assessment of their fatigue life. Previous studies have shown that the fatigue behavior of
Received in revised form 23 January 2020 hot-riveted connections depends on many factors; among these, the residual tensile force in the rivets that
Accepted 27 January 2020
clamps the plates together, i.e. the clamping force, is one of the most prone to uncertainty and scatter. Investiga-
Available online xxxx
tions p in the past made use of specimens produced in controlled laboratory conditions, potentially leading to op-
Keywords:
timistic results. This paper presents an experimental investigation on the clamping force of as-built hot-driven
Hot riveting process rivets extracted from an old steel bridge. On average, the clamping stress was found to be ∼100 MPa and ∼60
Steel rivets MPa, but with large scatter, for two or three plates being clamped, respectively, and for grip length over diameter
Iron and steel bridges ratios close to unity. This significant dependency on the number of clamped plates, as well as the lower values
Clamping force observed as compared to earlier studies, are attributed to larger imperfections in rivets installed in-service, as
Clamping stress compared to the controlled laboratory environment. In addition, a finite element model is presented that simu-
lates the development of the clamping force following the installation of the rivet. The finite element model was
validated on the basis of the experimental data and it appears able to predict the effect of the grip length on the
clamping force. The larger the grip length over diameter ratio, the larger is the clamping force.
© 2020 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://
creativecommons.org/licenses/by-nc-nd/4.0/).
1. Introduction of a cherry red color. After heating, the rivet is inserted into the pre-
pared hole in the plates.
The hot riveting process has been widely used up to about 1970 for 3. The shop head is blocked using a bucking bar with a concave hemi-
wrought iron and steel structures, giving rise to thousands of infrastruc- spherical end, and a second head, the field head, is forged through
tures that currently form a valuable cultural heritage. Many of these are hammering. In the past, the hammering process was carried out by
still in service for railways and roads [1]. Rivets were mostly used for a man holding hammer, later replaced by a pneumatic or a hydraulic
joining plates in built-up cross-sections and for creating structural de- hammer. The hammering also affects the shaft of the rivet, which fills
tails, such as girder to cross beam connections or splice connections. the clearance previously existing with the hole. The original length of
A Rivet is a permanent mechanical fastener, originally consisting of a the shank must, therefore, include the useful length to cover the sum
hemispherical head, called shop head, and a smooth cylindrical shank. of the thicknesses of the parts to be connected, and an extra length,
The hot-riveting process is divided into several phases: commonly called tail [2]. It not only accounts for the volume neces-
sary to forge the field head, but also for the volume of the hole not
1. Holes are created in the plates to be joined. The holes have a properly
filled by the original rivet shank, see Fig. 1. As stated in [3] the rivet
calibrated diameter, greater of at least 1 mm than the diameter of the
reaches a temperature of about 700 °C just after the forging of the
original rivet shank, and are the results of punching processes, some-
second head. At this stage, because of the Young modulus and yield
times followed by rimming, or, in case of plates that are too thick for
stress that the steel exhibits, which are one order of magnitude
punching, the holes are drilled.
lower than at the service temperature, no significant clamping
2. The rivet is heated up to about 900 °C in a special forge. In the past,
force can be established.
since no sufficient measurement instruments were available, this
4. Following the forging phase, cooling of the rivet (in air) takes place:
temperature was assumed to be reached when the rivet appeared
during this phase, both the yield stress and the ultimate tensile
strength of the steel increase and the rivet shank shortens. The com-
bination of these aspects causes that the plates to be joined are
⁎ Corresponding author. pressed against each other by the rivet heads and that an internal
E-mail address: d.leonetti@tue.nl (D. Leonetti). axial force arises in the shaft, known as “clamping force”. Moreover,
https://doi.org/10.1016/j.jcsr.2020.105955
0143-974X/© 2020 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
2 D. Leonetti et al. / Journal of Constructional Steel Research 167 (2020) 105955
300 Moreover, the obtained numerical results are used to corroborate and
explain the experimental analyses and to further study the effect of
Clamping Stress [MPa]
250
the grip length on the clamping force.
200
2. Models and methods
150
Fig. 3. Structural details extracted from the Botlek Bridge in Rotterdam from which the coupons have been obtained.
4 D. Leonetti et al. / Journal of Constructional Steel Research 167 (2020) 105955
d ≥ dmin ¼ g þ a ð1Þ
where g is the grip length and a is the diameter of the rivet head. For
each specimen, the diameter was selected given the value of a and the
grip length g, in accordance with Eq. 1.
As shown in Fig. 5a, in order to carry out the second step of the pro-
cedure, a hole having a diameter of 2 mm has been machined into the
shaft. The length l1 has been imposed so to position the gauge center
of the strain gauge in the center of the rivet shaft. Given the specifica-
tions of the strain gauges BTM-6C type used for the current analysis, a
value of 8 mm has been considered for l1. As it is shown in Fig. 5, a
shorter hole contained in the rivet head and having a diameter equal
to 5 mm has been drilled to facilitate the operations. Moreover, a longi-
tudinal slot has been produced in order to accommodate the gauge
leads. In order to install the strain gauge, the hole was first thoroughly
cleaned with an air jet and a liquid solvent; then, it was filled with a spe- Fig. 5. Drawing of the specimen machined for the installation of the strain gauge (a), and
cial adhesive. Therefore, the strain gauge was inserted, leaving 3 mm picture of the specimen after the installation of the strain gauge.
from the end of the hole, according to the producer specification. Suc-
cessively, the adhesive was first cured for 12 h at room temperature,
and then 4 h at 140 °C. In this phase, rapid variations of temperature measured strain in the rivet at the beginning and after complete ejec-
have been avoided so to exclude air bubbles or cracks in the adhesive tion, is proportional to the relaxation of the rivet and gives an evaluation
provoked by shrinkage at high strain rate. of the level of pre-stress. Due to the fact that the strain gauge is sub-
After installing the strain gauge and connecting it to the control unit, merged in the adhesive, which does not necessarily have the same stiff-
the second head has been removed using a band saw, and water as cool- ness of the steel, the strain value cannot be directly related to the
ant liquid (step 3 of the procedure). Successively, the rivet was nominal longitudinal stress in the rivet shank by using the Hook law.
completely ejected from the plate assembly using a manual jack- Therefore, a calibration procedure was implemented in order to evalu-
hammer. The quantity Δε, i.e. the recorded difference between the ate the relation between the measured strain and the axial force in the
rivet shank.
In the calibration step (step 4 of the procedure), the rivet has been
loaded in compression by a jack-hammer equipped with a load cell,
allowing the determination between the applied axial force, Fcal, and
the measured strain, Δε. In particular, the rivet was equipped with a
hinge in order to avoid secondary bending, see Fig. 6a. The goal was to
obtain a linear relationship between the applied axial force and the
measured strain and to evaluate the compliance as the ratio between
the measured strain and the applied force [μm/(mm kN)]:
Δε
k1 ¼ ð2Þ
ΔF cal
gauge location since for relatively short rivet lengths the strain gauge is for a rivet shank diameter dr = 22 mm. It resulted that the following
placed in a region of stress concentration. Therefore, it is necessary to functional equation is suitable to describe the trend of k2 as function
evaluate a second correction factor, named k2, which takes into account of the grip length:
the difference in the load type. This is estimated through a finite ele-
ment model of the rivet. This finite element model consists of a rivet k2 ¼ 1 þ 6686g −3:433 for g ≥ 10 mm ð3Þ
modeled using axisymmetric elements, considering the geometrical
symmetry with respect to the plane perpendicular to the axis of the where g should be applied in [mm]. The equation indicates that k2 de-
shaft. As for the mechanical modeling, a linear elastic material model creases with increasing grip length. The comparison between the finite
with Youngs modulus equal to 2E+05 MPa and a Poissons modulus element results and the equation is depicted in Fig. 7. The maximum de-
equal to 0.3 has been considered. The scheme depicting the two loading viation is 5.67E-02. Therefore, the strain range value, Δε, acquired from
cases is in Fig. 6b. The first loading case consists of a compressive load the testing phase has to be divided by k2 in order to obtain the average
applied to the rivet head, which simulates the calibration test, see Fig. strain value, which in the calibration is correlated to the applied load.
6a. In the second loading case, a load has been applied to the portion Following these considerations, the relation between the measured
of the surface of the rivet head, which was constrained by the contact strain range and the clamping stress, σc, is:
with the plates, determining the rivet shank to be in tension, see Fig.
6b. Therefore, the rivet has been constrained only by its symmetric 4Δε
σc ¼ ð4Þ
boundary conditions. The average strain in the axial direction, evaluated k1 k2 πd
2
along a path of nodes positioned in the same location where the gauge
strain gauge is positioned, has been evaluated from the results of the fi-
nite element model. The factor k2 has been considered as the ratio be-
2.2. Numerical model
tween the average strains resulting from the two load cases. Following
a parametric study, executed by varying the grip length between 10
The numerical analysis to simulate the development of a clamping
and 50 mm, k2 [−] has been calculated as function of the grip length g
force after installation, i.e. during cooling of the rivet, involved a fully
coupled thermo-mechanical Finite Element model, implemented in
ABAQUS environment [31]. This is a different and much more complex
model than the one described in the previous section, which was used
solely to determine the linear elastic stress concentration. The analysis
described in the current section is able to consider the interaction be-
tween temperature and displacement fields and vice versa. The finite el-
ement model considers a geometry consisting of two plates clamped by
a rivet having both heads already formed. Thus, the effect of the ham-
mering process has not been considered in the numerical determination
of the clamping force. This assumption has been justified by the fact that
the driving process and the hot forming of the field head are executed
when the temperature in the rivet is above 700°C [3]. At this tempera-
ture, both the yield stress and the Young Modulus of the steel are con-
siderably lower than at room temperature [32], this entailing that the
stresses that correspond to the developing strains can be neglected.
The geometry is modeled considering three values of the grip length,
namely 25, 31.8, and 50 mm. The rivet geometry has been constructed
according to the type A defined in the Dutch standard NEN 667:1944,
see Fig. 8. The diameter of the rivet hole is set equal to the 22.2 mm,
which equals the diameter of the rivet after forging the rivet head,
when the rivet is assumed to completely fill the hole as a consequence
of the hot forging process. The size of the plates, which is five times
the grip length, has been set to minimize the boundaries effects on the
analysis. Because of the computational effort required to perform a
3.5
FE results
3 Equation (3)
Correction factor k 2 [-]
2.5
1.5
0.5
20 40 60 80 100
Grip length [mm]
Fig. 6. Rivet during the calibration step (a), and loading schemes of the rivet while
clamping the plates and during the calibration step (b). Fig. 7. Comparison between the results of the FE model and Eq. 3.
6 D. Leonetti et al. / Journal of Constructional Steel Research 167 (2020) 105955
T E σy Ca λa ν
[°C] [MPa] [MPa] [J/Kg°C] [W/m°C] Table 2
Thermal conductivity of steel to steel contact as a func-
20 210,000 277.3 439.8 53.33 0.2837 tion of the gap between the contacting surfaces, values
100 210,000 277.3 487.6 50.67 0.2868 from [33].
200 189,000 277.3 529.8 47.34 0.2906
300 168,000 277.3 564.8 44.01 0.2943 Gap [mm] λa [W/m°C]
400 147,000 277.3 605.9 40.68 0.2981
0.0 2500
500 126,000 216.3 666.5 37.35 0.3050
0.5 50
600 65,100 130.3 760.2 34.02 0.3142
1.0 25
700 27,300 63.78 1008 30.69 0.3234
1.5 0
D. Leonetti et al. / Journal of Constructional Steel Research 167 (2020) 105955 7
the signal is recorded during the ejection of the rivet (d). Finally, the 200
Fig. 10. The qualitative trend of the strain acquired by the strain gauge during the test:
during sawing at different cutting depth (a–c), and during (d) and after (e) the Fig. 12. Status of the red lead paint after curing. (For interpretation of the references to
complete ejection of the rivet. color in this figure legend, the reader is referred to the web version of this article.)
8 D. Leonetti et al. / Journal of Constructional Steel Research 167 (2020) 105955
Fig. 13. Clamping stress resulting from the new and the old datasets. Fig. 14. Typical imperfections encountered on the rivet shank.
D. Leonetti et al. / Journal of Constructional Steel Research 167 (2020) 105955 9
300
250
150
100
Previous works
50 Current work
FE model
0
1 2 3 4 5
Grip length / Rivet diameter
Fig. 15. Comparison of the trend of the temperature measured in [29] with the numerical Fig. 16. Comparison between the average clamping force resulting from the experimental
trend of the temperature obtained by the proposed thermo-mechanical finite element analyses in the present work (only 2 plates), in the previous literature [3,4,24], and the
model. finite element model. In this case, the box-plot diagram indicates for each dataset the
mean value and the 95% confidence interval of the mean.
• A procedure to measure the clamping force in hot-driven steel rivets mised, with a fair chance of affecting the friction coefficient be-
has been described. Different from other studies, a conversion factor tween the plates. This has been addressed to the high
for short grip lengths has been introduced to correct for dissimilar temperatures induced by the hot driving process close to the
stress concentration factors existing between the initial status and rivet shank. Also, the presence of wet paint demonstrates that
the calibration phase, making the proposed procedure more accurate. the joints are almost air-tight, so that corrosion is not expected
• Consistently with previous experimental results, it has been found to be a major problem for fatigue cracks starting from the rivet
that the rivet clamping force increases with the grip length. However, holes, not even in joints without paint.
the effect of imperfections present in real structures limits this effect. • The proposed finite element model allows to well predict the ther-
The clamping stress was approximately 100 MPa on average for a grip mal and mechanical behavior of the rivet after installation. By
length over diameter ratio close to unity and two plates clamped. using the finite element model it is possible to study the effect of
However, the results are found to be dependent on the number of the clamping force as a function of the grip length. The clamping
plates. For three plates clamped, the value drops to approximately force increases with about a factor of two if the grip length over
60 MPa. This has been attributed to the misalignment of the holes in rivet diameter increases from 1 to 2.5. The model results in a
the plates to be clamped, determining a reduction of the clamping good accuracy with some of the test datasets, being bounded be-
force and an increase in its scatter. The coefficient of variation is ob- tween the 95% confidence interval of the mean response.
served to be higher with a factor between 2 and 3 when three plates • The results of this research can be used in the fatigue assessment
are considered instead of 2, as effect of the hole-misalignment. of a riveted connection.
• With respect to data generated using specimens produced in a con-
trolled laboratory environment, the present dataset shows lower Acknowledgements
values of clamping force. This is addressed to a higher incidence of im-
perfections, such as hole-misalignment, head eccentricity, hammering The authors would like to thank the Dutch infrastructural asset
time, and temperature profile, which might negatively affect the owner Rijkswaterstaat for its support.
clamping force and can be determined only if test data are produced
by rivets driven in realistic conditions. Declaration of Competing Interest
• In the case of assemblies in which red lead paint was used to pro-
tect the material from corrosion, such paint has been found to be The authors declare that they have no known competing financial
still wet. However, in the immediate vicinity of the rivet hole, interests or personal relationships that could have appeared to influ-
the integrity of the paint layers has been found to be compro- ence the work reported in this paper.
Table A.6
Complete set of experimental results.
(*) Evaluated before the ejection of the rivet, i.e. stage (c) of the procedure as depicted in Fig. 10
(**) Evaluated after the ejection of the rivet, i.e. stage (e) of the procedure as depicted in Fig. 10
(a) Positive Strain
(b) Increase in strain after ejection
(c) Disturbed signal during test
(d) Evaluated in the range between −1 to −5 kN
(e) Evaluated in the unloading
(f) Damaged
(g) Unreadable
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