High-strength preload indicator inner washer forward design method

The preload indicator bolt assembly is a fastener that achieves the desired preload effect by simply tightening the preload nut within a specified range without additional measuring tools. The inner washer is a critical component in this assembly, with its outer diameter and height serving as crucial design parameters. In this paper, an equivalent mechanical model is established for the preload indicator bolt assembly. Utilizing this model, an iterative search process is developed to determine the optimal outer diameter and height of the inner washer. The analytical relationship between the bolt preload force and nut displacement is compared and validated against finite element analysis and experimental results, yielding favorable agreement. Notably, the nut tightening angle can vary within the range of 187°–242°, while the preload force exhibits a minimal variation of only ±2% for type 10-0A bolt connection (Bolt diameter and bolt pitch are φ16 mm and 1.41 mm, respectively. The material of bolt, inner ring, and flat ring are GH4169, 40CrNiMoA, and 30CrMo, respectively). This feature significantly simplifies the installation process of the preload indicator bolt assembly in real-world applications, offering great convenience. The increment in tension force on preloaded bolts under external loads exhibits an almost identical trend for both connection methods. Under the same preload force and the same eccentric working load conditions, the thickness of the connected components follows the same trend as their contact area.