Tolerance synthesis of fastened metal-composite joints based on probabilistic and worst-case approaches

This paper presents an approach for tolerance synthesis of uncertain parameters in fastened metal-composite joints. The low time-cost of the approach is ensured by using a reduced finite element model of the joints and a strategy to reduce the number of calculations. Both probabilistic and worst-case approaches for the propagation of uncertainties can be applied through the proposed tolerancing synthesis. An allowable tolerance value for an uncertain parameter can then be easily calculated by identifying an analytical law which links tolerance to a structural performance criterion. The robustness of the proposed approach is illustrated by its application to a 4-bolt metal-composite single-lap joint where several sources of variability are introduced (i.e. hole-location error, pin/hole clearance, fastener preload).