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Tolerance Allocation With Simulation-Based Digital Twin for CFRP-Metal Countersunk Bolt Joint

Deviations in the countersunk hole’s angle and depth affect the strength of the bolted composites under tensile loading. Tolerance of the countersunk hole’s angle and depth could be allocated by the Digital Twin of the bolted CFRP-Metal bolt joint. The paper presents a simulation-based Digital Twin for tolerance allocation of CFRP-Metal countersunk bolt joint, mainly considering the strength of the single bolt countersunk joint. Using the design-of-experiment method, nine numerical models with different hole’s angle and depth are constructed to simulate the countersunk holes with different deviations. Simulation results are input into the Digital Twin of the CFRP-Metal countersunk bolt joint. Analysis of variation (ANOVA) method is employed to deeply investigate the interaction between the angle deviation and the depth deviation under tensile loading. Tolerance of the countersunk hole is allocated based on the proposed Digital Twin involving simulation information. The depth should be more strictly controlled than the angle during the course of countersinking. The reported work enhances the understanding of the tolerance allocation for the bolted joint of the composites, and of the simulation-based Digital Twin for CFRP-Metal countersunk bolt joint.