In this paper, the failure mode of bolt clamped single lap
joints of aluminum alloy 2024-T3 have been studied using numerical
finite element method. To do so, a 3D model according to the
available experimental fatigue test specimens has been created and
the stress and strain analysis has been carried out using finite
element based package. The stress distribution, contact details such
as pressure and slip amplitudes have been employed to study the
failure modes such as tensile failure or fretting fatigue. The results
have been compared to the available experimental fatigue tests
results. The numerical results show that in low applied clamping
forces, the fatigue failure of the specimens occurs around the stress
concentration location without wear but when the clamping force
increases, the fatigue life increases and the cracks nucleate and
propagate far from the hole edge because of fretting fatigue. Also,
with the further increase of clamping force, the fatigue life reduces
due to occurrence of the fretting fatigue in the critical location where
the slip amplitude is within its critical region and the fretting failure
occurs earlier than tensile failure.