Tailored assembly interface for high-performance bolted structures

• A shape optimization strategy is tailored for bolted interface. • Improved optimization is obtained by adaptive regulation. • Simulations are experimentally verified. • Applications to pipe flange and aero-engine rotor are demonstrated. High contact performance of bolt connection goes a long way towards ensuring the high-performance and high-reliability of precision electromechanical systems. This study attempts to achieve a uniform contact stress distribution at bolted interface by tailoring interface shape. A bolted interface shape optimization strategy based on reduced dimensional stress-based parametric curve and mathematical programming algorithm is proposed, in which the shape’s manufacturability is considered. Influence of the parametric curve form and the starting design point is investigated, based on an experimentally verified finite element model of a single-bolted structure. Then a method that can adaptively regulate the bolted interface shape optimization process is further developed by introducing Kriging model. Influence of the adaptive regulation process on optimization effect and efficiency is illustrated comparatively. Further applications of the proposed method to real complex bolted structures including pipe flanges and aero-engine rotors are presented.