Optimized fastener construction system and method

Claim 2

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a smooth shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said smooth shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, said smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, the axial widths of said pin grooves and shoulders and said collar grooves and shoulders being preselected in accordance with the relative shear strengths of said different materials whereby said pin shoulders and said collar shoulders are adapted to fail in shear generally at said design tensile load applied between said pin member and said collar, said collar having a minimum wall thickness, and hence weight, such that after swage compressive yielding could occur generally at said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin grooves into which said collar is swaged.

Claim 3

The fastening system of claim 1 with said axial widths providing generally for said pin shoulders to fail at a tensile load just above said design tensile load whereby said collar shoulders generally fail before said pin shoulders.

Claim 4

The fastening system of claim 1 with said wall thickness of said collar selected for compressive yielding at tensile loads just above said design tensile loads whereby failure occurs in shear across said pin shoulders or said collar shoulders before compressive yielding of said collar.

Claim 5

The fastening system of claim 3 with said axial widths providing generally for said pin shoulders to fail at a tensile load just above said design tensile load whereby said collar shoulders generally fail before said pin shoulders.

Claim 6

The fastening system of claim 1 with said pin member prior to swage having a pintail portion connected with said grooved portion by a breakneck groove, said pintail portion adapted to be gripped by a tool actuable for applying a relative axial force between said pin member and said collar, said breakneck groove adapted to accept a combined tensile and bending load and to fracture at a preselected axial force after completion of swaging, said breakneck groove having a stress concentration factor providing for fracture at said preselected axial force and further providing for fracture within around 12% from said preselected axial force when said fastener is applied to workpieces having its collar engaging surface at an angle of 7° normal to the axis of said pin member, said stress concentration factor (Kt) being expressed by the relationship: (d/D) (Kt) where `d` is the minimum diameter of said breakneck groove and D is the diameter of said pintail portion immediately adjacent said breakneck groove, said relationship being approximately 1.6 for said fastener for application in aligned openings of around 3/16" diameter where said smooth shank portion is around 0.189".

Claim 7

The fastening system of claim 1 with said fastener adapted to secure workpieces of a preselected total thickness and with said pin grooves being of just a sufficient number to accept said design tensile load.

Claim 8

The fastening system of claim 1 with said fastener adapted to secure workpieces of a preselected total thickness within a grip range varying at least around twice the width of one of said pin grooves, said pin grooves being of a number which is one greater than that required to provide said design tensile load, said collar being of a minimum length to engage all or all but one of said pin grooves when said fastener is applied to workpieces varying in total thickness by said grip range.

Claim 9

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a smooth shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said smooth shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, said smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, the axial widths of said pin grooves and shoulders and said collar grooves and shoulders being preselected in accordance with the relative shear strengths of said different materials whereby said collar shoulders are adapted to fail in shear generally at said design tensile load and said pin shoulders at around 110% of said design tensile load applied between said pin member and said collar, said collar having a minimum wall thickness, and hence weight, such that after swage compressive yielding could occur generally at around 110% of said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin grooves into which said collar is swaged.

Claim 10

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a smooth shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said smooth shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, said smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, the axial widths of said pin grooves and shoulders and said collar grooves and shoulders being preselected in accordance with the relative shear strengths of said different materials whereby said collar shoulders are adapted to fail in shear generally at said design tensile load and said pin shoulders at around 110% of said design tensile load applied between said pin member and said collar, said collar having a minimum wall thickness, and hence weight, such that after swage compressive yielding could occur generally at around 110% of said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin grooves into which said collar is swaged.

Claim 11

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a smooth shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said smooth shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, said smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the pin member having a higher ultimate shear stress than said collar with the ultimate shear stress of said collar being selected to be generally as high as possible without crushing said pin member during swage, said collar having a minimum wall thickness, and hence weight, such that, after swage, compressive yielding could occur generally at said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin lock grooves into which said collar is swaged.

Claim 12

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a smooth shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said smooth shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, said smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the pin member having a higher ultimate shear stress than said collar with the ultimate shear stress of said collar being selected to be generally as high as possible without crushing said pin member during swage, said collar having a minimum wall thickness, and hence weight, such that, after swage, compressive yielding could occur generally at said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin lock grooves into which said collar is swaged.

Claim 13

The fastening system of claim 9 with the ratio of ultimate shear stress of said pin member to said collar being in the range of from around 1.8 to around 2.7.

Claim 14

The fastening system of claim 9 with said pin member prior to swage having a pintail portion connected with said grooved portion by a breakneck groove, said pintail portion adapted to be gripped by a tool actuable for applying a relative axial force between said pin member and said collar, said breakneck groove adapted to accept a combined tensile and bending load and to fracture at a preselected axial force after completion of swaging, said breakneck groove having a stress concentration factor providing for fracture at said preselected axial force and further providing for fracture within around 12% from said preselected axial force when said fastener is applied to workpieces having its collar engaging surface at an angle of 7° normal to the axis of said pin member, said stress concentration factor (Kt) being expressed by the relationship: (d/D) (Kt) where `d` is the minimum diameter of said breakneck groove and D is the diameter of said pintail portion immediately adjacent said breakneck groove, said relationship being approximately 1.6 for said fastener as applied to the aligned openings of around 3/16" diameter where said smooth shank portion is around 0.189".

Claim 15

The fastening system of claim 9 with said fastener adapted to secure workpieces of a preselected total thickness and with said pin grooves being of just a sufficient number to accept said design tensile load.

Claim 16

The fastening system of claim 9 with said fastener adapted to secure workpieces of a preselected total thickness within a grip range varying at least around twice the width of one of said pin grooves, said pin grooves being of a number which is one greater than that required to provide said design tensile load, said collar being of a minimum length to engage all or all but one of said pin grooves when said fastener is applied to workpieces varying in total thickness by said grip range.

Claim 17

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight for the material utilized, said fastener comprising: a pin member having an elongated shank including a smooth shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said smooth shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, said smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin lock grooves into which said collar is swaged.

Claim 18

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight for the material utilized, said fastener comprising: a pin member having an elongated shank including a smooth shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said smooth shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, said smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin lock grooves into which said collar is swaged.

Claim 19

The fastening system of claim 14 with said pin member prior to swage having a pintail portion connected with said grooved portion by a breakneck groove, said pintail portion adapted to be grippei by a tool actuable for applying a relative axial force between said pin member and said collar, said breakneck groove adapted to accept a combined tensile and bending load and to fracture at a preselected axial force after completion of swaging, said breakneck groove having a steess concentration factor providing for fracture at said preselected axial force and further providing for fracture within around 12% from said preselected axial force when said fastener is applied to workpieces having its collar engaging surface at an angle of 7° normal to the axis of said pin member, said stress concentration factor (Kt) being expressed by the relationship: (d/D) (K/t) where `d` is the minimum diameter of said breakneck groove and D is the diameter of said pintail portion immediately adjacent said breakneck groove, said relationship being approximately 1.6 for said fastener for application in the aligned openings of around 3/16" diameter where said smooth shank portion is around 0.189".

Claim 20

The fastening system of claim 14 with said fastener adapted to secure wcrkpieces of a preselected total thickness and with said pin grooves being of just a sufficient number to accept said design tensile load.

Claim 21

The fastening system of claim 14 with said fastener adapted to secure workpieces of a preselected total thickness within a grip range varying at least around twice the width of one of said pin grooves, said pin grooves being of a number which is one greater than that required to provide said design tensile load, said collar being of a minimum length to engage all or all but one of said pin grooves when said fastener is applied to workpieces varying in total thickness by said grip range.

Claim 22

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a smooth shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a groove portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said smooth shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, said smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, said colar having a minimum wall thickness, and hence weight, such that, after swage, compressive yielding could occur generally at said design tensile load, said pin member prior to swage having a pintail portion connected with said grooved portion by a breakneck groove, said pintail portion adapted to be gripped by a tool actuable for applying a relative axial force between said pin member and said collar, said breakneck groove adapted to accept a combined tensile and bending load and to fracture at a preselected axial force after completion of swaging, said breakneck groove having a stress concentration factor providing for fracture at said preselected axial force and further providing for fracture within around 12% from said preselected axial force when said fastener is applied to workpieces having its collar engaging surface at an angle of 7° normal to the axis of said pin member, said stress concentration factor (Kt) being expressed by the relationship: (d/D) (Kt) where `d` is the minimum diameter of said breakneck groove and D is the diameter of said pintail portion immediately adjacent said breakneck groove, said relationship being approximately 1.6 for said fastener for application in the aligned openings of around 3/16" diameter where said smooth shank portion is around 0.189".

Claim 23

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a smooth shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a groove portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said smooth shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, said smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, said colar having a minimum wall thickness, and hence weight, such that, after swage, compressive yielding could occur generally at said design tensile load, said pin member prior to swage having a pintail portion connected with said grooved portion by a breakneck groove, said pintail portion adapted to be gripped by a tool actuable for applying a relative axial force between said pin member and said collar, said breakneck groove adapted to accept a combined tensile and bending load and to fracture at a preselected axial force after completion of swaging, said breakneck groove having a stress concentration factor providing for fracture at said preselected axial force and further providing for fracture within around 12% from said preselected axial force when said fastener is applied to workpieces having its collar engaging surface at an angle of 7° normal to the axis of said pin member, said stress concentration factor (Kt) being expressed by the relationship: (d/D) (Kt) where `d` is the minimum diameter of said breakneck groove and D is the diameter of said pintail portion immediately adjacent said breakneck groove, said relationship being approximately 1.6 for said fastener for application in the aligned openings of around 3/16" diameter where said smooth shank portion is around 0.189".

Claim 24

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight, the fastener comprising a pin member having an elongated shank including a smooth shank portion adapted to be located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, the smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar adapted to be swaged into said pin grooves whereby the workpieces are fastened together, said collar when swaged having collar grooves and shoulders interlocking said pin grooves and shoulders, the method of optimizing the fastener comprising the steps of: forming the smooth shank portion to be of a preselected length relative to the combined thickness of the workpieces whereby the grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, forming the tubular collar to have a minimum length sufficient to overlay and to be swaged into the pin grooves, forming the pin member and collar from different materials having ultimate shear stresses with different magnitudes with the ratio of such shear stresses of the pin member to the collar being such that the pin member will substantially resist crushing during swage, forming the pin grooves and shoulders of preselected axial widths in accordance with the relative shear strengths of the different materials of the pin member and collar whereby the pin shoulders and collar shoulders formed in swaging will fail in shear generally at the design tensile load applied between the pin member and collar, the collar when formed having a predetermined volume of material which is at least around 20% greater than that required to fill the pin grooves when swaged to a minimum wall thickness, and swaging the collar to the minimum wall thickness which has a magnitude such that compressive failure could occur generally at the design tensile load.

Claim 25

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight, the fastener comprising a pin member having an elongated shank including a smooth shank portion adapted to be located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, the smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar adapted to be swaged into said pin grooves whereby the workpieces are fastened together, said collar when swaged having collar grooves and shoulders interlocking said pin grooves and shoulders, the method of optimizing the fastener comprising the steps of: forming the smooth shank portion to be of a preselected length relative to the combined thickness of the workpieces whereby the grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, forming the tubular collar to have a minimum length sufficient to overlay and to be swaged into the pin grooves, forming the pin member and collar from different materials having ultimate shear stresses with different magnitudes with the ratio of such shear stresses of the pin member to the collar being such that the pin member will substantially resist crushing during swage, forming the pin grooves and shoulders of preselected axial widths in accordance with the relative shear strengths of the different materials of the pin member and collar whereby the pin shoulders and collar shoulders formed in swaging will fail in shear generally at the design tensile load applied between the pin member and collar, the collar when formed having a predetermined volume of material which is at least around 20% greater than that required to fill the pin grooves when swaged to a minimum wall thickness, and swaging the collar to the minimum wall thickness which has a magnitude such that compressive failure could occur generally at the design tensile load.

Claim 26

The method of claim 19 with the collar swaged to the minimum wall thickness such that compressive yielding could occur generally at 110% of the design tensile load.

Claim 27

The method of claim 20 with the pin shoulders and collar shoulders formed such that the collar shoulders generally fail first in shear.

Claim 28

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight, the fastener comprising a pin member having an elongated shank including a smooth shank portion adapted to be located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, the smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar adapted to be swaged into said pin grooves whereby the workpieces are fastened together, said collar when swaged having collar grooves and shoulders interlocking said pin grooves and shoulders, the method of optimizing the fastener comprising the steps of: forming the smooth shank portion to be of a preselected length relative to the combined thickness of the workpieces whereby the grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, forming the tubular collar to have a minimum length sufficient to overlay and to be swaged into the pin grooves, the collar when formed having a predetermined volume of material which is at least around 20% greater than that required to fill the pin grooves when swaged to a minimum wall thickness, and swaging the collar to the minimum wall thickness which has a magnitude such that compressive yielding could occur generally at the design tensile load.

Claim 29

In a fastening system, including a two piece fastener, for securing a plurality of workpieces together with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener optimized to meet said design shear and tensile loads with a minimum weight, the fastener comprising a pin member having an elongated shank including a smooth shank portion adapted to be located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, the smooth shank portion being of a diameter sufficient to provide the necessary shear strength to accept said design shear load, a tubular collar adapted to be swaged into said pin grooves whereby the workpieces are fastened together, said collar when swaged having collar grooves and shoulders interlocking said pin grooves and shoulders, the method of optimizing the fastener comprising the steps of: forming the smooth shank portion to be of a preselected length relative to the combined thickness of the workpieces whereby the grooved portion will be located outside of and extend for a minimum length beyond the confines of the aligned openings, forming the tubular collar to have a minimum length sufficient to overlay and to be swaged into the pin grooves, the collar when formed having a predetermined volume of material which is at least around 20% greater than that required to fill the pin grooves when swaged to a minimum wall thickness, and swaging the collar to the minimum wall thickness which has a magnitude such that compressive yielding could occur generally at the design tensile load.

Claim 30

The method of claim 19 with the collar swaged to the minimum wall thickness such that compressive yielding could occur generally at 110% of the design tensile load.

Claim 31

In a fastening system, including a fastener, for securing a plurality of workpieces within a selected grip range from a minimum to a maximum thickness and with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said fastener constructed to meet said design shear and tensile loads with a preselected minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will generally extend for a minimum length beyond the confines of the aligned openings for the workpieces having a combined thickness at the maximum thickness of workpieces, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, the axial widths of said pin grooves and shoulders and said collar grooves and shoulders being preselected in accordance with the relative shear strengths of said different materials whereby said pin shoulders and said collar shoulders are adapted to fail in shear generally at said design tensile load applied between said pin member and said collar, said collar having a miniumu wall thickness such that after swage compressive yielding could occur generally at said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin grooves into which said collar is swaged.

Claim 32

In a fastening system, including a fastener, for securing a plurality of workpieces within a selected grip range from a minimum to a maximum thickness and with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said fastener constructed to meet said design shear and tensile loads with a preselected minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will generally extend for a minimum length beyond the confines of the aligned openings for the workpieces having a combined thickness at the maximum thickness of workpieces, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, the axial widths of said pin grooves and shoulders and said collar grooves and shoulders being preselected in accordance with the relative shear strengths of said different materials whereby said pin shoulders and said collar shoulders are adapted to fail in shear generally at said design tensile load applied between said pin member and said collar, said collar having a miniumu wall thickness such that after swage compressive yielding could occur generally at said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin grooves into which said collar is swaged.

Claim 33

The fastening system of claim 24 with said wall thickness of said collar selected for compressive yielding at tensile loads just above said design tensile loads whereby failure occurs in shear across said pin shoulders or said collar shoulders before compressive yielding of said collar.

Claim 34

The fastening system of claim 24 with said pin member prior to swage having a pintail portion connected with said grooved portion by a breakneck groove, said pintail portion adapted to be gripped by a tool actuable for applying a relative axial force between said pin member and said collar, said breakneck groove adapted to accept a combined tensile and bending load and to fracture at a preselected axial force after completion of swaging, said breakneck groove having a stress concentration factor providing for fracture at said preselected axial force and further providing for fracture within around 12% from said preselected axial force when said fastener is applied to workpieces having its collar engaging surface at an angle of 7° normal to the axis of said pin member, said stress concentration factor (Kt) being expressed by the relationship: (d/D) (Kt) where `d` is the minimum diameter of said breakneck groove and D is the diameter of said pintail portion iamediately adjacent said breakneck groove, said relationship being approximately 1.6 for said fastener for application is aligned openings of around 3/16" diameter where said smooth shank portion is around 0.189".

Claim 35

In a fastening system, including a fastener, for securing a plurality of workpieces within a selected grip range from a minimum to a maximum thickness and with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener constructed to meet said design shear and tensile loads with a preselected minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will generally extend for a minimum length beyond the confines of the aligned openings for the workpiece having a combined thickness at the maximum thickness of workpieces, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, the axial widths of said pin grooves and shoulders and said collar grooves and shoulders being preselected in accordance with the relative shear strengths of said different materials whereby said collar shoulders are adapted to fail in shear generally at said design tensile load and said pin shoulders at around 110% of said design tensile load applied between said pin member and said collar, said collar having a minimum wall thickness such that after swage compressive yielding could occur generally at around 110% of said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin grooves into which said collar is swaged.

Claim 36

In a fastening system, including a fastener, for securing a plurality of workpieces within a selected grip range from a minimum to a maximum thickness and with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said two piece fastener constructed to meet said design shear and tensile loads with a preselected minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will generally extend for a minimum length beyond the confines of the aligned openings for the workpiece having a combined thickness at the maximum thickness of workpieces, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, the axial widths of said pin grooves and shoulders and said collar grooves and shoulders being preselected in accordance with the relative shear strengths of said different materials whereby said collar shoulders are adapted to fail in shear generally at said design tensile load and said pin shoulders at around 110% of said design tensile load applied between said pin member and said collar, said collar having a minimum wall thickness such that after swage compressive yielding could occur generally at around 110% of said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin grooves into which said collar is swaged.

Claim 37

In a fastening system, including a fastener, for securing a plurality of workpieces within a selected grip range from a minimum to a maximum thickness and with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said fastener constructed to meet said design shear and tensile loads with a preselected minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said shank portion of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will generally extend for a minimum length beyond the confines of the aligned openings for the workpieces having a combined thickness at the maximum thickness of workpieces, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the pin member having a higher ultimate shear stress than said collar with the ultimate shear stress of said collar being selected to be generally as high as possible without crushing said pin member during swage, said collar having a minimum wall thickness such that, after swage, compressive yielding could occur generally at said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin lock grooves into which said collar is swaged.

Claim 38

In a fastening system, including a fastener, for securing a plurality of workpieces within a selected grip range from a minimum to a maximum thickness and with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said fastener constructed to meet said design shear and tensile loads with a preselected minimum weight for the materials utilized, said fastener comprising: a pin member having an elongated shank including a shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said shank portion of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will generally extend for a minimum length beyond the confines of the aligned openings for the workpieces having a combined thickness at the maximum thickness of workpieces, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the pin member having a higher ultimate shear stress than said collar with the ultimate shear stress of said collar being selected to be generally as high as possible without crushing said pin member during swage, said collar having a minimum wall thickness such that, after swage, compressive yielding could occur generally at said design tensile load, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin lock grooves into which said collar is swaged.

Claim 39

In a fastening system, including a fastener, for securing a plurality of workpieces within a selected grip range from a minimum to a maximum thickness and defining a selected grip range with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said fastener constructed to meet said design shear and tensile loads with a preselected minimum weight for the material utilized, said fastener comprising: a pin member having an elongated shank including a shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will generally extend for a minimum length beyond the confines of the aligned openings for the workpieces having a combined thickness at the maximum thickness of workpieces, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin lock grooves into which said collar is swaged.

Claim 40

In a fastening system, including a fastener, for securing a plurality of workpieces within a selected grip range from a minimum to a maximum thickness and defining a selected grip range with the fastening system having a required preselected magnitude of design shear load and a required preselected magnitude of design tensile load and with said fastener constructed to meet said design shear and tensile loads with a preselected minimum weight for the material utilized, said fastener comprising: a pin member having an elongated shank including a shank portion located in aligned openings in the workpieces and terminating in one end in an enlarged head and at its opposite end in a grooved portion comprising a plurality of circumferentially extending pin grooves and associated pin shoulders, said shank portion being of a preselected length relative to the combined thickness of the workpieces such that said grooved portion will generally extend for a minimum length beyond the confines of the aligned openings for the workpieces having a combined thickness at the maximum thickness of workpieces, a tubular collar swaged into said pin grooves whereby the workpieces are fastened together, said tubular collar being of a minimum length sufficient to overlay and to be swaged into said pin grooves, said swaged collar having collar grooves and shoulders interlocking said pin grooves and shoulders, said pin member and said collar being of different materials having ultimate shear stresses of different magnitudes with the ratio of such shear stresses of said pin member to said collar being such that crushing of said pin member in swage is substantially avoided, said collar being swaged into said pin grooves via a swage anvil having an effective throat swage portion, said collar having a predetermined volume of material which is generally at least around 20% greater than the available volume defined by said effective throat swage portion and the confronting portion of said pin lock grooves into which said collar is swaged.

Claim 41

The fastening system of claim 29 with said pin member prior to swage having a pintail portion connnected with said grooved portion by a breakneck groove, said pintail portion adapted to be gripped by a tool actuable for applying a relative axial force between said pin member and said collar, said breakneck groove adapted to accept a combined tensile and bending load and to fracture at a preselected axial force after completion of swaging, said breakneck groove having a stress concentration factor providing for fracture at said preselected axial force and further providing for fracture within around 12% from said preselected axial force when said fastener is applied to workpieces having its collar engaging surface at an angle of 7° normal to the axis of said pin member, said stress concentration factor (K/t) being expressed by the relationship: (d/D) (Kt) where `d` is the minimum diameter of said breakneck groove and D is the diameter of said pintail portion immediately adjacent said breakneck groove, said relationship being approximately 1.6 for said fastener for application in the aligned openings of around 3/16" diameter where said smooth shank portion is around 0.189".

Claim 42

The fastening system of claim 29 with said fastener adapted to secure workpieces of a preselected total thickness within a grip range varying at least around twice the width of one of said pin grooves, said pin grooves being of a number which is one greater than that required to provide said design tensile load, said collar being of a minimum length to engage all or all but one of said pin grooves when said fastener is applied to workpieces varying in total thickness by said grip range.