Modelling and simulation of lightweight hollow pins as a substitution for solid shear pins used for assembly joints in aerospace applications

Abstract Shear pins are generally used as a mechanical safeguard in assembly operations. They are considered sacrificial members which undergo early fracture to safeguard the other components in the assembly. Currently, solid shear pins are used and technically such pins add to the total weight of an assembly. Weight savings is one of the best contributions that can help the design of components to reduce weight and cost wise. In this regard, hollow shear pins can be a suitable alternative. However, there exists a minimum literature on the use of hollow shear pins in assemblies. The current work presents the theoretical and computational analysis of an industrially used solid shear pin that is modified as a hollow pin. Extensive modeling and simulation of the hollow pins are carried out to check the feasibility of replacing the solid shear pins with hollow shear pins. Due to the profound effect of the notch which changes stress concentration, it appears that weight savings using hollow notched pins possibly are not feasible while the hollow un-notched pins are beneficial. The industrial applicability of the hollow pins can be considered as beneficial components primarily towards functionality. In addition to the weight saving, they can also act as channels for passing wires and other similar entities of an assembly.