Jet engines are intricate structures comprised of numerous parts, and their functionality depends on the integrity of bolted joints connecting casing flanges. These flanges play a crucial role in maintaining pressure, preventing leakage that could have catastrophic consequences. The objective of this project is to expedite the simulation process against flange separation during early design stages using simplified Finite Element (FE) models, comparing them to full-scale models. Bolted joints not only face axial loads but also prying loads, introducing non-linear complexities. Prying induces additional bending in the bolts due to uneven loading on opposite sides of the same bolt. Monitoring how bolt loads change with increased external load reveals the critical point of flange separation.To simulate these conditions with finite element methods, the model is divided into small blocks or elements, forming a mesh. The mesh quality significantly influences result accuracy, emphasizing the need for meticulous modeling.

One simplification adopted is the assumption of uniform bolt spacing around the flange. This allows for efficient simulation using a sector of a few or one bolt, significantly reducing simulation time. However, notable discrepancies between results from the full-scale and simplified models emerged due to these simplifications. Sensitivity studies explored the impact of varying parameters, such as bolt spacing, press fit and material. Transitioning from uniform to non-uniform bolt spacing notably affected the load capacity before flange separation more than the other parameters.Further studies are imperative to verify the impacts of various parameters and to determine an optimal balance of simplifications for early design stage simulations in future projects.