| Summary: | The shear pin structure is widely used in aeronautics and astronautics structures to deal with emergency structure separation problems. The shear pin design has a strict restriction on the precise failure load and definite failure mode. Previous research has conducted shear fracture tests and simulations of solid shear pins while there is a lack of detailed research on the shear fracture of hollow shear pins with large diameters. In this research, a 3-dimensional finite element model was built based on the actual shear pin installed on the aircraft engine pylon and the model was validated by the experiment. The influences of the inner diameter of hollow shear pins on the shear fracture process were investigated by conducting finite element simulations. The structural deformation, energy dissipation in the fracture process, and failure load of shear pins were evaluated. It is found that as the inner diameter increases, the failure mode of shear pins changed and would result in difficulties on the structure separation. To solve this problem, a new configuration of hollow shear pin was proposed for the purpose of obtaining both desired failure load and failure mode. The new configuration was verified by the fracture simulation and it is found that the new configuration is effective and can be used to improve the shear fracture performance.
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