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CONNECTIONS
Design of Temporary
Connections
Structure
2.1
Introduction
Objectives
2.2
Stresses
2.3
2.4
Knuckle Joint
2.5
Cotter Joint
2.6
Summary
2.7
Key Words
2.8
Answers to SAQs
2.1 INTRODUCTION
We should understand that designing will be treated as finding dimensions or single
dimensions of a part. The input is normally available in terms of load or force to be
carried and material in which part is to be made. From the knowledge of material, mainly
the ultimate tensile strength and yield strength become known. It is understood that you
are familiar with stress and its types tensile, compressive (or bearing) and shear. The
design will be based upon the relationship between load and stress and the stress value
which is allowed to occur in a part is only fraction of yield strength or ultimate tensile
strength the joining of two parts which carry force and may be either stationary or
permanent is a common engineering practice. Bars may be joined, plates may be
connected or a pulley may be connected to shafts. Pins passing through plates may
connect them and the plates can be pulled apart by equal and opposite forces applied on
two plates. It is example of a temporary joint. Other joints will be described and sizes
calculated.
Objectives
After studying this unit, you should be able to
2.2 STRESSES
The simple definition of stress is that is force divided by area. If the force is
perpendicular to the area and pulling away from it, the stress is tensile. If the force is
perpendicular to area and pushing towards it, the stress is compressive. Both tensile and
compressive stresses come under general category of direct stress. If the force is parallel
to area to cause sliding of one area over other the stress is shearing. If two bodies are in
contact and pressed against each other the stress is bearing. The magnitude of bearing
stress will be the compressing force divided by contact area between two bodies. The
bearing stress is compressive in nature and is also called crushing stress.
37
Machine Design
P
A
AS
A
P= A
P= A
(a)
(b)
AC
P=c Ac
(c)
Figure 2.1 : Three Types of Stresses
(a)
(b)
(c)
The shearing stress and crushing stress are very common in circular cross-section pin
when it passes through two plates and plates are pulled apart. Figure 2.2(a) shows such
plates connected by a pin. The length of the pin equal to thickness t, of plate is subjected
to crushing force P on two cylindrical surfaces as shown in Figure 2.2(b). This surface is
pressed by cylindrical surface of hole in the plate as shown in Figure 2.2(c). Both the
surfaces of the hole in the plates and of the cylinder are subjected to the crushing stress.
The magnitude of this crushing stress is calculated as
c
P
Projected area of cylinder
P
. . . (2.1)
B
Plate 1
Plate 2
AS
P
P
2
P
P
P
2
(a)
(b)
Figure 2.2
t = Thickness of plate.
(c)
Also note that the two forces P, acting opposite to each other on pin as shown in
Figure 2.2(b) are separated by the pin cross-section of area As. This is the area in the
plane of contact of two plates in the Figure 2.2(a). The area As is subjected to shearing
stress .
P
As
As
and
Design of Temporary
Connections
. . . (2.2)
2
d
4
The plates has been cut along the line BB and shown in Figure 2.2(c). The area upon
which force P acts normally is seen as two rectangles. This is the cross-section of plate
subjected to tensile stress, .
P
A
. . . (2.3)
A (l d ) t
2
d
4
P
4P
A d 2
d2
4P
t
For example, if a fan weighing 100 N is suspended at the end of a steel bar in which
stress is not allowed to exceed 10 N/mm2, find the diameter of the bar.
The diameter is calculated from
d2
4P
t
d2
or
d = 3.6 mm
39
Machine Design
Solution
P
(l d ) t
P
2
d
4
P
dt
or
20
or
10
or
22
10,000
(100 d ) t
4 10,000
d2
10,000
dt
. . . (2.4)
. . . (2.5)
. . . (2.6)
Since in (2.4) and (2.6) there are two unknown, use (2.5) to find
d2
4000
d = 36.25 mm
. . . (2.7)
10,000
(100 36.25) t
10,000
7.8 mm
64 20
. . . (2.8)
So both d and t have been found. But we should check that c is not more than
22 N/mm2. From (2.5)
c
10,000
35.6 N/mm2
36 7.8
Since this stress is greater than permissible stress of 22 N/mm2. The value of d and
t are not acceptable.
From Eq. (2.6), dt = 554 which can be obtained with by increasing d or t or both.
t = 13 mm and d = 43 mm gives dt = 559 mm2 which is safe.
Check
10,000
13.5 N/mm2 (Safe)
(100 43) 13
Check
10,000
6.9 N/mm2 (Safe)
(43)2
4
Design of Temporary
Connections
1
2
2
1
Solution
Recognise following ways in which joint can fail.
(a)
Shearing of pin
(b)
(c)
Shearing of Pin
P
2
d s
4
8000
. . . (2.9)
2
d 7
4
d 38.2 mm
. . . (2.10)
Crushing of Pin
The pin comes in contact with the hole surface over half the diameter of the
bar. It can be seen by taking section through centre line of hole for pin.
(See Figure 2.4)
1
d
D
41
Machine Design
If bar 1 is pulled out of plane of paper, the bar 2 will be pulled in the
opposite direction. Only half circular section will carry the tensile force.
Similarly only half pin will compress against the half circle. Hence, area
resisting crushing is
Ac
1
Dd
2
D is he diameter of bar.
The area resisting tensile force
A
1
2
D Dd
4
Dd
1
Dd
2
2 P 2 8000
1142.9 mm2
c
14
1
2
D Dd
4
or by using value of D d
2
2 8000
D 1142.9
1333.33
4
12
i.e.
D2 (1333.33 1142.9)
D = 56.15 mm
4
3153
. . . (2.11)
It will be good idea to check what is the tensile stress in the rod when joint
has been made. The area of cross-section of rod is
2
D (56.15)2 2476.4 mm2
4
4
Hence, when joint carries a force of 8000 N, the stress in the rod
P 2
8000
D
3.23 N/mm2
2476.4
4
42
Two joints one between plates and other between rods can be easily understood as
temporary joints as they can be dismantled by removing pin. Knuckle joint which is
practically used to join two bars being pulled apart is similarly a temporary joint. This
joint also consists of three parts two rods and pin. But the ends of rods are made to
have specific shapes obtained by forging. These ends merge into circular rod. The Figure
2.5 shows a knuckle joint in which 1 is fork, 2 is eye and 3 is pin. Figure 2.6 shows three
parts separated.
Design of Temporary
Connections
Rod
2. Eye
1. Fork
Rod
3. Pin
Collar
4
5
Taper Pin
3
Sq. Sec.
PIN
Eye End
To hold the pin in assembly it is made with a round head at one end and a collar is
placed at the other end. The pin is tightened on the end with the help of a taper pin.
0.4 d
4d
4.5 d
1.5 d
1.2 d
3d
P
0.75d
1.1d
1.1 d
0.75d
0.6 d
2d
Split Pin
Octagon
43
Machine Design
shearing stress. Ideally the pin subjected to shearing stress at two cross-sections
must have twice the permissible stress is single shear but practically permissible
stress in double shear is 1.75 of that in single shear. Eq. (2.9) may be used for
calculating, d.
Diameter of Eye
The hole in the eye has the same diameter as the pin. This is d. the outside
diameter of the eye is D and its thickness is t as shown in Figure 2.8. The force P
pulls the eye to the right and force equal P is exerted by pin on the inside surface
of the hole. Thus, the section BB is subjected to tensile stress. The area of
section BB (hatched area) is (D d) t. D is the outside diameter of the eye. If
tensile stress produced in the section is t then
P t ( D d ) t
. . . (2.12)
Section BB
B
But remember the pin is compressed against inside surface of hole and contact
length is t. Hence, the projected area for crushing is dt. If c is crushing stress,
then
P t dt
. . . (2.13)
P t ( D d ) 2t1
. . . (2.14)
44
t
2
The dimensions of head of pin, collar and taper pin for collar are conveniently
chosen and calculated.
Design of Temporary
Connections
P
P
B
t1
t1
Bending of Pin
Pin in the fork and eye tends to act like a beam. Its has three regions of
loading two in the fork and one in the eye. It is normally fitted tight in the
P
eye and slightly loose in the fork. This causes uniform pressure in the
t
P
P
eye but the pressure in the fork varies from zero to
over the length
t
2t1
per unit length. The force on pin is shown in Figure 2.10. For convenience
the pin is shown as loaded beam at (b) in the same figure. The force on
beam is due to eye and fork will provide reaction to the force on beam in
the eye.
P/ t per unit length
P/ 2 t1 per
unit length
t1
Fork
Eye
t1
Fork
(a)
P/ t per unit length
t
t1 / 3
t1 / 3
P/ 2
P/ 2
(b)
Figure 2.10 : Pin Loaded as a Beam in the Fork and the Eye
The maximum bending moment will occur in the middle of the span which
2t
P
t t
of 1 and due to udl over a length of t.
2 3
M max
P
2
2
t t1 P t
2 3 t 8
32M
d
t t 1
32 P 1
8 6 d3
. . . (2.15)
This stress should be less than t for design to be safe. The equation for is
used as a check.
45
Machine Design
Example 2.3
Design a knuckle joint for a tie rod of a circular section to sustain a maximum pull
of 70 kN. The ultimate tensile strength of the rod material is 420 N/mm2. The
ultimate tensile and shearing strength of pin material are respectively 720 N/mm2
and 390 N/mm2. A factor of safety of 5 is to be used. The permissible stresses in
tension and compression are equal.
Solution
Ultimate strength
Factor of safety
420
84 N/mm2
5
390
78 N/mm2
5
720
144 N/mm2
5
P = 70,000 N
Pin Diameter, d
The area of shearing
2
d
4
P 1.75 s
or
70000 1.75 78
or
d2
2
d
4
70000
652.9
107.2
d = 25.6 mm
. . . (2.16)
P c dt
or
70000 84 25.6 t
t = 32.6 mm
Diameter of Eye, D
See Figure 2.8, the section carries tensile stress.
46
P t ( D d ) t
. . . (2.17)
or
or
D = 51.2 mm
Design of Temporary
Connections
70000
25.6
84 32.6
. . . (2.18)
32.6
16.3 mm
2
. . . (2.19)
70000
84 D12
4
D1 = 32.6 mm
. . . (2.20)
1
32.6 32.6
32 70000
12 (25.6)3
8
713014
(4.075 2.72)
16777.2
= 289.8 N/mm2
It can be seen that this stress is higher than permissible stress
t 84 N/mm2 . Keeping 84 N/mm2 in Eq. (2.15), we may
calculate d.
i.e.
32.6 32.6 1
84 32 70000
12 d 3
8
d = 38.5 mm
1
57023.7
84
. . . (2.21)
This diameter will be safe against shearing of pin. But the outer diameter of
eye and fork found at Eq. (2.19) from Eq. (2.15) will be affected. Hence, we
calculate that diameter again. Using d = 38.5 mm in Eq. (2.15).
70000 ( D 38.5) 84 32.6
70000
38.5
84 32.6
or
D = 64.1 mm
. . . (2.22)
Machine Design
Diameter of pin, d = 38.5 mm. Outside diameter of eye and fork = 64.1 mm.
Thickness of eye, t = 32.6 mm. Thickness of form t1 = 16.3 mm. Diameter
of rod, D1 = 32.6 mm.
SAQ 1
(a)
(b)
If two rods are joined through a pin, show the section, that carries tensile
stress.
(c)
Show the area of eye of a knuckle joint which is subjected to tensile stress.
(d)
(e)
Two mild steel rods are connected in a knuckle joint to carry a tensile load
of 150 kN Design the joint. Use permissible stresses in tension,
t = 77.5 N/mm2, shear, s = 38 N/mm2, compression, c = 150 N/mm2.
P
b
(a) Cotter
48
Figure 2.11
Cotter
Design of Temporary
Connections
Slot
Collar (D2)
Rod
Slot
Collar (D1)
Rod (d)
Spigot (d1)
Socket
We do not make any calculations for joint of Figure 2.12 with a cotter in place of pin. If
you would do, you will find that the diameter of rod turns out large and joint becomes
uneconomical. A better proposition is to make a socket in one end of the rod and insert
the rod in the socket. Both the socket and inserted end of rod will have the slot in one
line through which cotter passes. The cotter is made with a slight taper so that it does not
just pass through the hole but is held in the hole.
A cotter joint for connecting two rods along which tension or compression act is made
with ends of the rod especially made. One rod end carries a spigot (the end to be
inserted) while the other rod end is finished in form of a socket. These ends are shown in
Figure 2.12. The ends are normally made by forging and rectangular hole is also created.
The rectangular hole (slot), the internal surface of socket and external surface of spigot
are finished by machining. The three parts that make a cotter joint are shown in
Figure 2.12. It is not difficult to see that to make the joint spigot is inserted into the
socket. The slots are coincided and cotter passed through the slots. You may note
features of spigot and socket. Collar of large diameter is provided at the mouth of the
socket. The internal diameter of socket (D) is same as external diameter of spigot. The
slot in the socket often passes through the collar and it is the straight edge of the cotter
that makes contact with the collar of the socket. If direction of force is reversed, the
inclined edge of cotter will not be able to make contact with the slot surface. Hence, a
collar is provided on the spigot which contacts the open surface of the mouth of the
socket. Thus, two collars bear against each other and crushing stress between them will
decide the diameter of collar on spigot (D1). The mean width of taper cotter is b which is
not much smaller than larger width as taper is 1 in 48. Parts shown in Figure 2.12 are
assembled in Figure 2.13.
The cotter joint was earlier used in steam engines to connect piston rod with cross-head.
It is still used as connector in a pump rod.
a
1
D2
D1
d d1 D
49
Machine Design
this area. The weakest area is the smallest area. The area of a section becomes
small if a hole or a slot passes through it. If no hole or slot passes, then whole
sectional area may be considered. For example, in spigot and socket the weakest
area is through the slot. For rod the area of section is the only area to be
considered. The weakness may arise where area of section changes. So the collars
on spigot and socket may be weak. The cotter may shear along the surfaces of
contact, hence, its area along contact surfaces may be weak. The stresses that may
cause failure may be tensile, crushing or shear. We will have to be careful to
examine if force P is pulling on one area to cause tensile stress or pushing on an
area to cause crushing or is parallel to the area to cause shearing. To make matters
easy we identify such modes of failure for cotter joint. Each will be used to
determine some dimension.
(a)
2
d t
4
. . . (2.23)
(a)
Figure 2.14
(b)
The spigot may fail due to tension or compression. Note, though the
spigot is a cylinder, it has a slot of width t. t is the thickness of the
cotter. So the weakest area of spigot will be through slot.
Figure 2.14(b) shows this area. Take help of Figures 2.12 and 2.13 to
understand how you draw Figure 2.14(b).
P d12 d1 t t
4
d1
(b)
50
Figure 2.14
. . . (2.24)
(c)
P ( D 2 d12 ) ( D d1 ) t t
4
Design of Temporary
Connections
. . . (2.25)
d1
(c)
Figure 2.14
(d)
The cotter will fail under shear at two sections which are along
surfaces of contact between the outer surface of spigot and inner
surface of socket. For your understanding these areas have been
marked as 1-1 and 2-2 in Figure 2.13.
P bt (1.75 s )
. . . (2.26)
. . . (2.27)
(d)
Figure 2.14
(f)
51
2
( D1 d12 ) as can be judged from
4
Figure 2.13, and shown in Figure 2.14(e).
Machine Design
2
( D1 d12 ) c
4
. . . (2.28)
. . . (2.29)
Dia D1
Dia d1
Rod
P
Spigot Collar of
length a.
Force P uniformly
distributed annular area
(e)
Figure 2.14
(g)
Shearing of socket collar against other. The cotter pushes the collar
over the area (D d1) t as shown in Figure 2.14(c) and also in
Figure 2.14(f). The cotter may cut through the thickness, c of collar if
collar fails in shear. The cotter will face shearing resistance on its two
sides. One side is shown facing the reader in Figure 2.14(f). The other
( D2 d1 )
side is in the back. One of two shaded areas is
c . There are
2
four such areas. Hence, shearing of socket collar against cotter will be
resisted along the area 2 (D2 d1) c.
P 2( D2 d1 ) c s
. . . (2.30)
P/2
Collar
dia., D2
Spigot
dia. d1
P/2
C
(f)
Figure 2.14
Similar situation exists at the tail of the spigot where the cotter may
shear tail over a length, e.
52
P 2 d1 e s
. . . (2.31)
Design of Temporary
Connections
. . . (2.32)
The use of understanding and Eqs. (2.23) and (2.32) will become
clear through a solved example. Everytime you solve a design
problem you must draw figures to show the area on which stress
(tensile, compressive or shear) is acting. P can be calculated.
It may be advisable to check cotter in bending in the same way as pin in knuckle joint. It
will be shown in solved example.
Example 2.4
Write equations for tensile and crushing failure of the spigot of a cotter joint.
Equating strengths of spigot in tension and crushing against cotter show that
d1
6P
t
P d12 d1 t t
4
You may note that left hand side of the above two equations are same, but
remember P is a symbol. If we really make both strengths equal, then we create a
co-relationship between any two dimensions. Such design is known as economical
design.
If we wish to solve first equation we cannot because it contains two unknowns
d1 and t. so we use the second equations and find
d1 t
Since
P
P
c 2t
c 2 t
P
P d12
t
2t
4
or
2
P 3P
d1 P
4
2
2
53
Machine Design
6P
t
d1
Note that t
. . . (2.33)
650
130 MPa or N/mm2
5
6 40000
24.24 mm
130
d1
. . . (2.33)
Thickness of the cotter is found from 2nd equation by putting d1 = 24.24 mm.
40000
6.3 mm
24.24 260
. . . (2.34)
Example 2.5
Two rods are to be joined in a cotter joint to carry 90 kN of axial force which may
change from tension to compression and vice-versa. The ultimate strengths in
tension, compression and shear respectively are 255 N/mm2, 510 N/mm2 and
130 N/mm2. Choose a factor of safety of 5.
Solution
The permissible stresses in tension, shear and compression are
t
255
51 N/mm2
5
130
26 N/mm2
5
510
102 N/mm2
5
Diameter of Rod
Use Eq. (2.23) with P = 90000 N, t = 51 N/mm2
d2
4P
4 90000
2246.89
t
51
d = 47.4 mm
say
47.5 mm
. . . (2.35)
d1 t
P 90000
882.35
c
102
. . . (2.36)
2 90000
d1
882.35 2647
4
51
d1
4 2647
58.1 mm
. . . (2.37)
54
882.35
15.2 mm
58.1
. . . (2.38)
Design of Temporary
Connections
2
( D1 d12 ) 102
4
4 90000
102
or
D1 = 67.1 mm
. . . (2.39)
Length of Collar, a
a is determined from Eq. (2.29). Also see Figure (2.14(e)).
Use s = 26 N/mm2 and d1 = 58.1 mm.
a
or
P
90000
d1 s 58.1 26
a = 19 mm
. . . (2.40)
or
P
90000
2d1 s 2 58.1 26
l = 29.8 mm
. . . (2.41)
P ( D 2 d12 ) ( D d1 ) t t
4
or
4 90000
51
or
D2 19.85 D 4498 0
D 9.925
1
394 17992.3 9.925 67.8
2
D = 77.72 mm
. . . (2.42)
The cotter compresses against the collar of the socket. The area over which
cotter bears (compresses) on cotter is made of two rectangles similar to that
shown in Figure 2.14(c) with outer diameter being D2, the diameter of
collar.
P ( D2 d1 ) t c
90000
58.1 D2
102 15.2
or
D2 = 116.2 mm
. . . (2.43)
55
Machine Design
or
90000
(116.2 58.1) c
2 26
c = 29.8 mm
. . . (2.44)
The thickness f of the bottom of hollow of socket is found from Eq. (2.32)
f
P
d s
90000
4.75 26
= 2.32 mm
Thus, all dimensions of socket, i.e. d1, D1, D2, c and f are determined.
Cotter Width, b
The thickness of cotter has been determined. the cotter fails in shear along
two sections, as shown in Figure 2.14(b) and the strength expressed in
Eq. (2.28).
90000
130 mm
1.75 15.2 26
. . . (2.45)
The length of cotter may 1 mm more than the diameter of spigot collar on
either side. Hence, length of cotter = 136 mm. Hence, width of cotter on
top = 130 + 1.3 = 131.1 mm and at bottom 126 1.3 = 124.7 mm.
The bottom of the spigot should not touch the bottom of the hollow of the
socket. A clearance of 10 mm is desired. Thus, the length of the socket from
rod is c + e + f + b.
= 29.8 + 29.8 + 23.2 + 130 + 10
= 222.8 mm
. . . (2.46)
. . . (2.47)
Design of Temporary
Connections
P D1 d1 d1 P d12
2 6
2 d1 8
P/ d, per unit length
d1
P/2
P/2
D2
D2 d1
D2 d1
58.1
2
6
2 58.1 8
= 1743000 653625
= 1089375 N-mm
Bending stress,
M b
1 3
(130)3 15.2
. , I
b t
2.783 106
I 2
12
12
1.1 106
2.78 10
130
25.72 N/mm2
2
This stress is less than permissible tensile stress, 51 N/mm2 hence, cotter is
safe in bending.
Dimensions Calculated (Figure 2.13)
Spigot
Socket
Cotter
Width = 130 mm
57
Machine Design
Thickness = 15.2 mm
Length = 136 mm
SAQ 2
(a)
(b)
(c)
(d)
(e)
2P
t
2.6 SUMMARY
In this unit, you have learnt the calculations of diameter of a bar. Knuckle joint and
cotter joint have been described in this unit. Knuckle joint is practically used to join two
bars being pulled apart. This joint consists tow rods and pin. A cotter joint is used to
connect rigidly two co-axial rods or bars which are subjected to axial tensile or
compressive forces. It is a temporary fastening.
58
or
2
d 38
4
4 15 104
0.5 104
38
d = 71 mm
. . . (2.48)
Design of Temporary
Connections
Thickness of Eye, t
150 103 c d t 150 71 t
or
150 103
14.1 mm
150 71
. . . (2.49)
Diameter of Eye, D
150 103 t ( D d ) t 77.5 14.1 ( D 71)
or
150 103
71 208.3 mm
77.5 14.1
. . . (2.50)
Diameter of Fork, D
Same
. . . (2.51)
. . . (2.52)
357911 8
6
. . . (2.53)
P d12 d1 t t
4
. . . (2.54)
and
P d1 t c d1 t 1.75 t
. . . (2.55)
d1 t
P
1.75 t
2
P
d1 t
4
1.75
1.57 P 4
d12
t
(e)
d1
2P
t
P D2 d1 d1 P d12
2 6
2 d1 8
59
Machine Design
75 34 34 30000 34
M max 15000
2
8
6
3.57 105 1.275 105
1 2
b t
12
Use b = 43 mm, t = 10 mm
1
(4.3)2 10
12
1
b
2
1 (4.3)2 10 2
3081.7 mm3
12
43
M max
2.3 105
Z
3.08 103
b 74.7 N/mm2
60