HARDWARES OF VEHICLE

-NARESH KUMAR
-SE/VEH
 TOTAL HARDWARE
ITEMS( VEH.)
• TOTAL 283 ITEMS
• 113 BOLTS
• 59 NUTS
• 49 WASHERS
• 34 SCREWS
• 16 STUDS,4 DOWELS AND 4 RIVETS
• 1 PIN
 BOLTS
• A BOLT IS AN EXTERNALLY
THREADED FASTENER DESIGNED
FOR INSERTION THROUGH HOLES IN
ASSEMBLED PARTS.
• IT IS NORMALLY INTENDED TO BE
TIGHTENED OR RELEASED BY
TORQUING A NUT
 BOLTED JOINT
• ADVANTAGE
– CONVENIENT TO ASSEMBLE/DISASSEMBLE
– WIDE RANGE OF APPLICATION
– CHEAP
– RELIABILITY IN OPERATION
– DOES NOT CAUSE DAMAGE TO PART OF
FASTENER DURING ASSEMBLY/DISASSEMBLY
• DISADVANTAGE
– STRESS CONCENTRATED ON THREADED
PORTION
 TYPES OF BOLTS USED IN VEH

• COMMON STANDARD BOLTS

– HEX HEAD BOLTS
– ROUND HEAD SQUARE NECK BOLTS
– BOLT ASM
 SIZES OF BOLTS USED IN VEH
SIZES OF BOLTS LENGTH OF BOLTS
1/4 .38 TO 1.5
5/16 .62 TO 5.5
3/8 .50 TO 5
1/2 .75 TO 5
5/8 1 TO 5.25
3/4 1.75 TO 7.5
1 1.5 TO 5
1 1/2 4.25 TO 9
 NO OF THREAD PER INCH
BOLTS SIZES UNC UNF
1/4 20 (9 bolts) 28 (1 bolt)

5/16 18 (9 bolts) 24
3/8 16 (25 bolts) 24
1/2 13 (17 bolts) 20 (3 bolts)
5/8 11 (12 bolts) 18
3/4 10 (16 bolts) 16 (1 bolt)
1 8 (05 bolts) 12
CHEMICAL COMPOSITION FOR
BOLTS
GM SAE MATERIAL CARBON S P B
NO NO

MIN. MAX. MAX. MAX MAX.

GM 5 MEDIUM 0.28 0.55 0.058 0.048

280M CARBON STEEL

GM 8 MEDIUM 0.28 0.55 0.045 0.040 0.003

300M CARBON ALLOY
STEEL
MECHANICAL PROPERTIES FOR
BOLTS USED IN VEH.
GM SIZES IN TENSILE ELONGATION HARDNESS
NO INCH STRENGTH IN 2 INCH ROCKWELL
MN.(PSI) (min %)
GM NO 6 THRU 1 120000 14 25 - 34
280M

OVER 1 TO 1- 105000 14 19 - 30
1/2

GM 1/4 TO 1-1/2 150000 12 33 - 39

300M
 SCREWS
• A SCREW IS AN EXTERNALLY THREADED
FASTENER DESIGNED FOR INSERTION
THROUGH HOLES IN ASSEMBLED PARTS,
WITH A PREFORMED INTERNAL THREAD OR
FORMING ITS OWN THREAD.
• IT IS NORMALLY INTENDED TO BE
TIGHTENED OR RELEASED BY TORQUING A
HEAD.
 THREAD FORMS
• COMMON THREADS
– UNIFIED INCH SERIES
• UN (DESIGNATED UN i.e. UNIFIED NATIONAL)
• UNR (ROUNDED ROOT ON EXTERNAL THREAD)
– METRIC SERIES
• M SERIES
• MJ SERIES (ROUNDED ROOT ON EXTERNAL THREAD
AND A LARGE MINOR DIA. OF BOTH INTERNAL &
EXTERNAL THREAD
– UNR & MJ FOR HIGH FATIGUE STRENGTH &
AEROSPACE APPLICATION
 THREAD FORMS
• BOTH THE UNIFIED AND METRIC M SERIES
USE THE SAME GEOMETRY
• UNIFIED SERIES
– STANDARDIZED CONSTANT-PITCH CONSIST OF
4, 6,8,12,16,20,28, AND 32 THREADS PER INCH
– UN A FOR EXTERNAL THREAD
– UN B FOR INTERNAL THREAD
– 1A, 2A, AND 3A FIT CLASS FOR EXTERNAL
– 1B, 2B, AND 3B FIT CLASS FOR INTERNAL
 THREAD
• DEFINITIONS
– MAJOR DIA. – LARGEST DIA OF AN EXTERNAL
OR INTERNAL THREAD. ALSO KNOWN AS
NOMINAL DIA.
– MINOR DIA – SMALLEST DIA.
– PITCH DIA – DIA. OF IMAGINARY CYLINDER THE
SURFACE OF WHICH WOULD PASS THROUGH
THE THREAD AT SUCH POINT AS TO MAKE
EQUAL THE WIDTH OF THREAD AND WIDTH OF
THE SPACE BETWEEN THE THREAD. ALSO
CALLED EFFECTIVE DIA
 THREAD
• DEFINITIONS
– PITCH – DISTANCE FROM A POINT ON ONE
THREAD TO THE CORRESPONDING POINT ON
THE NEXT. THIS IS MEASURED IN AN AXIAL
DIRECTION.
 THREAD
• 1A - EXTERNAL, LOOSE FIT FOR EASY
ASSEMBLY AND NON CRITICAL USES
• 2A – EXTERNAL, GENERAL APPLICATIONS
WHERE PLATING MAY BE APPLIED
• 3A – EXTERNAL, TIGHT FIT USED FOR GREAT
ACCURACY; NO PLATING ALLOWANCE
PROVIDED
• TYPICAL DRAWING CALLOUT- ¼-20UNC-2A
FOR A BOLT/SCREW
 THREAD
• 1B - INTERNAL, LOOSE FIT FOR EASY
ASSEMBLY AND NON CRITICAL USES
• 2B – INTERNAL, GENERAL APPLICATIONS
WHERE PLATING MAY BE APPLIED
• 3B – INTERNAL, TIGHT FIT USED FOR GREAT
ACCURACY; NO PLATING ALLOWANCE
PROVIDED
• TYPICAL DRAWING CALLOUT- ¼-20UNC-2B
FOR A TAPPED HOLE
 THREAD FORMS
• OTHER COMMON THREADS
– ACME
– STUB ACME
– WHITWORTH
– BUTTRESS
– NPT
– BSPT
– API
– TR DIN 103
– RD DIN 405
 BOLTS

The
Label1 bolt has

bolt

bolt
 GRADE MARKING
• SAE AND ASTM HAVE SPECIFIED HOW THE
HEAD OF BOLTS ARE TO BE MARKED FOR
IDENTIFICATION
 NUT

• LOCKING DEVICE WITH BOLT ACTUALLY

DOING THE HOLDING
• A NUT SHOULD BE OF A HIGHER OR
EQUIVALNET CLASS OF BOLT USED
 TYPE OF NUTS

– HEX NUT
– SQUARE NUT
– NYLOCK NUT
– CLT HEX LOCK NUT
– WELD NUT
– NUT RETAINER
 NUT
• GEOMETRIC AND MECHANICAL PROPERTIES
OF NUTS ARE DESIGNED TO PROVIDE A
HIGH DEGREE OF RESISTANCE TO
STRIPPING WHEN INADVERTENTLY OVER-
TORQUED
• IF STRIPPING IS A PROBLEM, NUTS OF NEXT
HIGHER PROPERTY CLASS IS TO BE USED.
 PLAIN WASHER
• TO DISTRIBUTE THE LOAD
• GENERAL PURPOSE
• FERROUS, NON-FERROUS, PLASTIC OR
OTHER MATERIAL
• CONCENTRICITY – WITHIN INSIDE DIA.
TOLERANCE
• FLATNESS - .005” FOR OD UPTO 0.875”, 0.010”
FOR LARGER OD
 HELICAL SPRING WASHER
• GENERAL INDUSTRIAL APLICATION
• CARBON STEEL, CORROSION RESISTANT
STEEL, TYPES 302 & 305; ALUMINUM-ZINC
ALLOY; PHOSPHO-BRONZE; SILICON-
BRONZE AND K-MONEL
• ANSI–REGULAR, HEAVY OR EXTRA DUTY
SERIES
 HELICAL SPRING WASHER
• FUNCTION: -
– PROVIDE GOOD BOLT TENSION PER UNIT OF
APPLIED TORQUE FOR TIGHT ASSEMBLY
– PROVIDE HARDENED BEARING SURFACES TO
CREATE UNIFORM TORQUE CONTROL
– PROVIDE UNIFORM LOAD DISTRIBUTION
THROUGH CONTROLLED RADII
– PROVIDE PROTECTION AGAINST LOOSENESS
RESULTING FROM VIBRATION OR CORROSION
 HELICAL SPRING WASHER
• QUALITY ASPECTS: -
– FLAT SURFACE AND INNER & OUTER DIA.
SHOULD BE SMOOTH FREE FROM KNURLING,
SERRATIONS, DIE MARKS, SCRATCHES
– FREE FROM BURRS, RUST, PIT MARKS ETC.THAT
MIGHT AFFECT SERVICIABILITY
– CLEARANCE AND ANGLES OF CUT ENDS
SHOULD BE IN SUCH A DEGREE THAT THEY DO
NOT CAUSE LAPPING WHEN THEY ARE
COMPLETELY COMPRESSED AND SHALL NOT BE
LIABLE TO TANGLE IN FREE CONDITION.
 HELICAL SPRING WASHER
• TWIST TEST: -
– SPRING LOCK WASHER IS TWISTED THROUGH
AN ANGLE OF 90 DEG. THE WASHER SHOULD
NOT SHOW SIGNS OF FAILURES.
 TOOTH LOCK WASHER
• FUNCTION: -
– PROVIDE LOCKING TO BOLTS OR NUTS
– INCREASE FRICTION BETWEEN FASTENER AND
THE ASSEMBLY
– INTERNAL TOOTH
– EXTERNAL TOOTH
 METHODS OF TIGHTENING
• TORQUE CONTROL TIGHTENING –
– Controlling the torque which a fastener is tightened to is the most
popular means of controlling preload.
– The nominal torque necessary to tighten the bolt to a given preload
can be determined either from tables, or, by calculation using a
relationship between torque and the resulting bolt tension.
 METHODS OF TIGHTENING
• ANGLE CONTROLLED TIGHTENING –
– A tightening procedure in which a fastener is first tightened by a
pre-selected torque (called the snug torque) so that the clamped
surfaces are pulled together, and then is further tightened by giving
the nut an additional measured rotation.
– Frequently bolts are tightened beyond their yield point by this
method in order to ensure that a precise preload is achieved.
– Bolts of short length can be elongated too much by this method
and the bolt material must be sufficiently ductile to cater for the
plastic deformation involved.
– Because of the bolt being tightened beyond yield, its re-use is
limited.
 MOST COMMON FAILURE
ORIGINS
• TRANSITION FROM THREAD TO SHANK
• BOLT THREAD ROOT IMMEDIATELY
ADJACENT TO THE EDGE OF THE NUT ON
THE WASHER SIDE –STRESS
CONCENTRATION MAXIMUM –BOLT
ELONGATES AS NUT TIGHTENED-MAXIMUM
LOAD ON THREADS NEAR BEARING FACE
OF NUT
 MOST COMMON FAILURE
ORIGINS
• ROLLED THREADS PREFERRED-
– EVEN LOAD DISTRIBUTION
– CONTINUITY OF GRAIN FLOW
– FOLLOWING CONTOUR LINES
• ROLLING TO FOLLOW INTERMEDIATE
STAGE HEAT TREATMENT.
 MOST COMMON FAILURE
ORIGINS
• HEAD TO SHANK FILLET-
– STRESS RAISER DUE TO CHANGE IN CROSS
SECTION-GRADUAL
• HEAD TO BE FORMED BY FORGING-
– SMOOTH UNBROKEN FIBRE FLOW THROUGH
HEAD TO SHANK FILLET
– MINIMIZE STRESS RAISERS
 TYPES OF FAILURES
• FATIGUE FAILURES-
– INSUFFICIENT TIGHTENING OF FASTENER
– FLEXING
– SUBSEQUENT FATIGUE FAILURE.
• POINTS OF STRESS CONC.-
– ABPRUT CHANGE IN SECTIONS
– DEEP SCRATCH
– NOTCH
– INCLUSION
 TYPES OF FAILURES
• FRETTING FAILURE-
– SMALL RELATIVE MOVEMENT
– BOLTED MACHINE PARTS
– VIBRATION MOST SUSCEPTABLE
– MINIMIZE CLEARANCES IN BOLT HOLES
 TYPES OF FAILURES
• CORROSION FAILURE
– ATMOSHERIC
• AIR
• LIQUID-IMMERSION-WATERLINE AREAS,
• CREVICE-DIRT,
– GALVANIC
• DISSIMILAR METALS
– STRESS CORROSION-
• CORROSIVE ENV.IN CONJUNCTION WITH SUSTAINED
TENSILE STRESS ABOVE THRESHOLD VALUE
 TYPES OF FAILURES
• HYDROGEN EMBRITTELMENT-
– DUE TO H2 ABSORBTION/DIFFUSION IN STEEL
– AT THE TIME OF ELECTRODEPOSIT COATINGS.
– EMBRITTLES THE STRUCTURE
– POST PLATING DE-EMBRITTLEMENT BAKING TO
BE CARRIEDOUT.
FATIGUE FAILURE AT THREADS
 BRITTLE FAILURE AT
THREADS
FRACTURE HERRING BONE
• Cr MORE,Ni LESS
• DENDRITE ,PITTING/PIPING
• RUPTURE UNDER LOAD.-BRITTLE
FAILURE.
BRITTLE FAILURE AT
THREADS
 Procurement of Veh. Hardware
• First time dlw has procure the Veh Hardware in a
Kit (233 items) from M/s LPS Bossard in 2001(kit
value- Rs 320718-/
• In 2005 -2006 dlw has procure individual
itemwise from M/s Pooja Forge,M/s LPS
Bossard,M/s Sundeep Eng.
• In 2006 we had made 34 kits stage wise like Cab
equip.,Deck equip.,Bogie, Longhood etc.
• In 2007 dlw has procure 277 hardware items in a
kit from M/s LPS Bossard(kit value- Rs 177302-/
 DETAILS
• TOTAL HARDWARE COSTOF VEH. FOR
LOCO – APPROX. Rs.177302/- (ABOUT
0.17%)
• COMMON FAILURE MODES
– THREAD LENGTH OVERSIZE
– THREAD GEOMETRY NON-CONFORMANCE
– METALLURGICAL FAILURE
 SOURCES OF SUPPLY
• MAJOR BOLT SOURCES
– POOJA FORGE
– STEEL & HARDWARE-PFL
– BIMCO
– PIONEER NUTS & BOLTS
– LPS
– SUNDARAM
– BOLTMASTER
– MICRON – NEW SOURCE
– SREE PAVITHRA – NEW SOURCE
 SOURCES OF SUPPLY
• MAJOR NUT SOURCES
– SUNDEEP ENGINEERING
– PARAMOUNT
• MAJOR WASHER SOURCES
– SPRING LOCK WASHER
 Action plan proposed
• TO BE PROCURED THROUGH LT PANEL
ONLY
– PANEL TO BE FORMED BY AUDITING
NEWSOURCE & REAUDITING OLD SOURCES
– BULKING OF FASTENERS FOR A MINIMUM
PERIOD OF 2 YEARS
– REDUCTION IN VARIETY (>250 TYPES OF
FASTENERS)