m
  

 m


p A \

 
is a temporary fastening and is used to

connect rigidly two co-axial rods or bars which are
subjected to axial tensile or compressive forces
p A cotter is a flat wedge shaped piece of rectangular
cross-section and its width is tapered (either on one
side or both sides) from one end to another for an easy
adjustment
p The cotter is usually made of mild steel or wrought iron

p It is usually used in connecting a piston rod to the

crosshead of a reciprocating steam engine

  

Õollowing are the three commonly used cotter joints

to connect two rods by a cotter:

\
 

\

 



 
\

 
and

  
\

 


  m
  

p In this joint, one end of the rods (say A) is provided with

a socket type of end as shown and the other end of the
other rod (say B) is inserted into a socket
p The end of the rod which goes into a socket is also
called spigot.
p A rectangular hole is made in the socket and spigot.

  m
  

p A \otter is then driven tightly through a hole in order to

make the temporary connection between the two rods.
p The load is usually acting axially, but it changes its
direction and hence the cotter joint must be designed to
carry both the tensile and compressive loads.
p The compressive load is taken up by the collar on the
spigot
 m
 
  m
 


? ô Load carried by the rods; µ ô Diameter of the rods; µ ô

Outside diameter of socket; µ ô Diameter of spigot or
inside diameter of socket; µ ô Outside diameter of spigot
collar; t ô Thickness of spigot collar; µ9 ô Diameter of
socket collar; \ ô Thickness of socket collar; ô Mean
width of cotter; t ô Thickness of cotter; l ô Length of cotter;
a ô Distance from the end of the slot to the end of rod;
m
 
  m
 


ô ?ermissible tensile stress for the rods material%
˜ô ?ermissible shear stress for the cotter material, and
\ ô ?ermissible crushing stress for the cotter material.
p The dimensions for a socket and spigot cotter joint may
be obtained by considering the various modes of failure:
à. Failure of the roµs in tension
The rods may fail in tension due to the tensile load ?÷
Area resisting tearing ô (•

Tearing strength of the rods ô (•
× ıt
Equating this to load (?)% we have ? ô (•
× ıt
Õrom this equation, diameter of the rods (d) may be
determined
 m
 
  m
 

Failure of spigot in tension a\ross the
weakest se\tion (or slot)
6ince the weakest section of the spigot is that
section which has a slot in it for the cotter,
as shown, therefore:
Area resisting tearing of the spigot across the
slot

and tearing strength of the spigot across the

slot

Equating this to load (?)% we have

Õrom this equation, the diameter of spigot (d2)
may be determined
m
 
  m
  

Failure of the roµ or \otter in

\rushing
Æe know that the area that resists
crushing of a rod or cotter ô d2 × t
~ Úrushing strength ô d2 × t × ıc
Equating this to load (?)% we have
? ô d2 × t × ıc
Õrom this equation, the induced crushing
stress may be checked
m
 
  m
  
9Failure of the so\ket in tension a\ross the
slot
The resisting area of the socket across the slot:

~ Tearing strength of the socket across the slot:

Equating this to load (?)% we have:

Õrom this equation, outside diameter of socket

(d1) may be determined
m
 
  m
 

Failure of \otter in shear
Úonsidering the failure of cotter in shear as
shown. 6ince the cotter is in double shear,
therefore shearing area of the cotter
ô 2b × t
and shearing strength of the cotter
ô2b × t × IJ
Equating this to load (?)% we have:
? ô2b × t × IJ
Õrom this equation, width of cotter (b) is
determined
jFailure of so\ket enµ in shearing
6ince the socket end is in double shear, therefore area that
resists shearing of socket collar:
ô2(d4 ± d2)c
and shearing strength of socket collar
ô2(d4 ± d2)c × IJ
Equating this to load (?)% we have:
? ô2(d4 ± d2)c × IJ
Õrom this equation, the thickness of socket collar (c) may be
obtained
MFailure of roµ enµ in shear
6ince the rod end is in double shear, therefore the area
resisting shear of the rod end
ô 2a × d2
and shear strength of the rod end
ô 2a × d2 × IJ
Equating this to load (?)% we have
? ô 2a × d2 × IJ
Õrom this equation, the distance from the end of the slot to
the end of the rod (a) may be obtained.
Úonsidering the failure of the spigot collar in crushing as
shown. The area that resists crushing of the collar:
ô•
  
and crushing strength of the collar:
ô•
  

Equating this to load (?)% we have
? ô •
  

Õrom this equation, the diameter of the spigot collar (d3)
may be obtained
Failure of the spigot \ollar in shearing
Úonsidering the failure of the spigot collar in shearing as
shown. The area that resists shearing of the collar:
ô •d2 × t1
and shearing strength of the collar,
ô •d2 × t1 × IJ
Equating this to load (?) we have
? ô •d2 × t1 × IJ
Õrom this equation, the thickness of spigot collar (t1) may be
obtained÷
Failure of \otter in enµing
In order to find out the bending stress induced, it is
assumed that the load on the cotter in the rod end is
uniformly distributed while in the socket end it varies
from zero at the outer diameter (d4) and maximum at the
inner diameter (d2)% as shown
The maximum bending moment occurs at the centre of the
cotter and is given by:
m
 
  m

  

The section modulus of the cotter:

À ô t × b2/6
~ ¯ending stress induced in the cotter:

This bending stress induced in the cotter should be less

than the allowable bending stress of the cotter.
m
 
  m
  
.The length of cotter (l) is taken as 9µ÷
 The taper in cotter should not exceed 9. In case
the greater taper is required, then a locking device must
be provided.

: 1. Æhen all the parts of the joint are made of steel,
the following proportions in terms of diameter of the rod
(d) are generally adopted:
d1 ô 1÷
d% d2 ô 1÷21d% d3 ô 1÷
d% d4 ô 2÷d% a ô c ô 0÷
d%
b ô 1÷d% l ô d% t ô 0÷1d% t1 ô 0÷
d% e ô 1÷2d÷
Taper of cotter ô 1 in 25
2. If the rod and cotter are made of steel or wrought iron,
then IJ ô 0.8ıt and ıc ô 2ıt may be taken
  
p Design and draw a cotter joint to support a load varying
from 0kN in compression to 0kN in tension÷ The
material used is carbon steel for which the following
allowable stresses may be used÷ The load is applied
statically÷
Tensile stress ô compressive stress ô
0M?a; shear
stress ô 
M?a and crushing stress ô 90M?a÷
:
? ô 0kN ô 0 × 103N; ıt ô
0M?a ô
0N/mm2; IJ ô 
M?a
ô 
N/mm2; ıc ô 90M?a ô 90N/mm2


 :
miameter of the roµs
et d ô miameter of the rods÷
  

Úonsidering the failure of the rod in tension. Æe know that

load (?):

d2 ô 0 × 103/9÷ ô 6 or d ô 2 ÷6 say M
miameter of spigot anµ thi\kness of \otter
et d2 ô miameter of spigot or inside diameter of socket%
t ô Thickness of cotter÷ It may be taken as d2/÷
Úonsidering the failure of spigot in tension across the
weakest section. Æe know that load (?):
  

(d2)2 ô 0 × 103/26÷ ô 1119÷ or d2 ô ÷ say 9

and thickness of cotter, t ô d2/ ô / ô ÷
mm
Now check the induced crushing stress. The load (?):
30 × 103 ô d2 × t × ıc ô  × ÷
× ıc ô 29ıc
~ ıc ô 0 × 103/29 ô 10÷N/mm2
6ince this value of ıc is more than the given value of ıc ô
90N/mm2, therefore the dimensions d2 ô 34mm and t ô
÷
mm are not safe÷
Now find the values of d2 and t by substituting the value
of ıc ô 90N/mm2 in the above expression, i.e÷
  
(d2)2 ô 0 × 103/22÷
ô 1 or d2 ô 6÷
say 9
and t ô d2/ ô 0/ ô 
§utsiµe µiameter of so\ket
et d1 ô Outside diameter of socket÷
Úonsidering the failure of the socket in tension across the
slot. Æe know that load (?):

30 × 103/50 ô 0.7854 (d1)2 ± 12
6÷6 ± 10d1 + 00

or (d1)2 ± 12÷ d1 ± 1
÷6 ô 0
  

ô 49.9 say 
9Æiµth of \otter
et b ô Æidth of cotter÷
Úonsidering the failure of the cotter in shear. 6ince the
cotter is in double shear, therefore load (?):
30 × 103 ô 2b × t × IJ ô 2b × 10 × 
ô 00b
~ b ô 0 × 103/ 00 ô 9 mm
miameter of so\ket \ollar
et d4 ô miameter of socket collar÷
Úonsidering the failure of the socket collar and cotter in
crushing. Æe know that load (?):
  
30 × 103 ô (d4 ± d2)t × ıc ô (d4 ± 0)10 × 90 ô (d4 ± 0)900
~ d4 ± 0 ô 0 × 103/900 ô ÷ or d4 ô ÷ + 0 ô ÷
say j mm
×Thi\kness of so\ket \ollar
et c ô Thickness of socket collar÷
Úonsidering the failure of the socket end in shearing. 6ince
the socket end is in double shear, therefore load (?):
30 × 10 ô 2(d4 ± d2)c × IJ ô 2 (
± 0 )c × 
ô 2
0c
~ c ô 0 × 103/2
0 ô à
mm
jmistan\e from the enµ of the slot to the enµ of the
roµ
et a ô mistance from the end of slot to the end of the rod.
  
Úonsidering the failure of the rod end in shear. 6ince the
rod end is in double shear, therefore load (?):
30 × 103 ô 2a × d2 × IJ ô 2a × 0 × 
ô 200a
~ a ô 0 × 103/200 ô 10÷ say ààmm
Mmiameter of spigot \ollar
et d3 ô miameter of spigot collar÷
Úonsidering the failure of spigot collar in crushing. Æe
know that load (?):

(d3)2 ô 2 + (0)2 ô 202 or d3 ô 9 mm

  

Thi\kness of spigot \ollar

et t1 ô Thickness of spigot collar÷
Úonsidering the failure of spigot collar in shearing.
Æe know that load (?):
30 × 103 ô •µ
 • 
 00t1
~ t1 ô 0 × 103/00 ô 6÷ say Mmm

 \

l ) is taken as 4d.
~ l ô  d ô  × 2 ô àà
mm

  e is taken as 1.2 d.
~ e ô 1÷2 × 2 ô ÷6 say 9mm

  m  

p In this type of joint, a sleeve or muff is used over the two

rods and then two cotters (one on each rod end) are
inserted in the holes provided for them in the sleeve and
rods
p The clearance is so adjusted that when the cotters are
driven in, the two rods come closer to each other thus
making the joint tight

  m  

The various proportions for the sleeve and cotter joint in

terms of the diameter of rod (d ) are as follows:
Outside diameter of sleeve: d1 ô 2÷
d
miameter of enlarged end of rod:
d2 ô Inside diameter of sleeve ô 1÷2
d
ength of sleeve, L ô d

  m  

Thickness of cotter, t ô d2/ or 0÷1d

Æidth of cotter, b ô 1÷2
d
ength of cotter, l ô d
mistance of the rod end (c) from its end to the cotter
hole ô 1.25d
m
 
  m  

et ? ô oad carried by the rods% µ ô miameter of the rods%

µ ô Outside diameter of sleeve% µ
ô miameter of the
enlarged end of rod% t ô Thickness of cotter% l ô ength of
cotter% ô Æidth of cotter% a ô mistance of the rod end
from the beginning to the cotter hole (inside the sleeve
end), \ ô mistance of the rod end from its end to the
cotter hole; t % ˜ and \ ô ?ermissible tensile, shear and
crushing stresses, respectively% for the material of the
rods and cotter.
m
 
  m  

p The dimensions for a sleeve and cotter joint may be

obtained by considering the various modes of failure as
discussed below:
Failure of the roµs in tension
The rods may fail in tension due to the tensile load ?÷
Area resisting tearing ô •
× 
~ Tearing strength of the rods ô •
×  × ıt
Equating this to load (?)% we have
? ô •
×  × ıt
Õrom this equation, diameter of the rods (d) may be
obtained
m
 
  m  
Failure of the roµ in tension a\ross the weakest
se\tion (i.e. slot)
6ince the weakest section is that section of the rod which
has a slot in it for the cotter, therefore, area resisting
tearing of the rod across the slot:
•
    × t
and tearing strength of the rod across the slot:

Equating this to load (?)% we have

Õrom this equation, the diameter of enlarged end of the

rod (d2) may be obtained.

The thickness of cotter is usually taken as d2/
 m
 
  m  
Failure of the roµ or \otter in \rushing
Æe know that the area that resists crushing of a
rod or cotter ô d2 × t
~ Úrushing strength ô d2 × t × ıc
Equating this to load (?)% we have ? ô d2 × t × ıc
Õrom this equation, the induced crushing stress
may be checked.
9Failure of sleeve in tension a\ross the slot
Æe know that the resisting area of sleeve across
the slot

~ Tearing strength of the sleeve across the slot:

m
 
  m  

Equating this to load (?)% we have

Õrom this equation, the outside diameter of sleeve (d1)

may be obtained÷
Failure of \otter in shear
6ince the cotter is in double shear, therefore shearing
area of the cotter ô 2b × t
and shear strength of the cotter ô 2b × t × IJ
Equating this to load (?)% we have: ? ô 2b × t × IJ
Õrom this equation, width of cotter (b) may be
determined.
×Failure of roµ enµ in shear
6ince the rod end is in double shear, therefore area
resisting shear of the rod end
ô 2a × d2
and shear strength of the rod end
ô 2a × d2 × IJ
Equating this to load (?)% we have
? ô 2a × d2 × IJ
Õrom this equation, distance (a) may be determined÷
jFailure of sleeve enµ in shear
6ince the sleeve end is in double shear, therefore the
area resisting shear of the sleeve end
ô 2(d1 ± d2)c
and shear strength of the sleeve end
ô 2(d1 ± d2)c × IJ
Equating this to load (?)% we have
? ô 2(d1 ± d2)c × IJ
Õrom this equation, distance (c) may be determined
  
-> mo yourself
 m  

p A gib and cotter joint is usually used in strap end (or big
end) of a connecting rod as shown
p In such cases, when the cotter alone (i÷e÷ without gib) is
driven, the friction between its ends and the inside of the
slots in the strap tends to cause the sides of the strap to
spring open (or spread) outwards as shown
p In order to prevent this, gibs as shown% are used which
hold together the ends of the strap.
 m  

p Poreover, gibs provide a larger bearing surface for the

cotter to slide on, due to the increased holding power
p Thus, the tendency of cotter to slacken back owing to
friction is considerably decreased
 m
    m   
 
m     m

p Úonsider a gib and cotter joint

for strap end (or big end) of a
connecting rod as shown
et ? ô Paximum thrust or pull in
the connecting rod%
µ ô miameter of the adjacent end
of the round part of the rod%
¯ ô Æidth of the strap%
¯ ô Total width of gib and cotter,
t ô Thickness of cotter,
t ô Thickness of the strap at the
thinnest part%
m
    m   

  m     m

ô ?ermissible tensile stress for the material of the
strap, and
˜ ô ?ermissible shear stress for the material of the
cotter and gib.
The width of strap (B1) is generally taken equal to the
diameter of the adjacent end of the round part of
the rod (d)÷ The other dimensions may be fixed as
follows:
Thickness of cotter,
Thickness of gib ô Thickness of cotter (t)
Height (t2) and length of gib head (l3) ô Thickness of
cotter (t)
 
m
   m 

Failure of the strap in tension
Assuming that no hole is provided
for lubrication, the area that
resists the failure of the strap due
to tearing ô 2 × B1 × t1
~ Tearing strength of the strap
ô 2B1 × t1 × ıt
Equating this to the load (?)% we get
? ô 2B1 × t1 × ıt
Õrom this equation, the thickness of
the strap at the thinnest part (t1)
may be obtained.
The thickness of the strap at the
cotter (t3) is increased such that
the area of cross-section of the
strap at the cotter hole is not
less than the area of the strap
at the thinnest part.
In other words:
2t3(B1 ± t) ô 2t1 × B1
Õrom this expression, the value of
t3 may be obtained
Failure of the gi anµ \otter
in shearing
6ince the gib and cotter are in
double shear, therefore area
resisting failure
ô 2B × t
and resisting strength ô 2B × t ×
IJ
Equating this to the load (?)% we
get
? ô 2B × t × IJ
Õrom this equation, the total
width of gib and cotter (B)
may be obtained÷
In the joint, as shown, one gib is
used, the proportions of which
are:
Æidth of gib,b1 ô0÷

B; and width
of cotter% b ô 0÷
B
The other dimensions may be
fixed as follows:
Thickness of the strap at the
crown:
t4 ô 1÷1
t1 to 1÷
t1
l1 ô 2t1; and l2 ô 2÷
t1
  
p The big end of a connecting rod is subjected to a
maximum load of
0kN÷ The diameter of the circular part
of the rod adjacent to the strap end is
mm÷ Design the
joint% assuming permissible tensile stress for the material
of the strap as 2
M?a and permissible shear stress for
the material of cotter and gib as 20M?a÷
: ? ô
0kN ô
0 × 103N; d ô
mm; ıt ô 2
M?a ô
2
N/mm2; IJ ô 20M?a ô 20N/mm2


 :
Æiµth of the strap
et B1 ô Æidth of the strap÷
  
The width of the strap is generally made equal to the
diameter of the adjacent end of the round part of the rod
(d)÷
~ B1 ô d ô j
Other dimensions are fixed as follows:
Thickness of the cotter ô t ô B1/ ô
/ ô 18.75 say

Thickness of gib ô Thickness of cotter ô 
Height (t2) and length of gib head (l3) ô Thickness of cotter
ô 
Thi\kness of the strap at the thinnest part
et t1 ô Thickness of the strap at the thinnest part÷
  
Úonsidering the failure of the strap in tension. Æe know
that load (?):
50 × 103 ô 2B1 × t1 × ıt ô 2 ×
× t1 × 2
ô 
0t1
~ t1 ô
0 × 103/
0 ô 1÷ say 
Thi\kness of the strap at the \otter
et t3 ô Thickness of the strap at the cotter÷
The thickness of the strap at the cotter is increased such
that the area of the cross-section of the strap at the
cotter hole is not less than the area of the strap at the
thinnest part. In other words:
2t3(B1 ± t) ô 2t1 × B1
2t3(
± 20) ô 2 × 1
×
or 110t3 ô 22
0
~ t3 ô 22
0/110 ô 20÷
say 
  
9Total wiµth of gi anµ \otter
et B ô Total width of gib and cotter÷
Úonsidering the failure of gib and cotter in double shear.
Æe know that load (?):
50 × 103 ô 2B × t × IJ ô 2B × 20 × 20 ô 00B
~ B ô
0 × 10/00 ô 62÷
say ×
6ince one gib is used, therefore width of gib:
b1 ô 0÷

B ô 0÷

× 6
ô 
÷
say ×
and width of cotter, b ô 0÷
B ô 0÷
× 6
ô 29÷2
say

The other dimensions are fixed as follows:
t4 ô 1÷2
t1 ô 1÷2
× 1
ô 1÷
say 
l1 ô 2t1 ô 2 × 1
ô 
and l2 ô 2÷
t1 ô 2÷
× 1
ô  ÷
say 9
x  
Numerical ?roblems  9(Úhapter ; Khurmi ¯ook)