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Unit-2-60 TEMPORARY CONNECTIONS PDF
Unit-2-60 TEMPORARY CONNECTIONS PDF
CONNECTIONS
Structure
2.1 Introduction
Objectives
2.2 Stresses
2.3 Calculation of Diameter of a Bar
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
correlate stress and load,
learn how rods can be connected, and
know types of joints, and causes of their failures.
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 Three stresses described above are illustrated in Figure 2.1.
P P
A
A AS
P= A
P= A
P (a) (b)
AC
P=c Ac
(c)
Figure 2.1 : Three Types of Stresses
(a) Force P causing tensile stress on cross-section of a rectangular bar.
(b) Force P causing shearing stress on a rectangular section.
(c) Force P acting on a circular bar, presses it against a rectangular plate,
causing compressive or bearing stress on circular section of the bar.
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
P
c . . . (2.1)
Projected area of cylinder
B
P
Plate 1
Plate 2
AS P
P P P 2
P l
t P
2
B
38 t = Thickness of plate.
Also note that the two forces P, acting opposite to each other on pin as shown in Design of Temporary
Connections
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
. . . (2.2)
As
2
and As 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
. . . (2.3)
A
A (l d ) t
l = Width of the plate.
P 10,000
t or 20 . . . (2.4)
(l d ) t (100 d ) t
P 4 10,000
s or 10 . . . (2.5)
2 d2
d
4
P 10,000
c or 22 . . . (2.6)
dt dt
Since in (2.4) and (2.6) there are two unknown, use (2.5) to find
4000
d2
d = 36.25 mm . . . (2.7)
Use this value of d in (2.4) so that
10,000
20
(100 36.25) t
10,000
t 7.8 mm . . . (2.8)
64 20
So both d and t have been found. But we should check that c is not more than
22 N/mm2. From (2.5)
10,000
c 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.
10,000
Check t 13.5 N/mm2 (Safe)
(100 43) 13
10,000
Check s 6.9 N/mm2 (Safe)
(43)2
4
Thus, d = 43 mm and t = 13 mm are finally selected dimension. The example
shows how design problems reed reiteration.
Example 2.2
Two steel rods are proposed to be connected by a pin in the same way as plates.
The force of tension to be carried by the joint is 8000 N. The joint is made by
removing metal from rod ends to create flat surfaces of depth of half the diameter
of the rod as shown in Figure 2.3. A hole is drilled in the centre of the flat in each
rod, the two parts are matched and a pin is passed through the hole. Find diameters
of rod and pin. The permissible stresses in tension, shear and crushing are :
Solution
Recognise following ways in which joint can fail.
(a) Shearing of pin
(b) Crushing of pin against hole surface
(c) Tensile failure of bar along section through pin.
Shearing of Pin
2
P d s . . . (2.9)
4
2
8000 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
2. Eye
1. Fork
Rod
3. Pin
4
5
1
Taper Pin
3
Sq. Sec.
2
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.
4d 4.5 d
0.4 d
1.5 d
0.6 d
0.75d
d
1.1 d
1.1d
d
3d
d
P P
0.75d
1.2 d
2d Split Pin
Octagon
D d P
P
Section BB
B
Figure 2.8 : The Eye of Knuckle Joint
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)
P
P D
B
t1 t t1
Figure 2.9 : The Fork of Knuckle Joint
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 t1 t t1
unit length Fork Eye 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
is equal to t 1 . The BM at the middle will be due to at a distance
3 2
t t
of 1 and due to udl over a length of t.
2 3
2
P t t1 P t
M max
2 2 3 t 8
For circular section beam, bending stress
32M t t 1
32 P 1 . . . (2.15)
d 3
8 6 d3
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
First find permissible stress =
Factor of safety
Permissible stress in tension for rod, eye and fork
420
t 84 N/mm2
5
Permissible shearing stress in pin
390
s 78 N/mm2
5
Permissible compressive stress in pin
720
c 144 N/mm2
5
Permissible compressive stress in eye and fork
c t 84 N/mm2
P = 70,000 N
Pin Diameter, d
2
The area of shearing d
4
The pin is in double shear
2
P 1.75 s d
4
2
or 70000 1.75 78 d
4
70000
or d2 652.9
107.2
d = 25.6 mm . . . (2.16)
Thickness of the Eye, t
t is determined by considering crushing. Note that while pin is under
compression from cylindrical surface of hole in the eye, opposite of it is
also true, i.e. the cylindrical surface is under compression against pin. The
surface which has lesser compressive strength is likely to fail. We have
found that permissible compressive stress for pin is 144 N/mm2, the same
for eye is 84 N/mm2. Hence, crushing of eye is to be considered.
P c dt
or 70000 84 25.6 t
t = 32.6 mm . . . (2.17)
Diameter of Eye, D
See Figure 2.8, the section carries tensile stress.
P t ( D d ) t
46
or 70000 84 ( D 25.6) 32.6 Design of Temporary
Connections
70000
or D 25.6
84 32.6
D = 51.2 mm . . . (2.18)
Diameter of the fork will be 51.2 mm
32.6
Thickness of fork will be 16.3 mm . . . (2.19)
2
Diameter of the Rod, D1
2
P D1 t
4
70000 84 D12
4
D1 = 32.6 mm . . . (2.20)
Check for bending stress in the pin.
Eq. (2.15),
t t 1
32 P 1
8 6 d3
32.6 32.6 1
32 70000
8 12 (25.6)3
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.
32.6 32.6 1
i.e. 84 32 70000
8 12 d 3
1
d 3 713014 (4.075 2.72) 57023.7
84
d = 38.5 mm . . . (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
D 38.5
84 32.6
or D = 64.1 mm . . . (2.22)
Thus, the dimensions of the joints are :
47
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) What is a temporary joint?
(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) How would you calculate the width of fork in knuckle joint?
(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
P t
b
P
P
48 Figure 2.11
Design of Temporary
Cotter Slot Connections
Collar (D2)
Slot Rod
Collar (D1)
Rod (d)
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 c e f
1 1
P b P
D2 D1 d d d1 D
2 2
(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 . . . (2.24)
4
t
d1
(b)
Figure 2.14
50
(c) Failure of socket under tension or compression. Note from Design of Temporary
Connections
Figures 2.12 and 2.13 that socket is a hollow cylinder. Its inner
diameter is same as outer diameter, d1 of spigot. The weakest section
is where slot is made.
P ( D 2 d12 ) ( D d1 ) t t . . . (2.25)
4
t
D 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)
(d)
Figure 2.14
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)
This equation will help determine c.
P/2
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.
P 2 d1 e s . . . (2.31)
52
In both Eqs. (2.30) and (2.31) 2 can be replaced by 1.75 as it is the Design of Temporary
Connections
case of double shear.
(h) The thickness of the end of socket where rod begins is shown as f in
Figure 2.14.
There is a likelihood that if force is compressive the rod may pierce
into the end of the socket. The resistance will be offered by shearing
stress acting on cylindrical surface of diameter d and length f.
P d f s . . . (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
6P
d1
t
2 P 3P
or t d1 P
4 2 2
53
Machine Design 6P
d1 . . . (2.33)
t
650
Note that t 130 MPa or N/mm2
5
6 40000
d1 24.24 mm . . . (2.33)
130
Thickness of the cotter is found from 2nd equation by putting d1 = 24.24 mm.
40000 24.24 t 2 130
40000
t 6.3 mm . . . (2.34)
24.24 260
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
255
t 51 N/mm2
5
130
s 26 N/mm2
5
510
c 102 N/mm2
5
Diameter of Rod
Use Eq. (2.23) with P = 90000 N, t = 51 N/mm2
4P 4 90000
d2 2246.89
t 51
d = 47.4 mm say 47.5 mm . . . (2.35)
Spigot Diameter d1 and Thickness of Cotter t and Collar Dimensions
In Eq. (2.27) put c = 102 N/mm2
P 90000
i.e. d1 t 882.35 . . . (2.36)
c 102
Use this value of d1 t in Eq. (2.24) to obtain
90000 d12 882.35 51
4
2 90000
d1 882.35 2647
4 51
4 2647
d1 58.1 mm . . . (2.37)
Use the value of d1 in Eq. (2.36) to obtain
882.35
t 15.2 mm . . . (2.38)
58.1
54
Diameter of Collar of Spigot, D1 Design of Temporary
Connections
Use Eq, (2.28) with c = 102 N/mm2
2
90000 ( D1 d12 ) 102
4
4 90000
(58.1) D12 44.99
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.
P 90000
a
d1 s 58.1 26
or a = 19 mm . . . (2.40)
Use Eq. (2.32) to obtain the length of tail of spigot
P 90000
e
2d1 s 2 58.1 26
or l = 29.8 mm . . . (2.41)
Thus, all dimensions, i.e. d1, D, t and a of spigot are determined.
Socket Rod and Socket Dimension
There is no need to calculate diameter of rod of socket. It is same as
diameter of spigot rod, d = 47.5 mm
The outside diameter of socket D is calculated from Eq. (2.25). Also see
Figure 2.14(c).
P ( D 2 d12 ) ( D d1 ) t t
4
Use d1 = 58.1 mm, t = 15.2 mm.
90000 ( D2 58.12 ) ( D 58.1) 15.2 51
4
4 90000
or D2 3375.6 19.35 D 1124.42
51
or D2 19.85 D 4498 0
1
D 9.925 394 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 The length of the collar, c, is found by considering penetration of cotter into
collar of socket as shown in Figure 2.14(f) and expressed in Eq. (2.30)
P 2 ( D2 d1 ) c s
90000
or (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)
P
f
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 1.75 b 15.2 26
90000
b 130 mm . . . (2.45)
1.75 15.2 26
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)
The spigot part of the joint has length
=a+c+b+e
= 19 + 29.8 + 130 + 29.8
= 208.6 mm . . . (2.47)
It is difficult to imagine if cotter will bend like a beam, although it has
already been assumed to act as beam (Figure 2.14(d)). The force as shown
to act uniformly distributed between 1 and 2 are not exactly correct because
cotter is taper on right hand side. However, we take the distribution as
shown in Figure 2.14(d) and calculate bending stress with assumptions
similar to those made for pin in case of knuckle joint. So draw the beam in
Figure 2.15.
The uniformly distributed force is acting over a length of d1 (the diameter of
spigot). The cotter is supported against inside of collar of diameter D2.
P D d1
Hence, force is distributed over length of 1 on two sides of the
2 2
56
cotter. This distribution is assumed as triangular. Therefore, it will act at a Design of Temporary
Connections
1 D d1
distance of 1 from the point where d1 begins. Hence, maximum
3 2
bending moment occurs at the central section of the cotter, where width = b
and thickness = t.
P D1 d1 d1 P d12
M max
2 6 2 d1 8
d1
P/2 P/2
D2
D2 d1 D2 d1
2 2
= 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
This stress is less than permissible tensile stress, 51 N/mm2 hence, cotter is
safe in bending.
Dimensions Calculated (Figure 2.13)
Spigot : Diameter of rod, d = 47.4 mm
Diameter of spigot collar, D1 = 67.1 mm
Width of collar, a = 19 mm
Diameter of spigot, d1 = 58.1 mm
Length of collar, 208.6 mm
Socket : Diameter of socket, D2 = 116.2 mm
Width of collar, c = 29.8 mm
Outside diameter of socket, D = 77.72 mm
Length of socket = 22.8 mm
Inside diameter of socket, d1 = 58.1 mm
Cotter : Width = 130 mm 57
Machine Design Thickness = 15.2 mm
Length = 136 mm
SAQ 2
(a) Describe three parts of cotter joint and sketch them separately.
(b) What materials will be used in making cotter joint?
(c) To what stresses spigot is subjected? Draw the areas of sections of spigot on
which tensile and compressive stresses act.
(d) If the permissible compressive stress is 1.75 of the permissible tensile
stress, then by equating tensile strength and crushing strength show
diameter d1 of spigot is given by
2P
d1
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.
or d = 71 mm . . . (2.48)
58
Thickness of Eye, t Design of Temporary
Connections
150 103 c d t 150 71 t
150 103
or t 14.1 mm . . . (2.49)
150 71
Diameter of Eye, D
150 103
or D 71 208.3 mm . . . (2.50)
77.5 14.1
Diameter of Fork, D
Same . . . (2.51)
Thickness of the Fork
t1 = 7.1 mm . . . (2.52)
Check for Bending Stress
t t 1
b 32 P 1
8 6 d3
b 13 N/mm2 . . . (2.53)
2P
d1
t
P D2 d1 d1 P d12
M max
2 6 2 d1 8
Use P = 30000 N, D2 = 75 mm, d1 = 34 mm 59
Machine Design 75 34 34 30000 34
M max 15000
6 2 8
b 74.7 N/mm2
60