Chapter 4.0 (Design For Strength) - Introduction & Fasteners

Chapter Four
4.0 Design for Strength of basic Machine Components

Machine parts fail if the stresses exceed their strength. While the stresses are induced by the
external loads, each machine component resists stress with it size, usually with it’s cross-
sectional area. In designing a machine part, the stresses in the machine part are determined and
then compared with the limiting strength of the material of the component for safety, and
finally the size (i.e. dimensions) of the component is determined.
The strength of various materials for engineering applications is determined in the laboratory
with standard specimens in test machines. For complex stress (i.e. combined stress) distribution
in a machine component, the design methodology may be based on the predicted mode of
failure. A machine component fails when it ceases to perform its function satisfactorily. This
failure can be either yielding or fracture. The yielding failure occurs in ductile materials due to
excessive inelastic deformation of the component, while fracture failure occurs in brittle
materials such that it tears the component apart in two or more parts.
However, for design purpose allowable stress is used in place of the critical stress (i.e. yield
stress for ductile materials and ultimate stress for brittle materials) to take into account
uncertainties including material inhomogeneity, uncertainties in loading, fluctuating loads,
reliability and safety. In this course, we shall concentrate on the design of fasteners, springs,
thin and thick-walled vessels.
4.1 Design of Fasteners

A machine is usually made of a number of parts which are suitably joined to operate
satisfactorily. Fasteners for joining machine components can be classified into permanent
and detachable fasteners. The permanent fasteners include: Riveted joints, Welded joints,
and Bounded joints. While the detachable fasteners include: Threaded fasteners (screws,
bolts and nuts, studs), cotter joints, and knuckle joints, key and pin joints.
4.1.1 Design of Key: A key is a piece of mild steel inserted between a shaft and a hub or
boss of a pulley in order to connect them to together, as shown in figure 4.1. In service,
keys are subjected to crushing and shearing stresses. There are different types of keys,
namely: Sunk keys, Saddle keys, Tangent keys, and Round keys or Pins. Figure 4.0, shows
examples of these keys. The sunk keys are sunk half way into the keyway or groove of the
shaft and half way into the keyway or groove of the hub or boss of a pulley
The saddle keys are taper keys which fit in a keyway in a hub and are flat on the shaft.
The tangent keys are fitted in pair at right angles. The round keys are circular in section
and fits into holes drilled partly in the shaft and partly in the hub. When a key is used in
Free Lecture Materials for MEE-323 (Machine Design I), Prepared by Mr. C. O. Eleghasim Chapter - 4
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transmitting torque from a shaft to a rotor or hub, forces mainly due torque transmission
by the shaft produce shear stresses and compressive (or crushing) stresses in the key.
(a) (b)
(c) (d)
(e) (f)
Figure 4.0: (a) Rectangular sunk key, (b) Gib-head sunk key, (c) Saddle key, (d) Tangent key, (e) Round
key, (f) Tapered round key
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Consider a rectangular sunk key in figure 4.1b., which connects a shaft of diameter D and
a hub. Let T be the torque transmitted by the shaft as it rotates clockwise. Due to the torque
T, force F acts tangentially on the circumference of the shaft along the length of the key
half way into the shaft, and also equal but resisting force F acts on the other half of the key
in the hub. The force F acting along the length of the key induces shear stress and
compressive stress in the key.
(a) (b)
Figure 4.1: (a) Exploded view of a rectangular sunk key, shaft and hub assembly, (b) cross-sectional
view of the assembly
If l, w, t represents respectively the length, the width, and the thickness of the key.
Considering the shearing of the key, the tangential shearing load F acting on the
circumference of the shaft and along the length of the key is:
F = shear stress × area resisting the shearing = τkey × l × w (4.1a)
Also, the torque transmitted by the shaft is:
T = F × (d/2) = l × w × τkey × (d/2) (4.1b)
Also, if we consider the crushing of the key, the tangent crushing load F acting on the
circumference of the shaft and along the length of the key is:
F = Stress × area resisting the compression = σc × [ l × (t/2)] (4.2a)
Also, the torque transmitted by the shaft is:
T = F × (d/2) = σc × [l × (t/2)] × (d/2) (4.2b)
If we consider the key to be equally strong in shearing and crushing, then equation (4.1b)
equals equation (4.2b). Thus,
l × w × τkey × (d/2) = σc × [l × (t/2)] × (d/2) (4.3a)
w/t = σc/(2× τkey) (4.3b)
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From equation 4.3b, the key material should be at least twice crushing stress permissible to
shearing stress, and w = t, meaning that the key is a square sunk key.
To determine the length l, of the key to transmit full power of the shaft, the shearing strength
of the key is equal to the torsional shear strength of the shaft. From equation (4.1b), we
have,
T = l × w × τkey × (d/2) (4.4a)
From equation 2.7, The torsional shear strength of the shaft is,
T = (16/π) × τshaft × d 3 (4.4b)
Equating equations (4.4a) and (4.4b), we have
l × w × τkey × (d/2) = (16/π) × τshaft × d 3 (4.4c)
Design Example 4.1: A shaft of diameter 50 mm is made of steel with yield strength of
405 MPa. A sunk key of 15 mm wide and 10 mm thickness made of steel with a yield
strength of 342 MPa is to be used to transmit torque to the hub of a rotor. Using a factor
of safety of 2, determine the required length of the key, if the shaft is to be loaded to
transmit maximum permissible torque.
Solution: Given d = 50 mm; w = 15 mm; t = 10 mm; σy(shaft) = 405MPa = 405 N/mm2;
σy(key) = 342MPa = 342 N/mm2, factor of safety (FS) = 2.
According to maximum shear stress theory (see equation 2.17), the maximum shear
stress for the shaft is
τsafe(shaft) = σy / (2 × FS) = 405/ (2×2) = 101.25 N/mm2 (E4.1-1)
Also, the maximum shear stress for the key will be
τsafe(key) = σy / (2 × FS) = 342/ (2×2) = 85.5 N/mm2 (E4.1-2)
Therefore, the maximum torque (see equation 2.7) transmitted by the shaft will be
T = (π/16) × τsafe(shaft) x d3 = (π/16) × 101.25 × (50)3 = 2.5 × 106 N-mm (E4.1-3)
First, if we now consider the failure of the key due to shearing, and also remember that
both the shaft and the key will transmit the same torque. Thus, from equation (4.1b) we
have
T = l × w × τkey × (d/2) (E4.1-4)
Therefore,
2.5 × 106 = l × 15 × 85.5 × (50/2) (E4.1-5)
l = (2.5 × 106) / (15 × 85.5 × 25) = 77.97 mm (E4.1-6)
Second, if we also consider the failure of the key due to crushing, we know that the
maximum torque transmitted is:
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T = l × (t/2) × σc(key) × (d/2) (E4.1-7)
Therefore,
2.5 x 106 = l × (10/2) × (342/2) × (50/2) (E4.1-8a)
= l × 5 × 171 × 25 (E4.1-8b)
l = (2.5 × 106) / (5 × 171 × 25) = 116.96 mm (E4.1-9)
We can take the larger value of the length of the key which is 116.96 mm
Assignment 4.1 (Deadline: 1 week)
1.) A shaft 75 mm diameter transmits power at maximum shear stress of 65 MPa. Calculate
the length of 18 mm wide key required to mount a pulley on a shaft, so that the stress
in the key does not exceed 42 MPa. Take the thickness of the key to be half the width.
2.) A shaft 30 mm diameter is transmitting power at a maximum shear stress of 80 MPa. If
a pulley is connected to the shaft by means of a key, find the dimensions of the key so
that the stress in the key is not to exceed 50 MPa and length of the key is 4 times its
width.
3.) A shaft of 42 mm diameter is made of steel with a yield strength of 410 MPa. A sunk
key of size 13 mm wide and 10 mm thick made of steel with a yield strength of 330
MPa is to be used. Find the required length of key, if the shaft is loaded to transmit the
maximum permissible torque. Use maximum shear stress theory and assume a factor of
safety of 2.
4.) The transmission shaft of an electric motor delivers maximum torque of 145 kN-m,
whose diameter is 38 mm. If the permissible shear and crushing stresses for the mild
steel are 55MPa and 110 MPa for the suitable sunk key, design the dimensions of the
key.
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4.1.2 Design of Riveted Joint: Figure 4.2c shows a typical rivet joint, joining two thin
metal plates. The cylindrical portion of the joint is known as the shank or body as seen in
figure 4.2a. Depending on the type, a rivet usually has an integral head and a tail. The tail
is formed into another head during the joining process in a Die, as shown in figure 4.2b.
(a) (b) (c)
Figure 4.2: A typical rivet, (c) riveting process, (b) A rivet Joint
Depending on the way the plates are to be joined, there are two possible types, namely –
Lap and Butt joints. Figure 4.2c is typical lap joint, such that the metals to be joined are
placed one overlapping the other. The Butt joint is such that the metals to be joined are
places edge to edge and then a cover plate is placed either on one side or on both sides, as
can be seen in figure (4.4b) and (4.4c).
(a) (b) (c)
Figure 4.3: Hole pattern for, (a) Single riveted lap joint, (b) Double riveted lapin chain formation, (c)
double rivet lap joint in Zig-Zag formation.
During the joining process, the metals to be joined are aligned in either lap or butt
formation and then holes are drilled through the plates. Afterwards, rivets are introduced
into the holes depending on the number of rivets to be used, and then die pressed. The
pattern of arrangement of the holes for the rivets can be in Chain or Zig-zag pattern for the
riveting process, as seen in figure 4.3c.
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In chain formation, rivets in various rows are opposite to each other as seen in figure 4.3b,
while in zig-zag formation the rows are staggered such that every rivet is in the middle of
two rivets of the opposite row as seen in figure 4.3c.
(a) (b)
(c)
Figure 4.4: Shearing off a rivet in, (a) Lap joint, (b) Single Cover Butt Joint, (c) Double Cover Butt Joint
Shearing of a Rivet: In figure 4.14a, the plates which are connected by the rivet exerts
tensile stress, making it possible for the rivet to fail in shear, as shown in figure 4.4a. It
can be seen that a rivet is in single shear when it is in a lap joint and in a single cover butt
joint, as in figure (4.4a) and (4.4b). As seen in figure (4.4c), each rivet is in double shear
in a cover butt joint
Let d, τ, n, represent respectively, diameter of rivet, allowable shear stress, number of
rivets per pitch length of the rivet.
We know that the shearing area is,
As = (π/4) × d2 … (in single shear) (4.5a)
= 2 × (π/4) × d2 … (in double shear) (4.5b)
Therefore, the shear strength of a rivet will be
Ps = n × (π/4) × d2 × τ … (in single shear) (4.5a)
= n × 2 × (π/4) × d2 × τ … (in double shear) (4.5b)
From equation 4.5, the required diameter of rivet can be determined given the number of
rivets required.
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Tearing of a Plate along a row of rivets: Let t, σt, l,
represent respectively, plate thickness, allowable
tensile stress of plate, pitch length of the rivet. Due to
tensile stresses in the plates, a plate or cover plates may
tear off across a row of rivets as shown in figure 4.5.
Thus,
The tearing area per pitch length is
At = (l - d) × t (4.6)
Therefore, the tearing strength per pitch length Figure 4.5: Tearing of a plate across a row
of plate will be, of rivets in a lap joint
Pt = (l - d) × t × σt (4.7)
The pitch length l of the rivet joint may be determined from equation (4.7).
Crushing of plates in a rivet hole: Sometimes, the rivets

do not actually shear off under the tensile stress, but the
plates are crushed in such a manner that the hole becomes
oval in shape and hence the joint becomes loose as shown
in figure 4.6. If σc is the allowable crushing stress for the
plate material, then crushing area per rivet (i.e. projected
area per rivet) is,
Ac = d × t (4.8)
Therefore, the total crushing area of plates for n rivets is Figure 4.6: Crushing of a plate in a
Ac = n × d × t (4.9) rivet hole
The crushing strength or pull required to crush the rivet per pitch length, is
Pc = Ac × σc = n × d × t × σc (4.10)
Design Example 4.2: A double riveted lap joint is made between 15 mm plates. The rivet
diameter and pitch are 25 mm and 75 mm respectively. If the ultimate stresses are 400 MPa
in tension and 320 MPa in shear, and 640 MPa in crushing.
a. Find the minimum force per pitch length that can rupture the joint.
b. If the above joint is subjected to a load such that
the factor of safety is 4, determine actual stresses
developed in the plates and the rivets
Solution: Since the ultimate stresses are given, therefore we shall find the ultimate
values of the resistances of the joint. We know that ultimate tearing resistance of the
plate per pitch,
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Ptu = (l - d) × t × σt = (75 – 25)15 × 400 = 300 000 N (E4.2-1)
and, ultimate shearing resistance of the rivets per pitch in a double riveted lap joint is
Psu = n x (π/4) × d2 x τu (E4.2-2a)

= 2 x (π/4) × (25)2 x 320 = 314 200 N ; n = 2 (E4.2-2b)
Also, ultimate crushing resistance of the rivets per pitch,
Pcu = n × d × t × σcu = 2 × 25 × 15 × 640 = 480 000 N (E4.2-3)
Therefore, the minimum force per pitch which will rupture the joint is 300 000 N
or 300 kN. The actual stresses in rivets and plates are determined as follows:
Safe tensile load per pitch length of the joint
Pt = Ptu / FS = 300 000/4 = 75 000 N (E4.2-4)
Therefore, actual tearing resistance of the plates will be

Pta = Pt = (l - d) × t × σta (E4.2-5a)
75 000 = (75 – 25)15 × σta = 750 σta (E4.2-5b)
σta = 75 000/750 = 100 MPa (E4.2-5c)
actual shearing resistance of the rivets will be
Pta = Ps = n x (π/4) × d2 × τsa (E4.2-6a)
75 000 = 2 × (π/4) × (25)2 × τsa = 982 τsa (E4.2-6b)
τsa = 75 000/982 = 76.4 MPa (E4.2-6c)
and finally, actual crushing resistance of the rivets will be
Pta = Pc = n × d × t × σca (E4.2-7a)
75 000 = 2 × 25 × 15 × σca = 750 σca (E4.2-7b)
σca = 75 000/750 = 100 MPa (E4.2-7c)

A spherical pressure vessel has an internal diameter of 1m and subjected to a pressure
of 2.75 MPa above the atmospheric pressure. If a triple rivet lap joint is used in joining
the two halves of the spherical vessel, and yield strength of vessel material is 176 MPa.
Find, (a) the pitch length for a row of rivets, (b) the number of rivets required to make
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the joint. Take thickness of the vessel, t = 20 mm, rivet diameter, d =28 mm, and safety
factor of 2.
4.1.5 Design of Welded Joint: Welding is extensively used in fabrication as an alternative
method for casting or forging and as a replacement for bolted and riveted joints. A weld joint
is a permanent joint which is obtained by the fusion of the edges of the two parts to be joined
together, usually with a filler material. There are different types of welded joints, namely: Lap
or fillet joints (see figure 4.7), Butt joints (see figure 4.8), Corner joint, Edge joint, T-joints,
etc. (see figure 4.9).
(a) (b) (c)
Figure 4.7:(a) Single transverse fillet joint, (b) Double transverse fillet joint, (c) Double parallel fillet joint
(a) (b) (c) (d) (e)
Figure 4.8:(a) single butt, (b) single V-butt, (c) single U-butt, (d) double V-butt, (e) double U-butt
(a) (b) (c)
Figure 4.9:(a) Corner joint, (b) Edge joint, (c) T-joint
Strength of Transverse Fillet Welded Joints: Considering a single fillet or lap joint
in figure 4.10, In order to determine the strength of the fillet joint, it is assumed that the
section of fillet is a right angled triangle ABC with hypotenuse AC making equal angles
with other two sides AB and BC. The length of each side s, is known as leg or size of
the weld and the perpendicular distance of the hypotenuse from the intersection of legs
BD, is known as throat thickness. The minimum area of the weld is then obtained at
the throat BD, which is obtained in triangle CDB as
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sin 45° = DB/CB = t/s (4.11)
Therefore
t = s × sin 45° = 0.707s (4.12)
(a) Transverse weld (b) Enlarge view of transverse weld
Figure 4.10: Single Transverse lap weld
If σt is the allowable tensile stress for the weld metal, then the tensile strength
of the weld joint for single fillet is,
Pweld = throat area × σt (4.13)
Where throat area, Athroat = t × l (4.14)
Pweld = t × l × σt (4.15a)
Pweld = 0.707s × l × σt … single fillet weld (4.15b)
and tensile strength of the joint for double fillet weld,

P = 2 × 0.707 s × l × σt
= 1.414 s × l × σt … double fillet weld (4.16)
Strength of Butt Joints: The butt joints are designed for tension or compression. In
case of butt joint, it is assumed that the size (or leg) of weld is equal to the throat
thickness which is equal to thickness of plates. Consider a single V-butt joint as shown
in figure 4.11a, the tensile strength is:
P = t × l × σt (4.17)
Also, tensile strength of double V-butt
joint as shown in figure 4.11b is given
by:
P = (t1 + t2) × l × σt (4.18)
Where (a) (b)
t1 = Throat thickness at the top, and Figure 4.11: V-butt joints (a) single, (b) double
t1 = Throat thickness at the bottom
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Design Example 4.3: A plate 75 mm wide and 12.5 mm
thick is joined with another plate by a single transverse
weld and a double parallel fillet weld as shown in figure
4.12. The maximum tensile and shear stresses are 70
MPa and 56 MPa respectively. Find the length of each
parallel fillet weld, if the joint is subjected to tensile load
P. Figure 4.12
Solution: Given : Width = 75 mm ; Thickness = 12.5 mm ; σt = 70 MPa = 70 N/mm2;

τ= 56 MPa = 56 N/mm2.
Now, we know that the maximum load which the plate can carry is
P = cross sectional Area of plate × tensile Stress = 75 × 12.5 × 70

= 65 625 N (E4.3-1)
If we consider the tensile strength of the single transverse weld alone, we have
Ptrans = 0.707 s × 75 × σt = 0.707 × 12.5 × 75 × 70 = 46 397 N (E4.3-2)
Also, if we consider the shear strength of the double parallel weld alone, we have
Pparallel = 2 × 0.707 s × l × τ = 2 × 0.707 × 12.5 × l × 56 = 989.8l N (E4.3-3)
Finally, the load carried by the welded joint will be
P = Ptrans + Pparallel (E4.3-4)
65 625 = 46 397 + 989.8l (E4.3-5)
989.8l = 65 625 – 46 397 = 19 228 (E4.3-6)
l = 19228 / 989.8 = 19.42mm (E4.3-7)
Therefore, the length of each parallel well will be 19.42/2 = 9.71 mm
Design Example 4.4: A 50 mm diameter solid shaft is

welded to a flat plate by 10 mm fillet weld as shown in
Figure 4.13. Find the maximum torque that the welded
joint can sustain if the maximum shear stress intensity in
the weld material is not to exceed 80 MPa.
Solution: Given: d = 50 mm; s = 10 mm; τmax = 80 MPa
= 80 N/mm2,
Figure 4.13
The weld can only fail in shear. Thus the shear
stress is:
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τ = (T × r) / Jweld ; Jweld = πtd3/4 where t is the throat thickness (E4.4-1)
80 N/mm2 = (T × d/2) / (πtd3/4) (E4.4-2)
80 N/mm2 = 2T/πtd2 ; t = 0.707s , where s is the weld size (or leg) (E4.4-3)
80 N/mm2 = 2T/(π × 0.707s × d2) (E4.4-4)
T = 80/2 × (π × 0.707s × d2) (E4.4-5)

= 40 × (3.142 × 0.707 × 10 × 502) (E4.4-6)
= 2.22 × 106 N-mm = 2.22 kN-m (E4.4-7)
1. A spherical pressure vessel shown in figure 4.14, has an

internal diameter of 1m and subjected to a pressure of 2.75
MPa above the atmospheric pressure, and the yield strength of
the vessel material is 176 MPa. Find, (a) The weld size or leg
s required, if a single transverse fillet or lap joint is used in
joining the two halves of the spherical vessel. Take thickness
of the to be 12 mm. (b) The throat t, if a single V-Butt joint is
used in joining the two halves of the spherical vessel. Also, Figure 4.14
take safety factor of 2.
2. A circular shaft 150 mm in length and 60 mm in diameter, is

welded to a support by means of a fillet weld, and carries a
vertical load of 7 kN applied at the free end as shown in figure
4.15. Determine the size of weld, if the permissible shear stress
in the weld is limited to 85 MPa. Take the section modulus of
weld, Z = πtD2/4, where t is the weld throat, D is the diameter
of shaft. Hint: failure of the weld is as a result of combined stress of
bending and shearing, using the maximum shear stress failure theory.
Figure 4.15
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4.1.6 Design of Threaded Fasteners
A bolted joint usually comprises of a bolt and a nut to join two machine elements that are
readily connected or disconnected without damage to the machine. Figure 4.16 shows the
details of a threaded bolt and a threaded nut. The major diameter is the largest diameter of an
external or internal threaded bolt or nut. The major diameter is known as outside or nominal
diameter for a bolt. The minor diameter is the smallest diameter of an external or internal
screw thread, also known as core or root diameter. The pitch diameter is the diameter at which
the ridges on the bolt are in complete touch with the ridges of the corresponding nut. Pitch is
the distance from a point on one thread to the corresponding point on the next, measured in an
axial direction between corresponding points in the same axial plane. Lead is the distance a
screw thread advances axially in one rotation of the nut. Lead is equal to the pitch in case of
single start threads, it is twice the pitch in double start, thrice the pitch in triple start and so on.
Crest is the top surface of the thread. Root is the bottom surface created by the two adjacent
flanks of the thread. Depth of thread is the perpendicular distance between the crest and root.
Flank is the surface joining the crest and root. Angle of thread is the angle included by the
flanks of the thread. Slope is half the pitch of the thread.
(a) (b)
Figure 4.16: (a) threaded bolt thread, and (b) threaded nut
There are different types of threaded fastener used for joints, as shown in figure 4.17. In figure
4.17a, the cylindrical part of the bolt known as the shank is passed through a drilled hole in
the two machine parts to be fastened together and clamped them securely as the nut is screwed
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(a) (b)
Figure 4.17: (a) bolt and nut, (b) tap and nut (or Stud)
onto the threaded end of the bolt. The bolt should pass easily in the hole. In figures 4.17b, a
tapped bolt (a bolt with its ends threaded) is screwed into a threaded hole of one of the machine
parts to be fastened together, while the other end receives a nut on it. Studs are chiefly used in
securing various kinds of covers e.g. covers of engine and pump cylinders, valves, chests etc.
However, the choice of type of bolted joint and its location are very important. The fastenings
should be located in such a way as to minimize stresses as they are subjected to tensile and
shear loads as well as bending loads.
A bolt or a stud is subjected to initial tensile stress due to screwing up forces (when screwed
up tightly), as well as combination of other stresses due to other possible external loads. These
stresses on a bolt or stud are not accurately determined, therefore bolts are designed on the
basis of direct tensile stress with a large factor of safety in order to account for the indeterminate
stresses. The initial tension in a bolt, based on experiments, may be found by the relation
Pi = 2840d N (4.17a)
Where Pi is the initial tensile load, d is the Nominal diameter of bolt.

The equation (4.17a) is used for making a fluid tight joint, like steam engine cylinder cover
joints etc. When the joint is not required as tight as fluid-tight, then the initial tension in
a bolt may be reduced to half of the above value. In such cases.
Pi = 1420d N (4.17b)
If the bolt is not initially stressed, then the maximum safe axial load which may be applied to
it, is given by
Pi = Permissible stress × Cross-sectional area at bottom of the thread (4.17c)
Where the stressed area may be found by using the relation
π
Stressed area = (dp + dc) (4.18)
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where dp is the pitch diameter, and dc is the core or minor diameter of bolt
Considering the torsional shear stress induced in the bolt caused by frictional resistance
of the threads during it’s tightening, may be obtained using torsional equation as follows:
τt = (T × r) / J (4.19a)
τt = [T × (dc/2)] / [(π dc4/ 32)] (4.19b)
τt = 16T/ π dc3 (4.19c)
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Also, we can consider shearing of the bolt’s threads, if we picture the entire length of the
thread stretched out such that the shearing occurs at the root of the thread. Therefore, the
shear area at the root of the thread for entire length of the thread is
Stressed area at the thread root = thread length in 1 revolution × b × n (4.20a)
Where b is thread width, and n is number of threads
Stressed area at the thread root = π dc × b × n (4.20b)
Therefore, the average thread shearing stress for the screw τthread is obtained by using the
relation,
τthread = Safe shear load applied / Stressed area at the thread root (4.21a)
= P / (π dc × b × n) (4.21b)
If we also consider crushing (i.e. compression) stress between the bolt’s and nut’s threads,
the area of their flanks in compression is π(d - dc)2 × n. therefore the crushing stress is
σthread = Safe shear load applied / [π(d - dc)2 × n] (4.22a)
= P / [π(d - dc)2 × n] (4.22b)
Finally, bending stress is induced in the shank of the bolt if the surfaces under the bolt’s head
or nut are not perfectly parallel to the bolt axis. The empirical relation for the determination of
the bending stress is:
σbolt = x .E / 2l (4.23)
where x is the difference in height between the extreme corners of the nut or head, l is the
length of the shank of the bolt, and E is the Young’s modulus for the material of the bolt.
Design Example 4.5: In figure 4.18, an eye bolt is to be

used for lifting a load of 60 kN. Find the nominal diameter
of the bolt, if the tensile stress is not to exceed 100 MPa.
Solution: Given: P = 60 kN = 60 × 103 N; σt = 100 MPa

= 100 N/mm2
Let d = Nominal diameter of the bolt, and dc= Core
diameter of the bolt.
We know that tensile load on the bolt (P), is
P = tensile stress × bolt’s cross-sectional area Front view side view

(E4.5-1a)
P = σbolt × [π(dc) /4]
2
(E4.5-1b) Figure 4.18: Eye bolt
16
60 × 103 = 100 × [π(dc)2/4] (E4.5-2)
dc = 27.6 mm (E4.5-3)
Design Example 4.6: A wall bracket is to be

fastened with four bolts at the points marked
1-4, and loaded with 40 kN inclined at 60°
to the vertical as shown in figure 4.19.
Determine the size or the diameter d, of the
bolts as well as the thickness of the arm of
the bracket t, if The material of the bracket
and the bolts is same for which the safe
stresses can be assumed as 70 MPa, 50 MPa
Front view side view
and 105 MPa in tension, shear and
compression respectively. Figure 4.19: wall bracket
Solution: Since the load W = 40 kN is inclined at an angle of 60° to the vertical, therefore
resolving it into horizontal and vertical components, we have
WH = 40 × sin 60° = 40 × 0.866 = 34.64 kN = 34 640 N (E4.6-1)
WV = 40 × cos 60° = 40 × 0.5 = 20 kN = 20 000 N (E4.6-2)
This horizontal component (WH), which acts parallel to the axis of the bolts, induces a direct
tensile load equally sheared by all the 4 bolts, and a turning moment about the centre of
gravity G, of the bracket, in the anticlockwise direction.
Therefore, the direct load on each bolt is:
Wd = WH /4 = 34 640 / 4 = 8660 N (E4.6-3)
And the anti-clockwise turning moment due to WH is:
TH = WH × 20 = 34 640× 20 = 692.8 × 103 N-mm (E4.6-4)
Also, the vertical component (WV), which acts perpendicular to the axis of the bolts, induces a
direct shear load equally shared by all the 4 bolts, and turning moment about to the centre
of gravity G.
Therefore, the shear load on each bolt is:
Ws = WV /4 = 20 000 / 4 = 5000 N (E4.6-5)
And the clockwise turning moment due to WV is:
TV = WH × 175 = 20 000 × 175 = 3500 × 103 N-mm (E4.6-6)
The net turning moment which is clockwise is

Tnet = 3500 × 103 - 692.8 × 103 = 2807.2 × 103 N-mm (E4.6-7)
17
This net clockwise turning moment will cause the bracket to tilt about the edge E, which induces
varying moment load Pm on each row of bolts about edge E. Therefore, considering each bolt,
the total moment acting on the 4 bolts is:
Ttotal = 2 (P1/2 × L1) + 2 (P3/4 × L2) (E4.6-8a)
Where P1/2 is the moment loads at bolts 1&2, P3/4 is the moment loads at bolts
4&3
If we let a constant load per unit length on each bolt about the edge E be w, then the total
moment due every w on each bolt about the edge E is:
Ttotal = 2 (wL1 × L1) + 2 (wL2 × L2) (E4.6-8b)

= 2 (w×60 × 60) + 2 (w×180 × 180) (E4.6-8c)
= 72 000w N-mm (E4.6-8d)
Combining equations (E4.6-8d) &(E4.6-7), we have
w = (2807.2 × 103 ) ÷ 72 000 = 39 N/mm (E4.6-9)
Design of the bolt core diameter: Since the heavily loaded bolts are those which lie at a greater
distance from the tilting edge, therefore the upper bolts 3 and 4 will be heavily loaded. Thus
the diameter of the bolt should be based on the load on the upper bolts. The maximum tensile
load on each upper bolt is:
Wb = w×L2 = 39 × 180 = 7020 N (E4.6-10)
Total tensile load on each of the upper bolt is:
Wt = Wd + Wb = 8660 + 7020 = 15 680 N (E4.6-11)
Since the upper bolts are subjected to a tensile load (Wt = 15 680 N) and a shear load (Ws =
5000 N), therefore the maximum equivalent or principal tensile load, is
Wt(max) = ½ [ Wt + √(Wt 2 + 4Ws 2)] N (E4.6-12a)
= ½ [ 15680 + √(15680 2 + 4×5000 2)] N (E4.6-12b)
= 17 140 N (E4.6-12c)
If the core diameter of the bolts is dc, then the tensile load on each bolt is:
17 140 N = (π/4) dc2 × σt (E4.6-13)
dc = √ [(17 140 × 4)/70π] = 17.66 mm (E4.6-14)
Design of the bracket arm thickness: the root cross-sectional area of the bracket arm is
18
A = b × t = 130t mm2 (E4.6-15)
section modulus of the arm,
Z = (1/6) tb2 = (1/6) × t × 1302 = 2817t mm3 (E4.6-16)
The horizontal component of the load WH induces direct tensile and bending tensile
stresses at upper most fibre on the root of the arm. Thus
σt,d = WH /A = 34640 /130t (E4.6-17a)

= 266.46/t N/mm2 (direct tensile stress) (E4.6-17b)
σt,d = MH /A = (WH × L) /A (E4.6-18a)
where L = [100 – 130/2] is the distance between WH and the cent centre of the
of travity of the arm take to be half of b =130 mm.
σt,d = (WH × L)/A = (34 640 × 35)/2817t (E4.6-18b)

= 430.39/t N/mm2 (bending tensile stress) (E4.6-18c)
The vertical component of the load WV induces direct shear and bending tensile
stresses at upper most fibre on the root of the arm. Thus
τ = WV /A = 20 000/130t (E4.6-19a)
= 153.4/t N/mm2 (direct shear stress) (E4.6-19b)
σt,d = MV /Z = (WV × 175)/ 2817t (E4.6-20a)

= (20 000× 175)/ 2817t (E4.6-20b)
= 1242.45/t N/mm2 (bending tensile stress) (E4.6-20c)
The net tensile stress induced in the upper most fibre of the arm of the bracket is:
σt = 266.46/t + 430.39/t + 1242.45/t = 1939.3/t N/mm2 (E4.6-21a)
Given the maximum allowable tensile stress to be 70 MPa, therefore
σt (max) = ½ [σt + √( σt 2 + 4τ 2)] N/mm2 (E4.6-21b)
70 = ½ [1939.3/t + √{(1939.3/t )2 + 4(153.4/t) 2}] (E4.6-21c)
70 = ½ [1939.3/t + 1963.42/t] (E4.6-21d)
70 = 1951.36/t (E4.6-21e)
t = 1951.36/70 = 27.87 mm (E4.6-22)
if we consider the maximum allowable shear stress, we have
19
τ(max) = ½ √( σt 2 + 4τ 2)] N/mm2 (E4.6-23a)
50 = ½ √[(1939.3/t )2 + 4(153.4/t) 2] (E4.6-23b)
50 = ½ [1963.42/t] = 981.71/t (E4.6-23c)
t = 981.71/50 = 19.63 mm (E4.6-24)
this value of thickness is low compared to 27.87 mm calculates from tensile failure, therefore
the higher value is taken. Thus the thickness of the arm is 27.87 mm.

1. A T-bracket shown in figure 4.19, is fitted to a wall with 5 bolts, such that 3 bolts are
at the top row and 2 bolts are at the bottom row, with all the bolts equally spaced. A
load of 20 kN is acting at a distance of 200 mm from the wall. Vertical distance of the
first and second rows from hinge point are 50 mm and 250 mm respectively. If the
material of the bracket as well as the bolts is mild steel with yield strength of 300 MPa.
Taking a safety factor of 3, design a suitable bolt size for the bracket.
Front view side view
Figure 4.19: T- bracket
2. A support bracket is shown in figure 4.20, whose detachable plate is to be secured to a

fixed plate by 6 bolts. The bracket is required to support a 40 kN load as indicated. If
the bolts are made of mild steel with yield strength of 160 MPa and safety factor is 3,
determine the size of bolts for the application.
20
Figure 4.20: Support bracket
Homework 2
A basketball goal consists of a hoop, a square arm and a flange plate all made of mild steel
of shear strength of 160 MPa, is shown in figure 4.21. The flange plate is attached to the
backboard by means of 4 bolts as arranged in the figure. The 30 mm square arm is
connected to the flange plate via a continuous fillet weld. If the maximum load w a player
can apply to the goal is 1570 N, determine the size of the bolt for the application. Take
safety factor of 3.
Figure 4.21 : Basketball goal
21
4.1.7 Design of Knuckle Joint
Figure 4.22: Exploded view of the knuckle joint
Looking at the exploded view of the knuckle joint as shown in figure 4.22, one end of the rods
is made into an eye and the end of the other rod is formed into a fork with an eye in each of
the legs. The knuckle pin passes through both the eye hole and the fork holes and may be
secured by means of a collar and taper pin or slip pin. The assembly view of the Knuckle joint
is shown in figure 4.23.
Figure 4.23: Assembly of the knuckle joint components
22
If P is the load on the joint in tension, D is the diameter of the rods, D1 is the enlarged diameter
of rod, d is the diameter of pin, d1 is diameter of pin head, d0 is outer diameter or eye hole or
fork hole, t1 is thickness of eye end, t2 is the thickness of forked end.
(1) Design of the Rods: Considering the failure of the rod in tension, we have
P = (π/4)D2 x σt (4.24)
The diameter of the rod can be determined from equation (4.24). In practice, the enlarged
diameter of the rod can be determined using empirical relation D1 = 1.1 D.
(2) Design of the Knuckle Pin: Considering the double shear of the knuckle joint, the pin may
shear off into three pieces as shown in figure 4.24. Thus,
the shear load equal to the shear strength is:
Resisting Areas
P = 2 x (π/4)d2 x τ (4.25)
From equation (4.25) the diameter of the knuckle pin may be

determined. Note that the service length of the Pin is, l = t1 + 2t2.
Also, the empirical relations can be used for the thickness of eye
and forked end: t1 = 1.25D, t2 = 0.75D. Figure 4.24: shear failure of the
Knuckle Pin
(3) Design of the Eye End: Considering the Eye’s failure in tension, the tensile load P is given
by equation (4.26), from which the
thickness t1 of the Eye may be determined. The empirical
relation can be used in service: d0 = 2d.
Resisting Area
P = (d0 - d)t1 x σt (4.26)
If we consider the failure of the Eye in shear, we have equation

(4.27), from which the determined thickness t1 of the Eye may
be checked.
P = 2 x (0.5d0 – 0.5d)t1 x τ (4.27a)

Figure 4.25: Tear failure of the Eye End
P = (d0 – d)t1 x τ (4.27b)
23
(4) Design of the Forked End: Considering the failure of the Forked end in tension, we obtain
its strength equal to the load from equation (4.28), from which the thickness t2 of the forked
end may be determined.
P = 2 x (d0 – d)t2 x σt (4.28)
If we also consider failure due to shear, we get equation (4.29), from which the determined
thickness t2 of the forked end may be checked.
P = 2 x (d0 – d)t2 x τ (4.29)

Design the dimensions of a knuckle joint to be used to connect two circular rods to be subjected
to 150 kN load. The material for the production of the knuckle is mild steel with allowable
yield stress of 150 MPa and allowable shear stress of 60 MPa.
Home Work 3
1. Design a knuckle joint to transmit a tensile load of 50 kN. If it connects two circular
rods made of the same material having yield stress of 340 N/mm2. Using a factor of
safety of 4, design the dimensions of the knuckle joint.
2. A knuckle joint is to be used to connect a piston and the connecting rod of an engine.
The piston is to be a cast iron and will undergo an ultimate compressive stress of 360
MPa during the power stroke, and ultimate shear stress of 165 MPa. The connecting rod
and the knuckle Pin is to be mild steel of ultimate compressive stress of 280 MPa and
ultimate shear stress of 130 MPa. If the diameter of the piston is 50 mm, design using a
safety factor of 4, the dimensions of,
(a) The Knuckle Pin

(b) The Forked End of the Piston
(c) The Eye End of the Connecting Rod
24

Chapter 4.0 (Design For Strength) - Introduction & Fasteners

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Chapter 4.0 (Design For Strength) - Introduction & Fasteners

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Chapter Four

4.0 Design for Strength of basic Machine Components

4.1 Design of Fasteners

Assignment 4.1 (Deadline: 1 week)

(a) (b) (c)

(a) (b) (c)

Crushing of plates in a rivet hole: Sometimes, the rivets

Psu = n x (π/4) × d2 x τu (E4.2-2a)

Pcu = n × d × t × σcu = 2 × 25 × 15 × 640 = 480 000 N (E4.2-3)

Safe tensile load per pitch length of the joint

Pt = Ptu / FS = 300 000/4 = 75 000 N (E4.2-4)

Therefore, actual tearing resistance of the plates will be

Assignment 4.2 (Deadline: 1 week)

(a) (b) (c)

(a) (b) (c) (d) (e)

(a) (b) (c)

Figure 4.9:(a) Corner joint, (b) Edge joint, (c) T-joint

(a) Transverse weld (b) Enlarge view of transverse weld

Figure 4.10: Single Transverse lap weld

Pweld = throat area × σt (4.13)

Where throat area, Athroat = t × l (4.14)

Pweld = 0.707s × l × σt … single fillet weld (4.15b)

and tensile strength of the joint for double fillet weld,

t1 = Throat thickness at the bottom

Solution: Given : Width = 75 mm ; Thickness = 12.5 mm ; σt = 70 MPa = 70 N/mm2;

P = cross sectional Area of plate × tensile Stress = 75 × 12.5 × 70

Ptrans = 0.707 s × 75 × σt = 0.707 × 12.5 × 75 × 70 = 46 397 N (E4.3-2)

Pparallel = 2 × 0.707 s × l × τ = 2 × 0.707 × 12.5 × l × 56 = 989.8l N (E4.3-3)

Finally, the load carried by the welded joint will be

P = Ptrans + Pparallel (E4.3-4)

65 625 = 46 397 + 989.8l (E4.3-5)

989.8l = 65 625 – 46 397 = 19 228 (E4.3-6)

l = 19228 / 989.8 = 19.42mm (E4.3-7)

Therefore, the length of each parallel well will be 19.42/2 = 9.71 mm

Design Example 4.4: A 50 mm diameter solid shaft is

T = 80/2 × (π × 0.707s × d2) (E4.4-5)

Assignment 4.3 (Deadline: 1 week)

1. A spherical pressure vessel shown in figure 4.14, has an

2. A circular shaft 150 mm in length and 60 mm in diameter, is

Where Pi is the initial tensile load, d is the Nominal diameter of bolt.

Pi = Permissible stress × Cross-sectional area at bottom of the thread (4.17c)

Where the stressed area may be found by using the relation

τt = [T × (dc/2)] / [(π dc4/ 32)] (4.19b)

τt = 16T/ π dc3 (4.19c)

Stressed area at the thread root = thread length in 1 revolution × b × n (4.20a)

Where b is thread width, and n is number of threads

Stressed area at the thread root = π dc × b × n (4.20b)

σthread = Safe shear load applied / [π(d - dc)2 × n] (4.22a)

= P / [π(d - dc)2 × n] (4.22b)

Design Example 4.5: In figure 4.18, an eye bolt is to be

Solution: Given: P = 60 kN = 60 × 103 N; σt = 100 MPa

We know that tensile load on the bolt (P), is

P = tensile stress × bolt’s cross-sectional area Front view side view

Design Example 4.6: A wall bracket is to be

Therefore, the direct load on each bolt is:

Wd = WH /4 = 34 640 / 4 = 8660 N (E4.6-3)

And the anti-clockwise turning moment due to WH is:

TH = WH × 20 = 34 640× 20 = 692.8 × 103 N-mm (E4.6-4)

Therefore, the shear load on each bolt is:

Ws = WV /4 = 20 000 / 4 = 5000 N (E4.6-5)

And the clockwise turning moment due to WV is:

TV = WH × 175 = 20 000 × 175 = 3500 × 103 N-mm (E4.6-6)

The net turning moment which is clockwise is