Design of Fasteners

A) Design of Screw
Fasteners
 Introduction
• A screw thread is formed by cutting a
continuous helical groove on cylindrical
surface.
• A continuous single helical groove is known as
single threaded or single start.
• If second groove is cut into the space between
the groove of first then it is double threaded or
double start.
• Screw joint are formed by bolt and nut used
for joining machine parts or for fastening,
adjustment, assembly, inspection, replacement.
• Advantages –
1) These are convenient to assemble and
disassemble.
2) Highly reliable in operation.
3) Screw joint are adopted in various operating
conditions.
4) Screws are relatively cheap to produce due to
standardization.
Disadvantages –
The main disadvantage of this joint is the
stress concentration in the thread portion and
strength is less than welded or riveted joint.
 Types of Screw fastening
Types of Screw
Fastening

1. Bolts

(i) Through Bolt

(ii) Tap Bolts

2. Cap Screw

3. Stud

4. Machine Screw

5. Set Screw
 Types of Screw Fastening
• Bolts - They are basically threaded fasteners
normally used with nuts.
• Screws - They engage either with a preformed or
a self made internal threads.
• Studs -They are externally threaded headless
fasteners. One end usually meets a tapped
component and the other with a standard nut.
• Tapping screws -These are one piece fasteners
which cut or form a mating thread when driven
into a preformed hole. These allow rapid
installation since nuts are not used.
• Set Screws -These are semi permanent fasteners
which hold collars, pulleys, gears etc on a shaft.
Different heads and point styles are available.
• Examples where screw joints are preferred
over welded joint.
1) Assembly of crank shaft and connecting rod.
2) In braking system of an automobile because
screw joints are convenient to assemble and
disassemble and relatively cheap to produce
due to standardization.
 Advantages of V thread
1) V threads offers greater frictional resistance
of motion than square thread and are thus
better suited for fastening purpose.
2) These are stronger than square thread.
3) These are cheaper because of easy to cut by
die or on machine.
4) These are used to tighten the parts together in
bolts, nuts, stud and nut, tap bolts etc. because
they prevent the nut from slacking back due
to high frictional resistance.
 Disadvantages
1) V threads are not suitable for power
transmission.
2) They have a component of force which acts
perpendicular to the axis causing bursting
action on the nut and increasing friction.
Forms of Threads
Terminology for Screw Threads
1. Major diameter (do)-
• It is the largest diameter of an external or
internal screw thread.
• The screw is specified by this diameter. It is also
known as outside or nominal diameter.
2. Minor diameter (dc)-
• It is the smallest diameter of an external or
internal screw thread.
• It is also known as core or root diameter.
3. Pitch diameter (dp) –
• It is the diameter of an imaginary cylinder, on a
cylindrical screw thread, the surface of which
would pass through the thread at such points as to
make equal the width of the thread and the width
of the spaces between the threads.
• It is also called an effective diameter.
4. Pitch (p) -
• It is the distance from a point on one thread to the
corresponding point on the next.
• This is measured in an axial direction between
corresponding points in the same axial plane.
5. Lead -
• It is the distance between two corresponding
points on the same helix.
• It may also be defined as the distance which 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.
6. Crest - It is the top surface of the thread.
7. Root - It is the bottom surface created by the two
adjacent flanks of the thread.
8. Depth of thread - It is the perpendicular
distance between the crest and root.
9. Flank - It is the surface joining the crest and
root.
10. Angle of thread - It is the angle included by
the flanks of the thread.
11. Slope - It is half the pitch of the thread.
 Stresses in screw fastenings
• It is necessary to determine the
stresses in screw fastening due to
both static and dynamic loading in
order to determine their dimensions.
In order to design for static loading
both initial tightening and external
loadings need be known.
A) Initial tightening load
When a nut is tightened over a screw following
stresses are induced:
(a) Tensile stresses due to stretching of the bolt
(b) Torsional shear stress due to frictional
resistance at the threads.
(c) Shear stress across threads
(d) Compressive or crushing stress on the threads
(e) Bending stress if the surfaces under the bolt
head or nut are not perfectly normal to the bolt
axis.
a) Tensile Stress –
Since none of the above mentioned stresses
can be accurately determined bolts are usually
designed on the basis of direct tensile stress
with a large factor of safety.
Pi 2840 d o
t  
A  ( d  dc )2
4 2
Where d  Mean diameter or pitch of screw
d c  Core diameter  0.84 d o
Pi  Initial tension in bolts
b) Torsional shear stress -
Due to twisting moment, the bolt is subjected to
torsional shear stress.
T  s G
 
IP r l
T
s  r
IP
T d c 16T
s   
 2  d 3
 dc
3 c
32

T   s  d c3
16
Where I P  Polar moment of inertia
T  Twisting torque
c) Shear stress across the threads -
The average shear stress for screw is
P
s 
d cbn
The average shear stress for nut is
P
n 
d obn
d o  no min al diameter of nou
n  Number of thread in contact
b  width of thread at the root
d) Crushing stress on threads
The compression or crushing stress between the
thread of screw nut is given by
P
 c   cr 
 (do  dc )n
2 2
e) Bending Stress
Let, X – difference in height between the extreme
corner of the nut or head.
E – Modulus of elasticity
l – length of shank of the bolt
The bending stress induced in the shank of the bolt is
given by

XE
b 
2l
 2. Stresses due to external forces
a) Tensile stress –
P
t  d c is found out

d c2
4
if n is the number of bolts then
P
t 

d n2
c
4
d o  0.84d c
b) Shear Stress in bolt –
P
s 

d n
2
o
4
c) Combine tension and shear stress
Maximum principal tensile sress
1
( t ) max  [ t   t2  4 2 ]
2
Maximum shear stress
1
 max  [  t2  4 2 ]
2
 3. Stress due to combine forces
• The resultant load on the bolt is
a
P  Pi  ( ) P2
1 a
 P  Pi  kP2
a
Where k  ( )
1 a
Pi  Initial tension due to tightening of bolts
P2  Extrnal load on the bolts
a  Ratio of elasticity of connected parts to the elsicity of bolt
Values of ‘K’
 Bolts with Uniform strength
• When a bolt is subjected to shock load. the In such
cases the bolt is designed to absorb impact load and
to resist the torque to prevent breakage of thread.
• In ordinary bolts, the effect of load concentration
on the weakest part of the bolt i.e. The c/s area of
the root of the thread.
• The stress in the threaded part will be more as
compared to the shank hence the maximum portion
of energy will be absorbed at the region of the
threaded part which may fracture the threaded
portion.
• If the diameter of shank of the bolt is turned to
the core diameter of the thread, then the shank
of the bolt will undergo a higher stress. This
means that shank will absorb large portion of
energy thus relieving the material at the
threaded portion.
• The bolt in this way become stronger and
lighter and it increases the impact load
carrying capacity. This gives us bolts of
uniform strength.
• Another method, an axial hole is drilled
through the head of the bolt as far as threaded
portion, such area of the shank become equal
to the root area of the thread.
 
D 
2
(d  d )
2
o
2
c
4 4
 D  (d  d ) 2
o
2
c

where, D  diameter of hole

d o  outer diameter of thread
d c  core diameter of thread
 Design of bolted joint subjected to
Eccentric Loading
• There are many application of the bolted joints
which are subjected to eccentric loading such as
machine foundation bolt, wall brackets, pillar
crane, etc.
1) Parallel to the axis of bolts.
2) Perpendicular to the axis of bolts.
3) In the plane containing the bolts.
Eccentric load parallel to the axis of bolt
a) Each bolt is subjected to direct tensile load.
W
Wtd 
n
Wtd  Direct tensile load
W  load acting on bracket
n  Number of bolts

b) Due to load W the bracket tends to rotate

about edge A-A
Let w – load in a bolt per unit distance due to
turning effect of the bracket
• W1 & W2 – load on bolt at a distance L1 & L2
from tilting edge.
Load on each bolt at distance L1
W1 = w L1
Similarly, load on each bolt at distance L2
W2 = w L2
The moment of load W1 about tilting edge
M 1  W1 L1  wL1  L1  wL 2
1
• Similarly, the moment of load W2 about tilting
edge
M 2  W2 L2  wL2  L2  wL22
Total moment of load about tilting edge
M  M 1  M 2  2[ wL12  wL22 ]  (1)
The moment of the load W at a dis tan ce L, about tilting edge
M  WL  (2)
Equating equation (1) and (2)
WL  2[ wL12  wL22 ]
 2 w[ L12  L22 ]
WL
w 
2[ L12  L22 ]
The bolts at dis tan ce L2 are most heavily loaded
Tensile load on each bolt at dis tan ce L2
W L L2
Wt 2  W2  wL2 
2[ L12  L22 ]
Total load on most heavily loaded bolts
WTotal  Wt  Wtd  Wt 2
As the bolt subjected to tensile stress
Wt
t 

d c2
4
Eccentric Load Acting Perpendicular to the
Axis of Bolts
The bolts are subjected to two types of loads
1. Bolts are subjected to direct shearing load which
are equally sheared by the bolts .
W
Ws 
n
Where, W  load acting at a dis tan ce ' L'
n  number of bolts
2. The eccentric load (W) will try to tilt the bracket
in clockwise direction about the tilting edge B-B.
Therefore maximum tensile load will be act on bolt
at position 3 and 4 which are at a greater distance
from the tilting edge.
Let, w = load in the bolt per unit distance due to
turning effect of the bracket.
Wt= Tensile load each bolt at a distance L1 from the
tilting edge B-B.
Wt1  w L1
Moment of this load about tilting edge
M 1  Wt1  L1  w L    (2)
2
1

As two bolts at a dist. L1 , hence

M 1  2 w L    (3)
2
1
• Similarly Wt will be the tensile load each bolt at
a distance L2 from the tilting edge B-B.
Wt 2  w L2
Moment of the load Wt 2 about tilting edge
M 2  Wt 2  L2  w L22
As the two bolts are at a dist. L2 , hence
M 2  2 w L22    (4)
Total moment about tilting edge is
M  M1  M 2
M  2wL  2wL
2
1
2
2

M  2 w[ L12  L22 ]  (5)

The moment of bracket due to load (W )
at a dist. L is
M  W L   ( 6)
Equating equation 5 & 6
W L  2 w [ L12  L22 ]
WL
w 
2 [ L12  L22 ]
The max imum tensile load willbe in a bolt 3 & 4
which are situated at a dist. L2 from tilting edge.
WL
Wt 2  w L2   L2
2 [ L1  L2 ]
2 2

W L L2
Wt 2     (7)
2 [ L1  L2 ]
2 2
As the bolts are subjected to combile tensile
as well as shear load .
 Equivalent tensile load (Wte )
1
Wte  [Wt 2  Wt 2  4 Ws ]
2 2

2
And
Equivalent shear load (Wse )
1
Wse  [ Wt 2  4 Ws ]
2 2

2
• By knowing the equivalent load, the core
diameter of the bolt is obtained.
Wte
t 

d 2
c
4
Eccentric Load acting in the plane
containing the Bolts
• In this case, the bolts are subjected to two types
of load –
1. The Direct shear load (Wsd) –
Wsd = (W/n) ----- (a)
2. The secondary shear load (Ws2)
a) This secondary load is perpendicular to line
joining the centre of the bolt.
b) This secondary load is perpendicular to the
radial distance.
W1 , W2 , W3 , W4 are the sec ondary shear loads
at a dist. l1 , l2 , l3 , l4 of bolt 1,2,3,4 from C.G.
As force is directly proportional to radial dis tan ce
W1 W2 W3 W4
  
l1 l2 l3 l4
l2
W2  W1 
l1
l3
W3  W1 
l1
l4
W4  W1 
l1
• Sum of turning moment due to eccentric load and
internal resisting moment of the bolt must be
zero.
W  e  W1 l1  W2 l2  W3 l3  W4 l4
l2 l3 l4
 W1 l1  W1 ( ) l2  W1 ( ) l3  W1 ( ) l4
l1 l1 l1
W1 2 2 2 2
 [l1  l2  l3  l4 ]    (b)
l1
From equation ' b'W1 is calculated
Calculate the resul tan t shear load
WSR  Wsd2  Ws2  2Wsd Ws cos 
Where,   Angle between primary and sec ondary
shear load
WSR
Then, shear stress   

 d c2
4
find d c and
0.84
do 
dc
Problems
B) Design of Welded
Joints
 Welded Joints
• Welding is a process of joining
two similar metal by heating
with or without application of
pressure and filler materials.
• Welded joint can be used an
alternatively to riveted joint.
 Advantages
1) The welded structure are usually lighter than
riveted structure because in welding, gussets and
other connecting component are not used.
2) Weld joint provide maximum efficiency which is
not possible by riveted joint.
3) Alteration and addition can be easily made in the
exiting structure.
4) It is smooth in appearance therefore looks
pleasing.
5) In welded connection, the tension member are
not weakened as in case of riveted joint.
6) A weld joint has greater strength often a
welded joint has the strength of the parent
metal itself.
7) Circular shape member are difficult to rivet
but they can easily welded.
8) The welding provide very rigid joints
9) Welding is possible at any point, any place.
10) Welding required less time than the riveting.
 Disadvantages
1) Due to uneven heating and cooling during
fabrication, the members get distorted or
addition stresses may developed.
2) Highly skilled worker and supervision is
required.
3) Due to uneven contraction and expansion in
the frame, there is possibilities of cracks.
4) The inspection of weld is difficult than
riveted joint.
 Types of welded joint
1) Lap Joint:
 The Lap Joint is obtained by over lapping the
plates and then welding the edge of plates.
a) Single transverse
b) Double transverse
c) Parallel fillet joints.
2) Butt Joints:
The butt joint is obtained by welding the ends
and edge of the two plates which approximately
in the same plane.
The Butt Joint may
1. Square butt joint,
2. Single V-butt joint
3. Single U-butt joint,
4. Double V-butt joint, and
5. Double U-butt joint.
Basic Weld Symbols
Strength of Transverse Fillet Welded Joints
• 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 enlarged view of the fillet is shown in Fig. 10.7.
• The length of each side is known as leg or size of the
weld and the perpendicular distance of the hypotenuse
from the intersection of legs (i.e. BD) is known as
throat thickness.
• The minimum area of the weld is obtained at the
throat BD, which is given by the product of the throat
thickness and length of weld.
 ABC is right angle isosceles triangle .
Let , t  BD  Throat thickness in mm
SW  AB  BC  Leg or size of weld
 Thickness of weld in mm
lw  Length of weld in mm
BAC  BCA  450
From figure
BD
sin 45 
0

AB
t
0.707 
Sw
Thickness of weld  t  0.707 S w    (1)
The min imum area of the throat or weld area
A  Throat thickness  Length of weld
A  t  lw
A  0.707 S w lw    (2)
The failure of fillet weld is due to tensile force
P
 t 
Area of throat
P
t 
0.707  S w  lw
 P  0.707  S w  lw   t
This equation for sin gle transverse
fillet weld .
For double transverse fillet weld
P P
t  
2 A 2  0.707  S w lw
P  2  0.707  SW lw   t
During welding, the slag and blow holes are
occur, so the weld is weaker than plate,
therefore the weld is provided with some
reinforcement which may be taken as 10% of
the plate thickness.
Strength of Parallel Fillet Weld
The stress indced in the fillet weld is
shear stress due to axial force
P
s 
2  Throat area
P
s 
2  0.707  S wlw
 P  2  0.707  S w lw  s
Combine Transverse & Parallel
Fillet weld
• In combination of parallel and transverse fillet
weld, the weld is subjected to tensile stress and
shear stress due to axial force.
For transverse fillet weld
P  0.707 S w lw1  t    (1)
For parallel fillet weld
P  2  0.707 S w lw 2  s    (2)
Total strength of weld is
Pt  [0.707 S w lw1  t ]  [2  0.707 S w lw 2  s ]
• Note –
1. Stress concentration factor for transverse
fillet weld Under dynamic (fatigue)
loading = 1.5
2. Stress concentration factor for parallel
fillet weld Under dynamic (fatigue)
loading = 2.7
PROBLEMS