1

ME 2501 DESIGN OF MACHINE ELEMENTS

UNIT III: DESIGN OF FASTENERS AND WELDED JOINTS
PART – A ANSWERS
III-1 Sketch any two types of lap and butt welded joints.

Single transverse Lap Joint Double transverse Lap Joint

Single V Butt Joint

Double V Butt Joint

III-2 Draw a diagram to indicate a welding joint and indicate the notations used.

L- Length of weld
L transverse Lap
h- throat thickness
S
h S- Size of weld
h = 0.707S
S

III-3 What are the assumptions made in the design of welded joint?
(i) It is assumed that the tensile stress is distributed uniformly across the section of the butt
weld. However, the actual stress distribution is having curved profile.
(ii) It is assumed that the shear stress in a parallel fillet weld is uniformly distributed along the
entire length of the weld. However, in actual case the stresses are higher at the ends of the
weld
(iii) The design calculation in a fillet weld is done with an uniform stress distribution, however
the actual stress profile is very complex.

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 2

III-4 What are the main indications of complete weld symbol?

(i) Size of weld
(ii) Contour symbol
(iii) Finish symbol
(iv) Length of weld
(v) Unwelded length

III-5 Define eccentrically loaded welded joints

When the line of action of the external load does not pass through the centre of gravity of a weld
joint, then it is called as eccentrically loaded welded joint. Eccentric loading produces bending
or torsional shear stress due to the presence of bending or twisting moments in addition to the
direct shear stresses in welded joints.

d
e

III-6 What are the reasons for replacing riveted joint by welded joint in modern equipment?

(i) Welded structures are usually lighter than riveted structures, since riveted joints require
additional cover plates, gusset plates and straps.
(ii) When two parts are joined by riveting method, holes are drilled in the parts to
accommodate rivets. The rivet holes reduce the cross sectional area of the parts and
result in stress concentration.
(iii) Machine components of certain shape such as circular steel pipes offer difficulty for
riveting. However, they can be easily welded.
(iv) The welded joints provide maximum efficiency closer to 100%, which is not possible in
riveted joints.

III-7 Write down the designation of threads with an example

A screw thread is designated by the letter ‘M’ followed by the diameter and pitch, the two being
separated by the sign ’x’. When there is no indication of the pitch, it shall mean a coarse pitch is
implied.

Example: M12 – 12mm nominal diameter metric thread with a coarse pitch

M24x2 – 24mm nominal diameter metric thread with a 2mm pitch

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 3

III-8 Indicate the type of stresses a threaded joint is subjected in its application.

(i) Tensile stresses due to stretching of bolt during initial tension

(ii) Torsional shear stresses due to frictional moment
(iii)Tensile stresses due to external loads
(iv) Shear stresses due to external loads

III-9 Define the term self-locking of power screws

Power screws refer to the square threaded screws used in jacks, press and similar applications to
lift loads. Power screws are used for lifting heavy loads by applying comparatively smaller
efforts at the end of the lever.
The thread of a power screw is considered as an inclined plane wound around a cylinder and the
load is raised by the principles of wedge-friction. Self-locking refers to the locking of screw
without sliding down under the lifting load. Self-Locking happens when the friction angle (φ)
is larger than lead angle (α) of the screw.
III-10 State three conditions where tap bolts are used.
Tap bolt is directly screwed into a threaded (tapped) hole made in one of the parts to be
connected and there is no nut used in this arrangement. Tap bolts are used under the following
three conditions.
(i) One of the part is thick enough to accommodate the threaded hole.
(ii) The material of the part with threaded hole has sufficient strength to ensure durable
threads.
(iii) There is no place to accommodate the nut.

III-11 Define the term pitch and lead in thread or Differentiate between pitch and lead of screw
Pitch is the distance between two corresponding points on adjacent threads measured parallel to
the axis of thread. Lead is the distance which a screw thread advances axially in one rotation of
the nut and it refers to the distance between two corresponding points on the same helix
measured parallel to the axis of thread.
Pitch – Distance between corresponding points in two adjacent threads
Lead – Distance between corresponding points in two adjacent threads on the same helix
Lead = Number of starts x Pitch
For a single start thread, lead is equal to pitch and for a double start thread, lead is equal to twice
the pitch and in a similar proportion for higher start threads.
III-12 What do you understand by the single start and double start threads?
A screw thread is formed by cutting a continuous helical groove on a cylindrical surface. A
screw made by cutting single helical groove on the cylinder is known as single-start screw.
If a second thread is cut in the space between the grooves of the first, a double-start screw
thread is formed. Similarly, triple, quadruple or multi-start threads may be formed.
Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University
Unit III : Design of Threaded & Welded Joints
 4

Double or multi-start threads are formed mainly to increase the speed of axial advancement of
threaded bolt against the nut or vice-versa. In a double start thread, the axial advancement is
twice that of a single threaded fastener and similarly for higher start threads.
III-13 State the advantages of threaded joints
(i) Threaded joints are used to hold two or more machine parts together. These parts can
be dismantled, when required, without any damage to machine parts or fastening.
Therefore, threaded joints are detachable joints, unlike welded joints.
(ii) Threaded joints are self-locking and hence highly reliable in operation.
(iii) Threaded fasteners are standardized and a wide variety is available for different
applications.
(iv) Threaded fasteners are economical to manufacture and hence they are cost effective.
III-14 Determine the safe tensile load for a bolt of M20 assuming a safe tensile stress of 40 MPa.
π
Safe tensile on bolt = ----- dc2 . σ [dc - Core Dia. of bolt]
4
π
= ----- (0.84d)2 x σ [dc = 0.84d; d – Nominal diameter of bolt]
4

3.142 x (0.84 x 20)2 x 40

= ---------------------------------- = 8868 N
4
Safe tensile on bolt = 8868 N

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 5

PROBLEM IN WELED JOINTS TYPE#1: Eccentrically Loaded Welded Joint with Twisting Load
{2 Shear stresses & Resultant Stress obtained through Parallelogram Law}

1. A plate of 200mm width is welded to a vertical plate by fillet welding on three sides to form a cantilever
with an overlap of 150 mm and overhang of 400 mm. A vertical down ward load of 35 kN is applied at
free end for a weld stress of 75 N/mm2. Determine the size of the weld.

150
35kN

R
200 ϴ 100 ϴ
105 τ2
--
Nx
τ1

Ny e = 505

150 400

Given: Load, P = 35 kN = 35000 N

Weld width, b = 150 mm
Weld depth, d = 200 mm
Allowable shear stress of weld, [τ] = 75 N/mm2

Solution: Step I : Fix the centroid of weld

b2 1502
Ny= --------- = ------------------ = 45 mm --------- [PSG 11.5]
2b + d (2x150) + 200

Nx= 200/2 = 100 mm

Step II : Calculate the direct / primary shear stress, τ1

P P
τ1= ----------------------------------------------- = ----------------
Length of weld x Throat thickness(h) (2b + d) x h

35000 70
τ1= ---------------------------- = -------
(2x150 + 200) x h h

Step III : Calculate the secondary shear stress due to twisting, τ2

Mt R
Secondary shear stress, τ2 = -----------
J

Mt = P x e = 35000 x 505 = 17675000 N-mm

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University
Unit III : Design of Threaded & Welded Joints
 6

e - Eccentricity, distance between the centroid of weld and line of action of load

R= 1052 + 1002 = 145 mm

(2b + d) 3 b2 (b + d)2 (2x150 +200)3 1502(150+200)2

J = ------------- – ---------------- = ------------------- – --------------------- = 4904167 [PSG 11.5]
12 (2b + d) 12 (2x150+200)

The above “J” eqn given in PSG 11.5 is meant for the weld considered as a line. This consideration is
valid, since the throat thickness (h) is constant along the length of weld. Hence, the polar moment of
inertia of the weld section is obtained as:

Polar moment of inertia of the weld section, J = 4904167 x h

Mt R 17675000 x 145 522.6

Secondary shear stress, τ2 = ----------- = ----------------------- = ----------
J 4904167 x h h

Step IV : Calculate the resultant shear stress, τmax

Resultant shear stress, τmax = τ12 + τ22 + 2τ1τ2Cosϴ

Cosϴ = 105/145 = 0.724

Resultant shear stress, τmax = (70/h)2 + (522.6/h)2 + 2x(70/h)x(522.6/h)x0.724 = 575.3/h

Step V : Calculate the weld size

Equating the resultant stress to allowable stress, 575.3/h = 75 h = 7.7 mm

Weld size, S = 1.414h = 1.414 x 7.7 = 10.8 mm = 11.0 mm

2. A rectangular steel plate is welded as a cantilever to a vertical column and supports a single
concentrated load P, as shown in Fig. determine the weld size if shear stress in the same is not to
exceed 140 MPa.
50
60kN

R
100 ϴ 50 ϴ
37.5 τ2
Nx
τ1

Ny e = 187.5

50 150

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 7

Given: Load, P = 60 kN = 60000 N

Weld width, b = 50 mm
Weld depth, d = 100 mm
Allowable shear stress of weld, [τ] = 140 MPa = 140 N/mm2
Solution: Step I : Fix the centroid of weld
b2 502
Ny= --------- = -------------------- = 12.5 mm --------- [PSG 11.5]
2b + d 2x50 + 100

Nx= 100/2 = 50 mm

Step II : Calculate the direct / primary shear stress, τ1

P P
τ1= ----------------------------------------------- = ----------------
Length of weld x Throat thickness(h) (2b + d) x h

60000 300
τ1= ---------------------------- = -------
(2x50 + 100) x h h

Step III : Calculate the secondary shear stress, τ2

Mt R
Secondary shear stress, τ2 = -----------
J
Mt = P x e = 60000 x 187.5 = 11250000 N-mm
e - Eccentricity, distance between the centroid of weld and line of action of load

R= 37.52 + 502 = 62.5 mm

(2b + d) 3 b2 (b + d)2 (2x50 +100)3 502(50+100)2

J = ------------- – ---------------- = ------------------- – --------------------- = 385417 [PSG 11.5]
12 (2b + d) 12 (2x50+100)

The above “J” eqn given in PSG 11.5 is meant for the weld considered as a line. This consideration is
valid, since the throat thickness (h) is constant along the length of weld. Hence, the polar moment of
inertia of the weld section is obtained as:
J = 385417 x h

Mt R 11250000 x 62.5 1824.3

Secondary shear stress, τ2 = ----------- = ----------------------- = -------------
J 385417 x h h

Step IV : Calculate the resultant shear stress, τmax

Resultant shear stress, τmax = τ12 + τ22 + 2τ1τ2Cosϴ

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 8

Cosϴ= 37.5/62.5 = 0.6

Resultant shear stress, τmax = (300/h)2 + (1824.3/h)2 + 2x(300/h)x(1824.3/h)x0.6 = 2018.6/h

Step V : Calculate the weld size

Equating the resultant stress to allowable stress, 2018.6/h = 140 h = 14.4 mm

Weld size, S = 1.414h = 1.414 x 14.4 = 20.4 mm = 21.0 mm

PROBLEM IN WELED JOINTS TYPE#2: Eccentrically Loaded Welded Joint with Bending Load
(Shear stress+ Bending stress & Resultant Stress obtained through Principal stress Eqn}

3. A bracket is welded to the welded column by means two fillet welds as shown in fig. determine the size
of welds, if permissible shear stress in weld is limited to 70 N/mm2.

P = 10kN

100
100

50

Given: Load, P = 10 kN = 10000 N

Weld width, b = 50 mm
Weld depth, d = 100 mm
Allowable shear stress of weld, [τ] = 70 N/mm2

Step I : Calculate the direct / primary shear stress, τ

P P
τ = ----------------------------------------------- = ----------------
Length of weld x Throat thickness(h) (2b) x h

10000 100
τ= ------------------ = -------
(2x50) x h h

Step II : Calculate the bending stress due to Bending Moment, σb

Mb
Bending stress, σb = --------
Z

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 9

Mb = P x e = 10000 x 100 = 1000000 N-mm

e - Eccentricity, distance between the centroid of weld and line of action of load

Z = bd = 50 x 100 = 5000 PSG 11.5

The above “Z” eqn given in PSG 11.5 is meant for the weld considered as a line. This consideration is
valid, since the throat thickness (h) is constant along the length of weld. Hence, the section modulus of
the weld section is obtained as:
Z = 5000 x h

Mb 1000000 200
Bending stress, σb = --------- = -------------- = ----------
Z 5000h h

Step III : Calculate the maximum shear stress, τmax

Maximum Shear Stress, τmax = ½ σb 2 + 4τ2

τmax = 0.5 (200/h)2 + 4 (100/h)2 = 141/h

Step IV : Calculate the weld size

Equating the resultant stress to allowable stress, 141/h = 70 h = 2.0 mm

Weld size, S = 1.414h = 1.414 x 2.0 = 2.9 mm = 3.0 mm

4. A welded joint as shown in figure is subjected to an eccentric load of 2 kN. Find the size of the
weld, if the maximum shear stress in the weld is 25 MPa.

40 mm square

S
120 2 kN

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 10

Given: Load, P = 2 kN = 2000 N

Weld width, b = 40 mm
Weld depth, d = 40 mm
Allowable shear stress of weld, [τ] = 25 N/mm2

Step I : Calculate the direct / primary shear stress, τ

P P
τ= ------------------------------------------------ = -------------
Length of weld x Throat thickness(h) (2b) x h

2000 25
τ = ------------------ = -------
(2x40) x h h

Step II : Calculate the bending stress due to Bending Moment, σb

Bending stress, σb = Mb /Z
Mb = P x e = 2000 x 120 = 240000 N-mm
e - Eccentricity, distance between the centroid of weld and line of action of load

Z = bd = 40 x 40 = 1600 ----------PSG 11.5

The above “Z” eqn given in PSG 11.5 is meant for the weld considered as a line. This consideration is
valid, since the throat thickness (h) is constant along the length of weld. Hence, the section modulus of
the weld section is obtained as:
Z = 1600 x h

Mb 240000 150
Bending stress, σb = --------- = -------------- = --------
Z 1600h h

Step III: Calculate the maximum shear stress, τmax

Maximum Shear Stress, τmax = ½ σb 2 + 4τ2

τmax = 0.5 (150/h)2 + 4 (25/h)2 = 79.1/h

Step IV : Calculate the weld size

Equating the resultant stress to allowable stress, 79.1/h = 25 h = 3.2 mm

Weld size, S = 1.414h = 1.414x3.2 = 4.5 mm = 5.0 mm

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 11

5. A rectangular cross section bar is welded to a support by means fillet welds as shown in fig. Determine
the size of welds, if the permissible shear stress in the weld is limited to 75 MPa.
500 25k

150

100

Given: Load, P = 25 kN = 25 x 103 N

Weld width, b = 100 mm
Weld depth, d = 150 mm
Allowable shear stress of weld, [τ] = 75 MPa = 75 N/mm2
Step I : Calculate the direct / primary shear stress, τ
P P
τ= ----------------------------------------------- = ----------------
Length of weld x Throat thickness(h) 2(b+d) x h

25000 50
τ= -------------------------- = -------
2x(100+150) x h h

Step II : Calculate the bending stress due to Bending Moment, σb

Bending stress, σb = Mb / Z

Mb = P x e = 25000 x 500 = 12500000 N-mm

Z = bd + d2/3 = (100x150) + (1502/3) = 22500 PSG 11.5

The above “Z” eqn given in PSG 11.5 is meant for the weld considered as a line. This consideration is
valid, since the throat thickness (h) is constant along the length of weld. Hence, the section modulus of
the weld section is obtained as:

Z = 22500 x h

Mb 12500000 555.6
Bending stress, σb = --------- = -------------- = ----------
Z 22500h h

Step III : Calculate the maximum shear stress, τmax

Maximum Shear Stress, τmax = ½ σb 2 + 4τ2

τmax = 0.5 (555.6/h)2 + 4 (50/h)2 = 282.2/h

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University
Unit III : Design of Threaded & Welded Joints
 12

Step IV : Calculate the weld size

Equating the resultant stress to allowable stress, 282.2/h = 75 h = 3.8 mm

Weld size, S = 1.414h = 1.414x3.8 = 5.3 mm = 6.0 mm

6. A shaft of rectangular cross section is welded to a support plate by means of fillet weld on its one end
as shown in fig. the other end is loaded by 25 kN. If the size of the weld is 6mm, find the maximum
normal and shear stress in the weld.

500 25kN

150

100

Given: Load, P = 25 kN = 25000 N

Weld width, b = 100 mm
Weld depth, d = 150 mm
Weld size, S = 6 mm
To find: Maximum normal stress &
Maximum shear stress in the weld
Step I : Calculate the throat thickness, h

h = 0.707S = 0.707 x 6 = 4.24 mm

Step II : Calculate the direct shear stress, τ

P P
τ= ----------------------------------------------- = ----------------
Length of weld x Throat thickness(h) 2(b+d) x h

25000
τ= ---------------------------- = 11.8 N/mm2
2x(100+150) x 4.24

Step III : Calculate the bending stress due to Bending Moment, σb

Bending stress, σb = Mb / Z

Mb = P x e = 25000 x 500 = 12500000 N-mm

Z = bd + d3/3 = (100x150) + (1503/3) = 22500 PSG 11.5

The above “Z” eqn given in PSG 11.5 is meant for the weld considered as a line. This consideration is
Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University
Unit III : Design of Threaded & Welded Joints
 13

valid, since the throat thickness (h) is constant along the length of weld. Hence, the section modulus of
the weld section is obtained as:
Z = 22500 x h = 22500 x4.24 = 95400

Mb 12500000
Bending stress, σb = --------- = -------------- = 131.0 N/mm2
Z 95400

Step IV : Calculate the maximum normal stress & maximum shear stress

Maximum Normal Stress, σmax = ½ σb + ½ σb 2 + 4τ2

σmax = (0.5x131) + 0.5 { 1312 + (4x11.82) } = 132 N/mm2

Maximum Shear Stress, τmax = ½ σb 2 + 4τ2

τmax = 0.5 1312 + (4x11.8)2 = 66.5 N/mm2

7. The bracket shown in fig is designed to carry a dead weight of P=15 kN. What sizes of the fillet welds
are required at the top and bottom of the bracket? Assume the forces act through the points A and B.
The welds are produced by shielded arc welding process with a permissible strength of 150 MPa.

PHA PVA
S1
A
75
PVB
P = 15kN S2
B
50
50
All Dimensions are in mm

Given: Load, P = 15 kN = 15000 N

Weld width, b = 50 mm
Weld depth, d = 75 mm
Allowable shear stress of weld, [τ] = 150 MPa = 150 N/mm2

Solution: Step I : Calculate the resultant force at A and B.

Equating the forces in vertical direction, PVA + PVB = 15000

Considering PVA = PVB , PVA = 15000/2 = 7500 N and PVB = 7500 N

To find PHA, taking moment about A,

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 14

PHA x 75 = 15000 x 50

PHA = (15000x50)/75 = 10000 N

Step II : Calculate the Size of weld at the top fillet

Resultant force at A, PA = PVA2 + PHA2 = 75002 + 100002 = 12500 ------------(1)

Resisting Force by weld at A, = Weld length(L) x Throat thickness(h1) x Allowable stress

= 50 x h1 x 150 = 7500h ------------------(2)

Equating (1) and (2), 7500h1 = 12500 h1 = 1.67

Weld Size at top, S1 = 1.414 x h = 1.414 x 1.67 = 2.4 mm = 3.0 mm

Step II : Calculate the Size of weld at the bottom fillet

Resultant force at B, = 7500 ------------(3)

Resisting Force by weld at B, = Weld length(L) x Throat thickness(h2) x Allowable stress

= 50 x h2 x 150 = 7500h ------------------(4)

Equating (3) and (4), 7500h2 = 7500 h2 = 1.0 mm

Weld Size at bottom, S2 = 1.414 x h = 1.414 x 1.0 = 1.4 mm = 2.0 mm

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 15

PROBLEM IN THREADED JOINT: Threaded Joint of Steam Engine Cylinder Head

8. The cylinder head of a steam engine is subjected to a steam pressure of 0.7 N/mm2. It is held in position
by means of 12 bolts. A flat copper gasket is used to make the joint leak-proof. The effective diameter
of cylinder is 300 mm. Find the size of the bolts so that the stress in the bolts is not to exceed 100 MPa.

Given: Steam Pressure, p = 0.7 N/mm2

Diameter of cylinder head, D = 300 mm
Number of bolts, n = 12
Allowable tensile stress of bolt material, [σ] = 100 MPa = 100 x 103 N/mm2

Solution: Step I: Calculate the load due to internal pressure

π
Load due to internal pressure, P = ------ D2 .p
4

3.142 x 3002 x 0.7

= ----------------------------- = 49487 N
4
Step II: Calculate the external load on each bolt

The load developed by steam pressure is resisted by the total number of bolts.

Total Load 49487 x 0.5

External load on each bolt, PE = -------------------- K = -------------------- = 2602
No of bolts 12

Selected stiffness factor, K = 0.5 for soft copper gasket

Step III: Calculate the pre-load due to initial tension on each bolt

For a leak-proof joint, pre-load due to initial tension, PI = 2840d {d- Nominal Dia. of bolt)

Step IV: Calculate the total load on each bolt

Total Load on each bolt, PT = PE + PI = 2062 + 2840d -------------(1)

Step V: Calculate the resistance offered by bolt

π π
Resistance offered by bolt, = ------ dc2 . σ = ------ (0.84d)2 . [σ] {dc- Core Dia. of bolt)
4 4

3.142 x (0.84d)2 x 100

= --------------------------------- = 55.4d2 --------------(2)
4
Step VI: Calculate the diameter of bolt by equating (1) & (2)

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 16

55.4d2 = 2062 + 2840d

55.4d2 - 2840d – 2062 = 0

– b ± b2 –4ac –(–2840) ± (–2840)2 – (4x55.4x(–2062))

d = ----------------------- = -----------------------------------------------------------
2a 2 x55.4

Calculated Nominal Diameter of bolt, d= 52.0 mm

Selected Nominal Diameter of bolt, d= 52.0 mm

9. The cylinder head of a steam engine with 250 mm bore is fastened by eight stud bolts made of 30C8
steel. Maximum pressure inside the cylinder is 1 MPa. Determine the bolt size and approximate
tightening torque. Take 20% overload. Assume σy = 300MPa for bolt material.

Given: Steam Pressure, p = 1.0 MPa = 1.0 N/mm2

Diameter of cylinder head, D = 250 mm
Number of bolts, n = 8
Yield strength of bolt material, σy = 300 MPa = 300 N/mm2
Allowable tensile stress of 30C8 bolt material, [σ] = σy /Factor of safety = 300/3 =100 N/mm2
Factor of safety = 3 {Selected}

Solution: Step I: Calculate the load due to internal pressure

π
Load due to internal pressure, P = ------ D2 .p
4
3.142 x 2502 x 1.0
= ----------------------------- = 49094 N
4
For 20% overload as stated in the problem, P = 49094 x 1.2 = 58913 N

Step II: Calculate the external load on each bolt

The load developed by steam pressure is resisted by the total number of bolts.

Total Load 49094 x 0.5

External load on each bolt, PE = -------------------- K = -------------------- = 3682.1
No of bolts 8

Selected stiffness factor, K = 0.5 for soft copper gasket

Step III: Calculate the pre-load due to initial tension on each bolt

For a leak-proof joint, pre-load due to initial tension, PI = 2840d {d- Nominal Dia. of bolt)

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 17

Step IV: Calculate the total load on each bolt

Total Load on each bolt, PT = PE + PI = 2062 + 2840d -------------(1)

Step V: Calculate the resistance offered by bolt

π π
Resistance offered by bolt, = ------ dc2 . σ = ------ (0.84d)2 . σ {dc- Core Dia. of bolt)
4 4

3.142 x (0.84d)2 x 100

= --------------------------------- = 55.4d2 --------------(2)
4
Step VI: Calculate the diameter of bolt by equating (1) & (2)

55.4d2 = 3682.1 + 2840d

55.4d2 - 2840d – 3682.1 = 0

– b ± b2 –4ac –(–2840) ± (–2840)2 – (4x55.4x(–3682.1))

d = ----------------------- = -----------------------------------------------------------
2a 2 x55.4
Calculated Nominal Diameter of bolt, d= 52.5 mm
Selected Nominal Diameter of bolt, d= 54.0 mm
Bolt tightening Torque = 0.2 x d x PI = 0.2 x 54 x (2840x54) = 1656288 N-mm = 1656 N-m

10. A cast iron cylinder head is fastened to a cylinder of 500 mm bore with 8 stud bolts. The maximum
pressure inside the cylinder is 2 MPa. The stiffness of part is thrice the stiffness of the bolt. What
should be initial tightening load, so that the point is leak proof at maximum pressure? Also choose a
suitable bolt for the above application.

Given: Steam Pressure, p = 2.0 MPa = 2.0 N/mm2

Diameter of cylinder head, D = 500 mm
Number of bolts, n = 8
Stiffness of connected part to bolt (km/kb) = 3
Allowable tensile stress in bolt, [σ] = 100 N/mm2
Solution: Step I: Calculate the load due to internal pressure,P
π
Load due to internal pressure, P = ------ D2 .p
4
3.142 x 5002 x 2.0
= ----------------------------- = 392750 N
4
Step II: Calculate the external load on each bolt
The load developed by steam pressure is resisted by the total number of bolts.
Total Load 392750 x 0.25
External load on each bolt, PE = -------------------- K = --------------------- = 12273.4
No of bolts 8
Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University
Unit III : Design of Threaded & Welded Joints
 18

Given stiffness of connected part to bolt = 3:1 Hence, (km/kb) =3

kb kb
Stiffness Factor, K = ------------- = ------------- = 0.25 [km =3 kb]
kb + km kb + 3kb

Step III: Calculate the Pre-load due to initial tension on each bolt

For a leak-proof joint, pre-load due to initial tension, PI = 2840d {d- Nominal Dia. of bolt)

Step IV: Calculate the total load on each bolt

Total Load on each bolt, PT = PE + PI = 12273.4 + 2840d -------------(1)

Step V: Calculate the resistance offered by bolt

π π
Resistance offered by bolt, = ------ dc2 . σ = ------ (0.84d)2 . σ {dc- Core Dia. of bolt)
4 4

3.142 x (0.84d)2 x 100

= --------------------------------- = 55.4d2 --------------(2)
4
Step VI: Calculate the diameter of bolt by equating (1) & (2)
55.4d2 = 12273.4 + 2840d
55.4d2 - 2840d – 12273.4 = 0

– b ± b2 –4ac –(–2840) ± (–2840)2 – (4x55.4x(–12273.4))

d = ----------------------- = -----------------------------------------------------------
2a 2 x55.4
Calculated Nominal Diameter of bolt, d= 55.3 mm
Selected Nominal Diameter of bolt, d= 56.0 mm
Required Initial tightening load, PI = 2840 x d = 2840 x 56 = 159040 N = 159 kN

PROBLEM IN THREADED JOINTS – Steam Engine Cylinder Head for Variable Load (Solderberg Eqn.)
11. A steam engine of effective diameter 300 mm is subjected to a steam pressure of 1.5 MPa. The cylinder
head is connected by 8 bolts having yield point 330 MPa and endurance limit at 240 MPa. The bolts
are tightened with an initial preload of 1.5 times the steam load. A soft copper gasket is used to make
the joint leak-proof. Assuming a factor of safety 2, find the size of the bolt required. The stiffness
factor for copper gasket may be taken as 0.5.
Given: Steam Pressure, p = 1.5 MPa = 1.5 N/mm2
Diameter of cylinder head, D = 300 mm
Number of bolts, n = 8
Yield strength of bolt material, σy = 330 MPa = 330 N/mm2
Endurance strength of bolt material, σ-1 = 240 MPa = 240 N/mm2
Factor of safety = 2
Stiffness factor of copper gasket, C = 0.5
Pre-load pressure = 1.5p = 2.25 N/mm2

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 19

Solution: Step I: Calculate the load due to internal pressure

π
Load due to internal pressure, P = ------ D2 .p
4

3.142 x 3002 x 1.5

= ----------------------------- = 106040 N
4
Step II: Calculate the external load on each bolt
The load developed by steam pressure is resisted by the total number of bolts.

Total Load 106040 x 0.5

External load on each bolt, PE = -------------------- K = -------------------- = 6627.5 N
No of bolts 8

Selected stiffness factor, K = 0.5 for soft copper gasket

Step III: Calculate the pre-load due to initial tension on each bolt

Bolt Pre-load, PI = 1.5 x 6627.5 = 9941.3 N

Step IV: Calculate the maximum and minimum load

Maximum Load on each bolt, Pmax = PE + PI = 6627.5 + 9941.3 = 16568.8

Minimum Load on each bolt, Pmin = PI = 9941.3

Step V: Calculate the mean and variable stress

Pmax + Pmin 16568.8 + 9941.3

Mean Load, Pm = ---------------- = ------------------------ = 13255
2 2
Pm 13255 23689
Mean stress, σm = ----------------- = ------------------------ = -----------
(π/4) x dc2 (π/4) x (0.844d)2 d2

Pmax - Pmin 16568.8 - 9941.3

Variable Load, Pa= ---------------- = ------------------------ = 3313.8
2 2

Pa 3313.8 5922.3
Variable stress, σm = ----------------- = ------------------------ = ------------
(π/4) x dc2 (π/4) x (0.844d)2 d2

Step VI: Calculate the diameter of using Soldereberg equation for variable stresses
1 σm σa
------- = ------- + -------
n σy σ-1

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 20

1 23689 5922.3
------- = ----------------- + --------------
2 d2 x 330 d2 x 240

Calculated Nominal Diameter of bolt, d= 13.9 mm

Selected Nominal Diameter of bolt, d= 14.0 mm

PROBLEM TYPE#3: THREADED JOINTS

ECCENTRICALLY LOADED THREADED JOINT – TWISTING With 2 Shear stresses

12. A steel plate subjected to a force of 5kN and fixed to a channel by means of three identical bolts is as
shown in Fig. the bolts are made from plain carbon steel 45C8 and the factor of safety is 3. Specify
the size of bolts.

R1 R3
5 kN

1 2 3

75 75 200
30 30

Given: Load, P = 5 kN = 5000 N

Yield strength of 45C8 bolt material, σy= 380 N/mm2
Factor of safety = 3

Allowable shear stress of weld, [τ] = (0.5 σy) / Factor of safety = (0.5x380)/3 = 63.3 N/mm2

Solution: Step I : Fix the centroid of bolted joint

Due to symmetry, the centre of bolt no 2 is the centre of bolted joint

Step II : Calculate the direct / primary shear load on each bolt, PI

Primary shear load on each bolt = total load/ no of bolts = 5000/3 = 1666.7 N
Hence, PI-1 = PI-2 = PI-3 = 1666.7

Step III : Calculate the secondary shear load on each bolt, PII

(Pxe) x R1 5000 x 305 x 75

Secondary shear force in bolt 1, PI-1 = --------------------- = ----------------------- = 10166.7 N
(R12 + R32) (752 + 752)

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 21

Secondary shear force in bolt 2, PI-2 = 0 since the centroid coincides with bolt-2 centre. [R2=0]

(Pxe) x R3 5000 x 305 x 75

Secondary shear force in bolt 3, PI-3 = --------------------- = ----------------------- = 10166.7 N
(R12 + R32) (752 + 752)

Step IV : Calculate the Maximum shear load on each bolt, Pmax

Total shear force in bolt 1 = PI-1 + PII-1 = 1666.7 + 10166.7 = 11833.3 N

Total shear force in bolt 2 = PI-2 + PII-2 = 1666.7 = 1666.7 N
Total shear force in bolt 3 = PI-3 + PII-3 = 1666.7 + 10166.7 = 11833.3 N

Maximum shear force = 11833.3 N

Step V : Calculate the nominal size of bolt, d

P = (π/4) dc2 [τ] = (π/4) x (0.84d)2 [τ] {dc- Core Dia. of bolt)

11833.3 = (3.142/4) x (0.84d)2 x 63.3

Calculated Nominal Diameter of bolt, d= 18.4 mm

Selected Nominal Diameter of bolt, d= 20.0 mm

13. For supporting the travelling crane in a workshop, the brackets are fixed on steel columns as shown
in fig. the maximum load that comes on the bracket is 12 kN acting vertically at a distance of 400 mm
from the face of the column. The vertical face of the bracket is secured to a column by four bolts in
two rows (two in each row) at a distance of 50 mm from the lower edge of the bracket. Determine the
size of the bolts if the permissible value of the tensile stress for the bolt material is 84 MPa. Also find
the cross-section of the arm of the bracket which is rectangular.

e= 400
12 kN

L1=375

L2=50 All dimensions are in mm

Given: Load, P = 12 kN = 12000 N

Allowable tensile stress of bolt, [σt] = 84 MPa = 84 N/mm2

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints
 22

Step I : Calculate the direct shear stress on bolt, τ1

Total load 120000

Load on each bolt = ----------------- = ------------ = 3000 N
No of bolts 4

Bolt Load 3000 5412.7

Direct shear stress in bolt , τ1 = --------------- = -------------------- = ----------
(π/4) dc2 (π/4) (0.84d)2 d2

Step II : Calculate the tensile stress on bolt, PII

Since the tendency of the bracket is to tilt about the bottom edge, the bolts on top row are subjected to
maximum tensile load.

(Pxe) x L1 12000 x 400 x375

Tensile load in top row bolt, Pt = --------------------- = ------------------------ = 6288.2 N
2(L12 + L22) 2 x (3752 + 502)

6288.2 6288.2 11345.5

Tensile stress in top row bolt, σtop = --------------- = ----------------------- = ------------
(π/4) dc2 (π/4) x (0.84d)2 d2

Step III : Calculate the Maximum principal stress in bolt, Pmax

Maximum Normal Stress, σmax = ½ σb + σb 2 + 4τ2

11345.5 11345.5 2 5412.7 2

Maximum Normal Stress, σmax = 0.5 ----------- + ----------- + 4 ---------
d2 d2 d2

13513.5
= -----------
d2

Step V : Calculate the nominal size of bolt, d

σmax = [σ]

13513.5
------------- = 84
d2
Calculated Nominal Diameter of bolt, d= 12.7 mm
Selected Nominal Diameter of bolt, d= 14.0 mm

Design of Machine Elements Dr.M.Ramakrishnan, Professor, Mechanical Engineering, Hindustan University

Unit III : Design of Threaded & Welded Joints