ME3070: Design of Machine Elements

Tutorial 6
Indian Institute of Technology Palakkad

November 14, 2023

1. The figure (right) shows the bolted connection be-

tween a steel cylinder head and Grade 30 cast iron
cylinder. It has ten M12 x 1.75 bolts of grade ISO
9.8, a sealing gasket that is NOT a part of the mem-
bers that carry the external load. The bolts are to be
reused. Consider the half apex angle of the pressure-
cone to be 30 degrees. The relevant dimensions are:
𝐴 = 𝐵 = 25 mm, 𝐶 = 100 mm, 𝐷 = 150 mm, 𝐸 = 200
mm, 𝐹 = 300 mm.
a. Determine the bolt length to be used. (Mark: 2)
Figure 1: Problem-1
b. If the cylinder is subject to a maximum gas pressure of 10 MPa, determine the factor of safety
against yielding, against overload (loading factor), and against joint separation. Also check if the
number of bolts is sufficient to achieve uniform sealing pressure on the gasket. (Mark: 4)
c. Determine the fatigue factor of safety and factor of safety against yielding if the cylinder is subject
to a fluctuating pressure between 20 MPa and 10 MPa for infinite life. Also check if the preload
satisfies the upper bound criterion for satisfactory fatigue performance. (Mark: 4)
Solution:
Grip length: 𝑙 = 𝐴 + 𝐵 = 25 + 25 = 50 mm (no washer)
Obtain the nut height for M12 bolt from table A-31; 𝐻 = 10.8 mm
Fastner length: 𝐿 ≤ 𝑙 + 𝐻 = 50 + 10.8 = 60.8 mm
Standard Table A-17 suggests L = 80 mm (too large). So, choose length L= 65 mm.
Threaded length: 𝐿𝑇 = 2𝑑 + 6 = 30 mm
Unthreaded length in the grip: 𝑙 𝑑 = 𝐿 − 𝐿𝑇 = 65 − 30 = 35 mm
Threaded Portion in the grip: 𝑙𝑡 = 𝑙 − 𝑙 𝑑 = 50 − 35 = 15 mm
Area of unthreaded portion:

𝜋𝑑 2 𝜋(12) 2
𝐴𝑑 = = = 113.1 mm2
4 4
Tensile stress area:
𝐴𝑡 = 84.3 mm2
Bolt stiffness:
𝐴 𝑑 𝐴𝑡 𝐸
𝑘𝑏 =
𝐴 𝑑 𝑙 𝑡 + 𝐴𝑡 𝑙 𝑑
113.1 × 84.3 × 207
𝑘𝑏 = = 424.7 × 106 N/m
113.1 × 15 + 84.3 × 35

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Cylinder head: 𝑡 = 25 mm, 𝑑 = 12 mm, 𝐷 = 1.5𝑑 = 18 mm, 𝛼 = 30◦
0.57744𝜋𝐸 𝑑
𝑘1 = = 4149 × 106 N/m
(1.155𝑡 + 𝐷 − 𝑑)(𝐷 + 𝑑)
𝑙𝑛
(1.155𝑡 + 𝐷 + 𝑑)(𝐷 − 𝑑)
Cast iron:
0.57744𝜋100 × 12
𝑘2 = = 2004.76 × 106 N/m
(1.155 × 25 + 18 − 12)(18 + 12)
𝑙𝑛
(1.155 × 25 + 18 + 12)(18 − 12)
Member stiffness:
  −1   −1
1 1 1 1 1
= + = + = 1351.74 × 106 N/m
𝑘𝑚 𝑘1 𝑘2 4149.84 2004.76
Stiffness constant
𝑘𝑏 424.7
𝐶= = = 0.239
𝑘 𝑏 + 𝑘 𝑚 424.7 + 1351.74
Proof Strength (from Table 8-11): 𝑆 𝑝 = 650 MPa
Pre load: 𝐹𝑖 = 0.75𝐴𝑡 𝑆 𝑝 = 0.75 × 84.3 × 650 × 10−3 = 41.4 kN
b) Static loading:
10 × 10−3 × 𝜋/4(100) 2
𝑃 = 𝑃𝑡𝑜𝑡𝑎𝑙 /𝑁 = = 7.854 kN/bolt
10
𝑆 𝑝 𝐴𝑡 650 × 10−3 × 84.3
Yielding factor of safety: 𝑛 𝑝 = = = 1.274
𝐶𝑃 + 𝐹𝑖 0.226 × 7.854 + 41.1
𝑆 𝑝 𝐴𝑡 − 𝐹𝑖 650 × 10−3 × 84.3 − 41.1
Overload factor of safety: 𝑛 𝐿 = = = 7.296
𝐶𝑃 0.226 × 7.854
Separation factor of safety:
𝐹 41.1
𝑛𝑜 = = = 6.876
𝑃(1 − 𝐶) 7.854(1 − 0.226)
Note: Check for Gasket Sealing:
𝜋𝐷 𝑏 𝜋 × 200
= = 5.236 (ok)
𝑁𝑑 10 × 12
From Table 8-1: 𝑀12 × 1.75 is a coarse thread. If fine thread was chosen the 𝐴𝑡 would increase
making the joint stronger.
c) Fatigue Loading: 𝑝 𝑔 | 𝑚𝑎𝑥 = 20 MPa; 𝑝 𝑔 | 𝑚𝑖𝑛 = 10 MPa

=⇒ 𝑃𝑚𝑎𝑥 = 15.708 kN; 𝑃𝑚𝑖𝑛 = 7.854 kN

𝐹𝑏|𝑚𝑎𝑥 = 𝐶𝑃𝑚𝑎𝑥 + 𝐹𝑖 = 44.854 kN

𝐹𝑏|𝑚𝑖𝑛 = 𝐶𝑃𝑚𝑖𝑛 + 𝐹𝑖 = 42.977 kN
Alternating Stress:
𝐶 (𝑃𝑚𝑎𝑥 − 𝑃𝑚𝑖𝑛 ) 0.239 × 7.854 × 103
𝜎𝑎 = = = 11.13 MPa
2𝐴𝑡 2 × 84.3 × 10−6
Mid range stress:
𝐶 (𝑃𝑚𝑎𝑥 − 𝑃𝑚𝑖𝑛 ) 𝐹𝑖
𝜎𝑚 = + = 33.40 + 487.54 = 520.94 MPa
2𝐴𝑡 𝐴𝑡

2
 and 𝜎𝑖 = 487.54 MPa

Figure 2: Fatigue loading

Fully corrected endurance limit: 𝑆 𝑒 = 140 MPa (from Table 8-17)

𝑆 𝑒 .𝜎𝑎 (𝑆𝑢𝑡 − 𝜎𝑖 )
𝑆𝑎 = = 43.74 MPa
𝑆𝑢𝑡 𝜎𝑎 + 𝑆 𝑒 (𝜎𝑚 − 𝜎𝑖 )
Fatigue factor of safety:
𝑆𝑎
𝑛𝑓 = = 3.93
𝜎𝑎
Static yielding criteria:
𝑆𝑝
𝑛𝑝 = = 1.22
(𝜎𝑎 + 𝜎𝑚 )
Upper Bound on preload:
(1 − 𝐶)𝑆𝑢𝑡 𝐴𝑡 = 57.737 kN
Since, 𝐹𝑖 < 57.737 kN, the joint will be okay.
2. A 10 mm thick cantilever beam made of AISI 1020 cold-drawn steel is fastened to a 30 mm thick
plate also made of the same material. The plate is a part of a larger structure. Two M12 x 1.75 bolts
of grade ISO 5.8 are arranged horizontally as shown in the figure below to fasten the cantilever to
the plate. The left bolt center is placed 25 mm away from the left edge. The shear-joint has to be
designed with a factor of safety of 2.5. Bending of bolts, the shear tear out, and tensile tear out may
be ignored.

Figure 3: Problem-2

3
a. Find the maximum safe load F on the cantilever. Check for bending of the cantilever at critical
locations as well. (Mark: 5)
b. If the bolts are arranged vertically, keeping the centroid location and the distance between the
bolts the same, what would be the maximum safe load? Is this arrangement better than the horizontal
one? (Mark: 3)
c. Arrange the bolts diagonally (at 45° with the horizontal) keeping the centroid location and the
distance between the bolts the same. Without any further calculation, comment on which arrangement
among horizontal, vertical, and diagonal can take the largest load. (Mark: 2)
Solution:
Given: Thickness t = 10 mm, n = 2.5

Primary shear: 𝐹𝐴′ = 𝐹𝐵′ ≈ 𝐹/2

Secondary shear: (𝐹𝐴′′ + 𝐹𝐵′′) × 0.025 = 0.3𝐹

𝐹𝐴′′ = 𝐹𝐵′′ (𝑟 𝐴 = 𝑟 𝐵 = 0.025 m) =⇒ 𝐹𝐴′′ = 𝐹𝐵′′ = 6𝐹

Resultant shear:
On Bolt A: 𝐹𝐴 = 𝐹𝐴′′ − 𝐹𝐴′ =⇒ 𝐹𝐴 = 5.5𝐹
On Bolt B: 𝐹𝐵 = 𝐹𝐵′′ + 𝐹𝐵′ = 6.5𝐹
Design will be based on the load on bolt B.

Figure 4: FBD of Bolt system

Bolt material Grad: ISO 5.8 =⇒ 𝑆 𝑦 = 420 MPa (Table 8-11)
Cantilever Material: AISI 1020 Cold Drawn: 𝑆 𝑦 = 390 MPa (Table A-20)
a) Ignore bending of bolts:
1. Shearing of bolts: Shoulder cross-section

𝜋(122 )
𝐴𝑠 = = 113.1 mm2
4
𝑆 𝑠𝑦 = 0.577(420) = 242.34 MPa
𝐹𝐵 𝑆 𝑠𝑦
𝜏𝑚𝑎𝑥 = = =⇒ 𝐹𝐵 | 𝑚𝑎𝑥 = 10.963 kN
𝐴𝑠 𝑛
=⇒ 𝐹𝑚𝑎𝑥 = 1.687 kN
2. Bearing on Bolt: 𝐴𝑏𝑒𝑎𝑟𝑖𝑛𝑔 = 𝑡.𝑑 = 10 × 12 = 120 mm2

𝐹𝐵 𝑆𝑦
𝜎𝑏𝑒𝑎𝑟𝑖𝑛𝑔 = ≤ =⇒ 𝐹𝐵 ≤ 20.16 kN =⇒ 𝐹𝑚𝑎𝑥 = 3.10 kN
𝐴𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑛

𝐹𝐵 𝑆 𝑦 390
3. Bearing of Cantilever: ≤ = MPa =⇒ 𝐹𝐵 ≤ 18.72 kN =⇒ 𝐹𝑚𝑎𝑥 = 2.88 kN
𝐴𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑛 2.5
At B:
1
𝐼= × 10 × (1003 − 123 ) mm4 = 8.319 × 105 mm4
12
𝐶 = 50 mm
𝑀𝐵 .𝐶 0.275𝐹 × 0.05 𝑆 𝑦 390 × 106
𝜎𝑚𝑎𝑥 = = ≤ =
𝐼 8.319 × 105 × 10−12 𝑛 2.5
390 8.319
=⇒ 𝐹 ≤ × × 10−1 =⇒ 𝐹𝑚𝑎𝑥 = 9.438 kN
2.5 0.275 × 0.05

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At C:
𝐼 = 1.042 × 105 mm4 , 𝐶 = 0.025 m = 25 mm, 𝑚 𝑐 = 0.2𝐹
=⇒ 𝐹𝑚𝑎𝑥 = 3.251 kN
=⇒ Critical load is 𝐹 = 1.687 kN based on shearing of bolts.

b) If the bolts were arranged vertically

𝐹𝐴′′ = 𝐹𝐵′′ = 6𝐹

Resultant shear :
√︂
𝐹2
𝐹𝐴 = 𝐹𝐵 = + (6𝐹) 2 = 6.02𝐹
4
Maximum load on both bolts is less than that of case A.
This arrangement is better.
Critical Load: 𝐹𝑚𝑎𝑥 = 1.821 kN

Figure 5: if bolts were arranged vertically

c) If bolts were arranged diagonally at same distance.

Scenario-1 Scenario-2
Maximum Load on bolt B. Maximum Load on bolt A.
Without doing any further calculation
𝑏 = 6.02𝐹 < 𝐹𝐵|𝑚𝑎𝑥 < 𝑎 = 6.5𝐹 𝑏 = 6.02𝐹 < 𝐹𝐴|𝑚𝑎𝑥 < 𝑎 = 6.5𝐹
Arrangement (b)- vertical is better as it can withstand larger load.