4.

2 Bolt Design
The design includes six bolts which attaches the hydraulic arm with the base cylinder that is
attached to the frame of the vehicle.

Material:-ASTM 307
Property:-min proof strength (𝜎𝑦 =227.53MPA
-min tensile strength (𝜎𝑡 =413.69MPA
Analysis
Assuming the bolt to be subjected to shear only

σy 227.53
Shear stress, τ = F.S = = 113.77Mpa
2

Therefore, shear load carried by the bolt is;

𝑃𝑠 = 𝑚 ∗ 𝑔 = 54 ∗ 9.81 = 529.74 𝑁

𝜋
𝑃𝑠 = ∗ 𝑑² ∗ 𝜏 ∗ 𝑛
4

From the formula we can calculate diameter

4𝑃𝑠
𝑑 = √𝜋∗𝜏∗𝑛 , n = number of bolts which is; n= 6

d= major diameter of the bolt.

4 ∗ 529.74
𝑑=√
𝜋 ∗ 113.77 ∗ 6

𝑑 = 9.94 ≈ 10mm for safety purpose.

From standard bolt table, I chose regular Hex Head with diameter, d=10mm.

Table 1. bolt dimensions

 (Budynas−Nisbett: Shigley’s, 2009)

I also select plain type of washer from the table with diameter d=M10

Table 2. dimensions of plain washers

4.3 Design of Nut
PROCEDURE

1. Number of threads in engagement is found.

2. Height of the nut is determined.
3. Shear stress produced at the threads of the screw at the core diameter and at threads of the nut
at the major diameter is studied.
4. For safe design, these shear stresses are compared with the allowable stresses.

Fig 1. Design of nut

MATERIAL SELECTION

 phosphor bronze
PROPERTIES

 𝜎𝑦𝑡 = 126𝑀𝑃𝑎
 𝜎𝑦𝑐 = 112𝑀𝑃𝑎
 𝜏𝑦 = 105𝑀𝑃𝑎
ASSUMPTION

 Bearing pressure 𝑃𝑏 = 15.05𝑀𝑝𝑎

 Factor of safety =2
𝜎𝑦𝑡𝑎𝑙𝑙 = 63𝑀𝑃𝑎 , 𝜎𝑦𝑐𝑎𝑙𝑙 = 56𝑀Pa , 𝜏 = 52.5𝑀𝑝𝑎

ANALYSIS

 Dimension of the nut:

Wear of the nut
𝜋
𝐹 = 4 (𝑑𝑜² − 𝑑𝑐²) ∗ 𝑃𝑏 ∗ 𝑛 ………….n= number of the thread.
 4𝐹
𝑛=
𝜋(𝑑𝑜² − 𝑑𝑐²) ∗ 𝑃𝑏

do= outer diameter = 6.85

dc= core diameter = 0.4

4 ∗ 529.74
𝑛=
𝜋 ∗ (6.85 − 0.4) ∗ 15

𝑛 = 6.97

ASTM A570 ST - 50

Density 7.80 g/cc

Mechanical Properties Metric

Tensile Strength, Ultimate 450 MPa
Tensile Strength, Yield 345 MPa
Elongation at Break 10 - 11 %
11 - 17 %
Bulk Modulus 160 GPa
Shear Modulus
AL. alloy

Hardness, Vickers 15
Modulus of Elasticity 68.0 GPa
Poissons Ratio 0.36
Shear Modulus 25.0 GPa

Table 1: Typical Minimum AWWA DIP and Steel Pipe Properties

Property Ductile Iron Pipe Steel Pipe
Yield 42 ksi 33 – 55 ksi
Tensile 60 ksi 50 – 70 ksi
Elongation 10% 18 – 30%
Impact 5 ft-lb @ 70 deg. F 15 ft-lb @ 32 deg. F
Bend Not required by AWWA 180 degree
 BOLT
Table3.9 Selection of bolt head type

Weight Rectangular Grooved Hexagonal

Design criteria (%)
score Utility Score utility score utility

Aesthetic 30 5 2.1 7 2.4 9 1.5

Cost 20 8 1.6 7 1.4 6 1.2

Assembly 30 7 2.1 8 2.4 6 1.8

Manufacturability 20 8 1.6 8 1.6 7 1.4

Total utility 6.8 7 7.2

Rank 3 2 1

Continue? No no yes

♦ Hexagonal shaped headed bolt is selected for its better properties of aesthetic,
manufacturability, minimum cost, and easy assembly.

Table3.10 Selection of bolt material

Wrought Mild ASTM -307

Design criteria iron Steel
Weight
score utility Score utility Score Utility
(%)

Durability 25 6 1.5 9 2.25 10 2.3

Manufacturability 20 7 1.4 7 1.4 7 1.4

Cost 20 9 1.8 6 1.2 9 1.3

Corrosion resistance 10 8 0.8 6 0.6 6 0.55

 Strength 25 6 1.5 9 2.25 7 2.3

Total utility 7 7.7 7.85

Rank 3 2 1

Continue? No No Yes

♦ Mild steel is the better choice for bolt because of its high durability, strength, minimum cost,
easy manufacturability, density, and heat treatment.

Material selection for Hydraulic Cylinder

Criteria Weighted Stainless Steel Wrought Iron Cast Iron
(%)
 Score Utility Score Utility Score Utility

Good Strength 20 8 1.6 7 1.4 7 1.5

Toughness 18 6 0.9 7 1.1 6 0.95

Durability 14 5 0.8 8 0.95 6 0.9

Density 12 6 0.65 9 0.8 7 0.75

Stiffness 20 7 0.9 9 1.2 8 1.1

Corrosion 16 8 0.9 7 0.6 7 0.7

Resistance

Total Utility 5.75 6.05 5.9

Rank 3 1 2

Continue No Yes No

Material selection for Pin

 Criteria Weighted Steel- 42 alloy En -8 (C-40)
(%)
Score Utility Score Utility

Shear Strength 27 8 1.9 9 2.1

Crushing 27 6 1.7 8 1.9

Strength

Small Weight 11 7 0.85 7 0.9

Machinability 15 9 0.95 8 0.7

Wear 15 7 0.9 7 0.85

Resistance

Total Utility 6.3 6.45

Rank 2 1

Continue No Yes

Material selection for Brake

Criteria Cork Wood Molded Woven Sintered metal

metal
 Weig Score Utilit Scor Utilit Scor Utilit Scor Utility Score Utility
hted y e y e y e
(%)

Quick 25 6 1.4 6 1.3 8 1.6 9 1.7 9 1.75

Heat
dissipatio
n

Durabilit 25 7 1.5 6 1.3 9 1.8 8 1.6 7 1.5

y

High 25 8 1.65 9 1.8 7 1.6 8 1.65 8 1.6

Friction
Coefficie
nt

High 25 7 1.6 6 1.55 8 1.75 8 1.75 9 1.8

Contact
Pressure

Total 6.16 5.95 6.75 6.7 6.65

Utility

Rank
4 5 1 2 3
Continue
No No Yes No No

Types of Brake Selection

Criteria Weighted (%) Disk Drum

 Score Utility Score Utility

Quick Dissipated 25 8 1.9 7 1.7

Heat

Durability 6 1.7 8 1.85

High Friction 6 1.6 9 1.8

Coefficient

High Contact 7 1.6 8 1.75

Pressure

Total Utility 6.8 7.1

Rank 2 1

Continue No Yes

Material selection for Chassis Frame

Criteria Weighted (%) Aluminum Alloy Carbon Steel (St – 50)

 Score Utility Score Utility

High Bending 20 7 1.5 8 1.6

Moment

High Torsional 20 6 1.4 8 1.55

Strength

Small Weight 18 8 1.2 6 0.95

Manufacturability 15 7 1.0 7 1.0

Easy to assemble 10 7 0.5 8 0.6

Weldability 17 6 0.9 8 1.0

Total Utility 6.5 6.7

Rank 2 1

Continue No Yes

Selection of Chassis Types

Criteria Weighted Ladder Monocoque Bobocoque

(%)
Score Utility Score Utility Score Utility

High Bending
Moment

High Torsional
Strength

Small Weight

Manufacturability

Easy to assemble
 Weldability

Total Utility

Rank

Continue

Selection of Chassis Types

Criteria Weighted Rack & pinion Telescopic x-bar(scissor) L-bar

(%) cylinder

Score Utility Score Utility Score Utility Score Utility

High 20 8 1.1 9 1.2 9 1.15 8 1

Bending
Moment

Carrying 20 6 0.8 8 1.1 9 1.2 7 1

capacity

Corrosion 15 6 0.85 8 1.1 7 1.05 8 1.1

resistant

Cost 10 5 0.5 7 0.65 7 0.6 8 0.8

Easy to 15 6 0.8 8 1.05 6 0.9 8 1.0

assemble

Output power 20 6 1.1 9 1.4 9 1.3 8 1.2

Total Utility 5.15 6.5 6.2 6.1

Rank 4 1 2 3

Continue No Yes No No

Therefor, we select Telescopic cylinder.

Design for pin in the hinge

Specification:-

Load on the cylinder W=2943N

For the reason of the mechanism (i.e. to satisfy the rotation required the base.) the following
dimensions are taken.

L = 200mm, z = 30mm, x = 35mm, and h =0.88xD.

Material:-

St37 (FE360)

σy = 235Mpa

Assumption:-

 Factor of safety (fs) = 1.5 (for static loading and ductile material fs recommended is 1.5
up to 2).
 The telescopic cylinder will induce reaction force on the upper and lower housings and
the load will transmit to the pin.
 The pin is subjected to bending stress, shear stresses, and a key which is on the pin has
subjected and crushing.

Load on the pin due the reaction force of the cylinder (W/2 = 1471.5N)

Its perpendicular component Wp = W/2*sine 600 = 1699.4N.

Its tangential component Wt = W/2*cosine 600 = 2943N.

 L  x    200  35  242.8KNm

W 2943
The maximum Bending moment M max 
2 2

𝜏 = 0.5 ∗ 𝜎𝑦 = 117.5𝑀𝑃𝑎
𝜏 117.5
𝜎𝑎𝑙𝑙 = = =78.33MPa
𝐹.𝑆 1.5

𝜋𝑑3 242.8𝐾𝑁𝑚
=
32 78.3𝑀𝑃𝑎

𝑑 3 = 31,589.36

D=31.61mm≈32mm
Check for shear stress:-

D 2 W 2943
As   803.84mm2     max    1.83Mpa   all   max , this is so safe.
4 2 As 2803.84

 The key dimensions are determined as follows:-

The critical stress in the key is crushing stress.

W
 cr   max   Acr  z  T 
2 Acr
W 2943N
T    6..2mm  8mm
2 * z   all 2 * 30mm  78.3MPa