ME3011D- Machine Design- I-Threaded fasteners

Ilango M

February 14, 2024

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Threaded fasteners
A threaded joint is a type of connection between machine parts, where they are held
together by a threaded fastening like a bolt and a nut.
▶ Detachable Connection: Allow machine parts to be held together and easily taken
apart without causing damage. This is different from welded joints, which are
permanent.
▶ Thread as the Basic Element: Threads, which are helical grooves on a cylindrical
rod or hole, are the essential components of threaded joints. These threads can
take the form of bolts, nuts, screws, or studs. In some cases, threads are cut
directly on the parts to be joined.
▶ Widespread Usage: Threaded joints are widely used in mechanical assemblies,
with over 60% of parts incorporating threads. This popularity is attributed to the
advantages they offer.

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TERMINOLOGY OF SCREW THREADS
▶ Right-hand threads are usually used unless a left-hand thread is
specifically needed. Unless stated otherwise, specifications for
threads assume right-hand threads.
▶ When a screw is vertical, right-hand threads have lines sloping
upward from left to right, while left-hand threads have lines
sloping downward from left to right.
▶ Major Diameter: The major diameter is the largest diameter
of the screw thread. For external threads, it’s the diameter
of a cylinder around the thread crest (d), and for internal
threads, it’s the diameter of a cylinder around the thread
root (D).
▶ Minor Diameter: The minor diameter is the smallest
diameter of the screw thread. For external threads, it’s the
diameter of a cylinder around the thread root (dc ), and for
internal threads, it’s the diameter of a cylinder around the
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Terminology of screw threads

▶ Pitch Diameter: The pitch diameter is the diameter of an

imaginary cylinder that intersects the threads to make the
thread width equal to the space between threads. Denoted
as dp for external threads and Dp for internal threads, it’s
also known as the effective diameter.
▶ Pitch: Pitch is the distance between similar points on adjacent threads measured
parallel to the thread axis, denoted by the letter ’p’.
▶ Lead: Lead is the distance the nut moves parallel to the screw axis with one turn.
▶ Thread Angle: The thread angle is the angle between the sides of the thread in an
axial plane. For ISO metric threads, the thread angle is 60 degrees.
▶ Tensile Stress Area: During testing, it’s observed that an unthreaded rod with a
diameter equal to the mean of the pitch diameter and the minor diameter
[(dp + dc )/2] has the same tensile strength as the threaded rod.
▶ The cross-sectional area of this unthreaded rod is called the ’tensile-stress area’
and is used to calculate the tensile strength of bolts. 4 / 49
Iso metric screw threads:
Metric threads- Distance between each thread in millimeters (mm). Fastening threads
are typically V-shaped threads, and they offer several advantages:
▶ Reduced Loosening: Vee threads create higher friction, reducing the chances of
threads coming loose.
▶ Increased Strength: Vee threads have higher strength because of the greater
thickness at the core diameter.
▶ Ease of Manufacturing: Vee threads are more convenient to manufacture.
▶ The profile of an ISO metric screw thread is like an equilateral triangle with a 60°
thread angle. The base of the triangle equals the pitch.

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Iso metric screw threads:

▶ The tooth profile shows flattened or rounded crests and roots, essential for
fastening threads, providing advantages
▶ Reduced Stress Concentration: Flattened or rounded crests and roots reduce
stress concentration in threads.
▶ Extended Tool Life: This tooth profile increases the tool life of the thread-cutting
tool.
▶ Prevention of Damage: It lowers the risk of damaging threads through denting.
▶ Leakage Prevention: In fluid-tight threads, it prevents leakage as there is
engagement on crests and roots.
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Iso metric screw threads:
Metric threads come in coarse and fine series, with the coarse thread considered the
basic series.
▶ Coarse Threads: preferred for: Higher Static Load Capacity, Ease of Cutting,
Resilience to Manufacturing Errors, Less Likely to Seize, Coarse threads are less
likely to seize during tightening. Coarse threads are recommended for general
industrial applications without vibrations. Even Stress Distribution. Designation:
Coarse series threads are designated by ’M’ followed by the nominal diameter in
mm (e.g., M 12).
▶ Fine Threads: Greater Strength for Fluctuating Loads: Fine threads have greater
strength when dealing with fluctuating loads. Resistance to Unscrewing: Due to a
lower helix angle, fine threads are more resistant to unscrewing. Fine series
threads are specified by ’M’ followed by the nominal diameter, pitch in mm, and
separated by the symbol ’X’ (e.g., M 12 X 1.25). Parts facing dynamic loads and
vibrations (e.g., automobile applications).

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Bolted joints - simple analysis:
In a bolted joint under tension, the maximum tensile stress at the core diameter
(weakest section) is given by a σt = πP 2
.
4
dc
To find the nut’s height (h), we compare the bolt’s strength in tension to its strength
in shear. This process relies on a few assumptions:
▶ Equal Load Distribution: Each turn of the thread supporting the
nut bears an equal load.
▶ No Stress Concentration in Threads: There is no stress
concentration in the threads.
▶ Yield Strength Relation: The yield strength in shear (Ssy ) is half
of the yield strength in tension (Syt ).
▶ Failure Location: Failure occurs in the bolt threads, not in the
nut threads.
By applying these assumptions, we can determine the nut’s height in
the bolted joint.
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Bolted joints - simple analysis:
▶ Tensile stress on the bolt, σt = P
.
π 2
d
4 c

▶ Considering yield strength-Syt and factor of safety-fs, σt = Sfsyt

▶ The strength of the bolt in tensile loading is given by
S

P = π4 dc2 fsyt
▶ The threads of the bolt in contact with the nut are sheared at
the core diameter dc . The shear area is equal to (πdc h), where h
is the height of the nut.
▶ The strength of the bolt in shear loading is given by
S
Syt

P = (πdc h) fssy = (πdc h) 2∗fs
▶ Equating the strength of the bolt in tension and shear h = 0.5dc
and assuming dc = 0.8d, h = 0.4d minimum is needed.
▶ The height of the standard nut is h = 0.8d. Hence, the threads
of the bolt in contact with the standard nut will not fail by shear
loading.
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Bolted joints - design:
▶ In designing a bolt, determining the correct size involves the nominal diameter (d)
and pitch (p).
▶ Design calculations often use the core diameter (dc), so converting dc to d is
necessary.
▶ This conversion is straightforward with tables like (7.1) and (7.2).
▶ By knowing the core diameter, you can find the corresponding thread designation
from these tables.
▶ In absence of tables, an approximate relationship is recommended: dc = 0.8d. It’s
better to use values from Tables 7.1 and 7.2 for accuracy in design.

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Practice problems on bolted joints :

(1) An electric motor weighing 10kN is lifted by means of an eye bolt as shown in
Figure. The eye bolt is screwed into the frame of the motor. The eye bolt has coarse
threads. It is made of plain carbon steel 30C 8(Syt = 400N/mm2 ) and the factor of
safety is 6. Determine the size of the bolt.

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Tables for bolted joints- coarse threaded:

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Tables for bolted joints- fine threaded:

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Practice problems on bolted joints :

(2) Two plates are fastened by means of two bolts as shown in Figure. The bolts are
made of plain carbon steel 30C 8(Syt = 400N/mm2 ) and the factor of safety is 5.
Determine the size of the bolts if,

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Eccentrically loaded bolted joints :
▶ Consider a group of bolts holding a frame as shown in the Figure. Each bolt has a
specific size (A1 , A2 , ..., A5 ) and is positioned at certain coordinates
(x1 , y1 ), (x2 , y2 ), ..., (x5 , y5 ).
▶ The geometric center of all these bolts is represented by G at coordinates (x̄, ȳ ).
Sometimes, the center is found through symmetry.
▶ Now, let’s say there’s an external force (P) acting off-center (eccentrically) from
the center of gravity.
▶ To make things simpler, we can pretend this force is actually acting at the center
of gravity with a certain imaginary force (P) and a moment (P ∗ e) creating a
turning effect.

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Eccentrically loaded bolted joints in shear:

′
▶ This imaginary force at the geometric center causes primary shear forces (P1 ,
′ ,...)
P2 at each bolt.
P
P1′ = P2′ = ,
n
′′ ′′
▶ The moment (P ∗ e) results in secondary shear forces (P1 , P2 , ...) at each bolt,
where the distance from the center of gravity (r1 , r2 , ...) is taken into account.
P1” ∗ r 1 + P2” ∗ r2 + P3” ∗ r3 + ... = P ∗ e
▶ It is assumed that the secondary shear force at any bolt is proportional to its
distance from the geometric centre. P1 ” = cr1 , P2 ” = cr2 , P3 ” = cr3
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Eccentrically loaded bolted joints in shear:

P1” ∗ r 1 + P2” ∗ r2 + P3” ∗ r3 + ... = P ∗ e =⇒ c ∗ r12 + c ∗ r22 + c ∗ r32 + ... = P ∗ e

▶ The primary P ′ and the secondary P” shear forces acting on the bolt can be
found.
▶ Adding up primary and secondary shear forces using vector addition gives us the
resultant shear forces (P1, P2, P3, P4). The analysis assumes that the connected
components are rigid, and all bolts have the same cross-sectional area.
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Problem based on eccentrically loaded bolted joints in shear:

Figure: Bolted joints in shear

(3) The structural connection shown in Figure 1 is subjected to an eccentric force P of

10 kN with an eccentricity of 500 mm from the CG of the bolts. The centre distance
between bolts 1 and 2 is 200 mm, and the centre distance between bolts 1 and 3 is
150 mm. All the bolts are identical. The bolts are made from plain carbon steel
30C 8(Syt = 400N/mm2 ) and the factor of safety is 2.5. Determine the size of the
bolts.
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Eccentric load perpendicular to axis of bolt:

Figure: Bolted joints in shear and tensile loading

▶ Imagine a bracket attached to a steel structure with four bolts, as shown in Figure
3.
▶ The bracket experiences an off-center force (eccentric force) labeled as P, located
at a distance e from the structure.
▶ This force P acts perpendicular to the axis of each bolt.
▶ The lower two bolts are referred to as 2, and the upper two bolts as 1.
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Eccentric load perpendicular to axis of bolt:

Figure: Bolted joints in shear and tensile loading

Assumptions:
1. The bracket and the steel structure are assumed to be rigid.
2. The bolts are placed in precisely made holes and are not preloaded.
3. There are no initial tensile stresses due to tightening.
4. Stress concentration in the threads is ignored.
5. All bolts are identical.
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Eccentric load perpendicular to axis of bolt:
▶ When force P is applied, it causes a direct shear force
on the bolts. Since all bolts are the same, the shear
force on each bolt, P1′ = P2′ = Pn
▶ The moment (P ∗ e) tries to tilt the bracket around the
edge C . Each bolt is stretched δ in proportion to its
vertical distance from point C . This means δ1 is
proportional to l1 , and δ2 is proportional to l2 .
▶ Using the relationships between force, stress, strain, and stretch, we find that the
resisting force in any bolt, due to the bracket’s tilting tendency, resisting force
acting on the bolt is proportional to its distance from the tilting edge.
▶ If P1 ” and P2 ” are the resisting forces in the bolts, then P1 ” is proportional to l1 ,
and P2 ” is proportional to l2 . Mathematically, P1 ” = cl1 and P2 ” = cl2 , where c
is a constant.

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Eccentric load perpendicular to axis of bolt:
▶ Equating the moment due to resisting forces with the
moment due to the external force P about edge C gives
us an equation.

P ∗ e = 2P1 ”l1 + 2P2 ”l2 =⇒ P ∗ e = (2cl12 + 2cl22 ) (1)

▶ Solving this equation, we find c in terms of P and the distances l1 and l2 .

Substituting this back into the expressions for P1 ” and P2 ” gives us the final
formulas for the resisting forces in the bolts.
P ∗ el1 P ∗ el2
P1 ” = , P2 ” =
2(l12 + l22 ) 2(l12 + l22 )
▶ In simple terms, these equations tell us the shear and tensile forces acting on each
bolt when an off-center load is applied perpendicular to the bolt axis. The bolts
farther from the tilting edge experience greater forces.
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Eccentric load perpendicular to axis of bolt:
▶ The bolts denoted by 1 are subjected to maximum force.

P ∗ el1 P ∗ el2
P1 ” = 2 2
, P2 ” =
2(l1 + l2 ) 2(l12 + l22 )

▶ P1′ = P2′ = P
n

▶ The tensile stress in the bolt is given by, σt = P1 ”

A
′
▶ Shear stress in the bolt τ = PA1 , where A is the cross-sectional area of the bolt at
the minor or core diameter.
▶ The bolts can be designed on the basis of principal stress theory or principal shear
stress theory.
▶ The cross-sectional area of the bolts and their size can be determined. The bolt
material is usually ductile. Therefore, it is appropriate to use the maximum shear
stress theory of failure.
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Problem involving solution of eccentric load perpendicular to axis of bolt:
(4) A bracket is fastened to the steel structure by means of six identical bolts as shown
in Figure. Assume the following data: l1 = 300mm, l2 = 200mm, l3 = 100mm,
l = 250mm, P = 50kN Neglecting shear stress, determine the size of the bolts, if the
maximum permissible tensile stress in any bolt is limited to 100N/mm2

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Eccentric load on circular base:
▶ Often, machine parts have circular bases and are attached to structures using
bolts arranged in a circle. Examples include flanged bearings in machine tools and
the pillars of cranes.
A typical setup is shown in Figure, where a round flange-bearing is secured with four
bolts and subjected to an external force (P) at a distance (l) from the support. When
the load tries to tilt the bearing around point C , each bolt stretches by an amount
(δ), which is proportional to its vertical distance from point C .
5. Shear stresses in bolts are alleviated with dowel
1. All bolts are the same. pins.
2. Bearing and structure- rigid.
3. Bolts are not preloaded, and
there’s no initial tensile stress
from tightening.
4. Stress concentration in
threads is ignored.
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Eccentric load on circular base:
▶ So, when a bearing tends to tilt, the resisting force on any bolt is proportional to
its distance from the tilting edge.
▶ Let’s call these resisting forces P1 , P2 , and so on. Each P is equal to some
constant C times the respective distance from the tilting edge, which we’ll call l1 ,
l2 , and so forth. P1 = Cl1
▶ By equating the moment due to the external force P about point C with the
moments due to the resisting forces,
Pl = P1 l1 + P2 l2 + P3 l3 + P4 l4
▶ Now, for a specific bolt (let’s say bolt 1), we find its force using its distance (l1 )
and the derived constant C. We use the P1 = (l 2 +lPll2 1+...) to determine this force.
1 2
▶ So we need to know the
lengths l1 , l2 , ... measured
from the tilting point C.
These lengths have a
dependence on the geometric
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Eccentric load on circular base:
▶ We have a flange with a radius (a) and bolts arranged in a circle with a radius (b).
▶ From Fig.(b), the distances (l1 , l2 , l3 , l4 ) from the center of the flange to each bolt
are calculated as follows:
l1 = a − bcos(α)
l2 = a + bsin(α)
l3 = a + bcos(α)
l4 = a − bsin(α)
▶ Now, to find the sum of the squares of these distances, we use:
(l12 + l22 + l32 + l42 ) = 4a2 + 2b 2

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Eccentric load on circular base:
▶ Substituting this into the formula for the force on bolt 1 (P1 ), derived previously,
we get:
P1 = 2Pl(a−bcos(α))
(4a2 +2b 2 )
▶ This formula can be generalized for any number of equally spaced bolts (n):
P1 = 2Pl(a−bcos(α))
(n∗(2a2 +b 2 ))
▶ When the angle ’α’ is 180 degrees, the force P1 on bolt 1 is at its maximum. This
happens because the term cos(α) reaches its minimum value (−1) at this angle.
Bolt 1 is positioned at the topmost location, farthest from the tilting edge C,
when α = 180o .
2Pl(a+b)
Pmax = (n(2a 2 +b 2 ))

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Eccentric load on circular base:
▶ This equation provides the absolute maximum force any bolt experiences. It’s
useful for determining bolt sizes, especially when the direction of the external
force P can change, as in the case of the base of a vertical pillar crane.
2Pl(a+b)
Pmax = (n(2a 2 +b 2 ))

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Eccentric load on circular base: Equally stressed arrangement
▶ When the direction of the external force P is fixed, we can reduce the maximum
load on the bolts so that two of them are equally stressed, as shown in Figure (c).
▶ In this specific case with 4 bolts, the angle ’α’ made by the center line of bolt 2 is
135o .
▶ For a general case with ’n’ bolts: Angle ’α’ can be calculated as
α = 180 − (360/n).
▶ The angle ’β’ between bolts can be calculated as (360/2n).
▶ To find cos(α), we use the formula:
cos(α) = cos(180 − (360/2n)) = −cos(360/2n) = −cos(180/n)

▶ Substituting this
value of cos(α), we
get:

2Pl(a + bcos(α))
P1 =
(n(2a2 + b 2 ) 30 / 49
Eccentric load on circular base: Equally stressed arrangement
▶ Substituting this value of cos(α), we get:

2Pl(a + bcos(α)) 2Pl(a + bcos( 180

n ))
P1 = 2 2
=⇒ 2 2
(n(2a + b ) (n(2a + b )

This equation only applies when two bolts are equally stressed. This condition holds
true when:
▶ The direction of the external
force P is fixed.
▶ The number of bolts is even.
▶ Two bolts at the top are
symmetrically spaced with
angle ’β’ on either side of the
vertical line.

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Problem involving eccentrically loaded on circular base bolted joints:
(5) A round flange bearing, as shown in Figure, is fastened to the machine frame by
means of four cap screws spaced equally on a 300mm pitch circle diameter. The
diameter of the flange is 400mm. The external force P is 25kN, which is located at a
distance of 150mm from the machine frame. There are two dowel pins to take shear
load. The cap screws are relieved of all shear force. Determine the size of the cap
screws, if the maximum permissible tensile stress in the cap screw is limited to
50N/mm2 .

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Problem involving eccentrically loaded on circular base bolted joints:
(6) A pillar crane, shown in Figure, is fastened to the foundation by means of 16
identical bolts spaced equally on 2m pitch circle diameter. The diameter of the pillar
flange is 2.25m. Determine the size of the bolts if a load of 50 kN acts at a radius of
7.5 m from the axis of the crane. The maximum permissible tensile stress in the bolt is
limited to 75N/mm2 .

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Preloading of Bolted joint:
A bolted assembly of two components is shown in Figure. Initially, the nut is tightened
by means of a spanner, which results in tensile stress in the bolt.
▶ The tensile stiffness of a bolt kb′ , P/δ = PAE
Pl =⇒ kb′ = AE l ,

Bolted joint stiffness

Bolt stiffness Annular area stiffness

▶ The combined stiffness of two components in the grip of the bolt (kc’)- springs in
series
1 1 1
′
= ′ + ′
kc k1 k2
▶ The area compressed by the bolt head and nut is assumed to be annular, with
outer and inner diameters of 3d and d respectively.
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Preloading of Bolted joint:
▶ Pre-load Calculation- when the nut is tightened initially, the bolt experiences a
pre-load (Pi ), causing elongation (δb ) of the bolt and compression (δc ) of the
parts.
▶ Force-Deformation Diagram- shows the elongation of the bolt (OA) and
compression of the parts (CA). Further external force (P) causes additional
elongation (∆δ) of the bolt, increasing the bolt load (∆P), and relieving
compression in the parts, reducing their load (P − ∆P).
∆P
kb′ =
∆δ
P − ∆P
kc′ =
∆δ
Simplifying the two equations

kb′

∆P = P ′ ′
(kb + kc )
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Preloading of Bolted joint:

′
▶ The change in bolt load (∆P) is calculated using the formula ∆P = P (k ′k+k
b
′)
b c
▶ The resultant load on the bolt (Pb = Pi + ∆P)
▶ Limiting Point- as the external load increases, the bolt continues to deform until
reaching point M, where compression in the parts becomes zero, and the joint
may start to open. The parts can no longer expand to maintain a tight joint,-
okay but so what?- leaky joint imagine a IC engine cylinder head.
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Preloading of Bolted joint- how to find the limiting point?

▶ Use similar triangles

¯
AG ¯
MC Pi (Pb )max
¯ = ¯ =⇒ =
OG OC δ b δb + δc
Pi
(Pb )max = ∗ (δb + δc )
δb

▶ As (δb = Pi Pi
kb′
) and (δc = kc′ )
Pi
▶ (Pb )max = kb′
∗ (kb′ + kc′ )

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Preloading of Bolted joint- gasketed joint
▶ We have
Pi
(Pb )max = ∗ (kb′ + kc′ )
kb′

as we derived earlier,
kb′

∆P = P ′ ′
(kb + kc )

′
▶ Dividing the numerator and denominator by kb′ and stating a term a = kkc′ (ratio of
b
stiffness)
P
∆P =
1+a
▶ Pb = Pi + ∆P - We get the relationship between the resultant load on the bolt
with initial tension Pi and the external load P
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Preloading of Bolted joint- gasketed joint
kc′
▶ a= kb′
(ratio of stiffness)

P
∆P =
1+a
▶ Pb = Pi + ∆P - We get the relationship between
the resultant load on the bolt with initial tension Pi
and the external load P
′
▶ Soft gasket kc is too small compared ▶ Hard gasket kc′ is too large compared
with the bolt stiffness kb′ , with the bolt stiffness kb′ ,
kc′ kc′
▶ As a = ,
a=0 ▶ As a = a = ∞,
kb′
,
kb′
1
 
▶ ∆P = P 1+a
 1 
▶ ∆P = P 1+a = P =0
▶ Pb = Pi + ∆P = Pi + P ▶ Pb = Pi + 0 = Pi
▶ Resultant load on the bolt is sum of ▶ Resultant load on the bolt is initial
initial tension and the external load. tension only.
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Problem involving preloading of threaded joint:
(7) Two circular plates with (2d) and (d) as outer and inner diameters respectively,
are clamped together by means of a bolt as shown in Figure. The bolt is made of plain
carbon steel 45C8 (Syt = 380N/mm2 and E = 207000N/mm2 ), while the plates are
made of aluminium (E = 71000N/mm2 ). The initial pre-load in the bolt is 5kN and
the external force acting on the bolted joint is 10 kN. Determine the size of the bolt, if
the factor of safety is 2.5.

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Fatigue loading in threaded joint:
▶ In many cases, the force on bolted joints fluctuates within certain limits. To
determine failure in these situations, we use the endurance limit as a criterion.
▶ Bolt grades are ranked by their tensile strength, with higher grades indicating
greater strength. Rolled threads, which have smoother finishes and continuous
material grain, are preferred for applications with fluctuating loads.
▶ After finding the endurance strength, a Goodman diagram is created to analyze
potential failures.
▶ One key point to note include incorporating surface finish into the fatigue stress
concentration factor, assuming a size factor of 1 for axial loading, and setting
reliability at 90%
▶ An analysis of bolt failures shows that a significant portion occur at the fillet
under the head- 15%, at the end of threads on the shank- 20%, and in the
threads that contact the nut- 65%.

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Fatigue loading in threaded joint:
kb′
▶ Force on the bolt is Pb = Pi + ∆P, where ∆P = ′
kb +kc′
P
′
▶ Defining a factor C = k ′k+k


′ , Pb = Pi + CP
b
b c
▶ In many cases, the external applied load acting on the bolt fluctuates from zero to
some maximum value (P).
▶ The maximum and minimum bolt load is given by,
(Pb )max = Pi + CP and (Pb )min = Pi and
▶ The maximum and minimum stresses in the bolt are given by,

Pi CP
σmax = +
A A
and
Pi
σmin =
A
where A is tensile stress area of the bolt.
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Fatigue loading in threaded joint:
▶ The maximum and minimum stresses in the bolt are given by, σmax = PAi + CP A
and σmin = PAi
▶ The mean stress is given by, σm = 12 (σmax + σmin ) = σm = PAi + CP2A
▶ The alternating stress is given by, σa = 12 (σmax − σmin ) = σm = CP
2A
▶ We have the relationship between the alternating stress and mean stress value as
Pi
σa = σm −
A
▶ Think about the above equation as y = x − a, as in fluctuating stress, we will be
plotting σm along x-axis and σa along y − axis

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Fatigue loading in threaded joint:-Goodman diagram
▶ Equation of the Goodman line is given by SSa + SSm = 1 =⇒ Sm = Sut (1 − SSa )
e ut e
▶ The equation of the bolt under fluctuating load varying between Pmax and 0 is ,
σa = σm − PAi =⇒ σm = σa + PAi
▶ Further, factor of safety (fs), fs = σSa and fs = σSm =⇒ Sm = Sa + PAi
a m
▶ Point C is Sm = Sa + PAi and Sm = Sut (1 − SSa )
e
▶ Combining the two,
Sut − PAi
Sa =
[1 + SSute ]
Sa
and σa = fs

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Problem involving fatigue loading of threaded joint:
(8) The assembly of two circular plates clamped together by means of a bolt, which is
shown in Figure, is subjected to a variable force P varying from 0 to 10 kN. The bolt is
made of plain carbon steel 45C8 (Sut = 630N/mm2 ; Syt = 380N/mm2 and
E = 207000N/mm2 ). The two circular plates are made of aluminium
(E = 71000N/mm2 ). The fatigue stress concentration factor is 2.2 and the expected
reliability is 90%. The initial pre-load in the bolt is 5 kN. Determine the size of the
bolt if the factor of safety is 2.

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Bolted joints used in connecting rods: Special case
▶ The bolts of a connecting rod are subjected to initial pre-load Pi plus fluctuating
external load P.′
▶ Pb = Pi + (k ′k+k
b
′ ) P =⇒ Pb = Pi +
1
kc′
b c (1+ k ′ )P
b

▶ The designer can select dimensions of

the bolt and the connected parts in
′
such a way that a specific ratio [ kkc′ ] is
b
obtained.
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Bolted joints used in connecting rods: Special case

▶ Suppose, the combined stiffness of

parts held together by bolt is ten times
the stiffness of the bolt ( kc′ = 10kb′ ).

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Bolted joints used in connecting rods: Special case
Connecting rod bolts are tightened with initial tension greater
than the external load for a few reasons:
▶ When the initial pre-load in the bolt is higher than the
external load, the fluctuating part of the load becomes
negligible compared to the total load. This means the bolt
mostly deals with a static load, simplifying the design
process to consider only static failure.
▶ If the initial pre-load isn’t high enough, the fluctuating load
becomes significant and affects the total load on the bolt.
This requires designing the bolt based on endurance limit to
prevent fatigue failure.
▶ In automotive applications, it’s preferable to design bolts
based on their static strength rather than their endurance
limit. Therefore, connecting rod bolts in IC engines
tightened with very high pre-load, bringing stress close to
the yield point.
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Problem involving fatigue loading in Bolted joints:
(9) A copper reinforced asbestos gasket is used between the cover plate and the
flanged end of a pressure vessel as shown in Figure. The pressure inside the vessel
varies from 0 to 1 MPa during the operation. The gasket requires a seating pressure of
5 MPa to make the joint leakproof. The total number of bolts used is 8. The ratio of
stiffness of the parts held together by the bolts to the stiffness of the bolts is 4. The
effective sealing area may be taken up to the mean radius of the gasket. The factor of
safety is to be 2 for the fluctuating load. The following data is given for the bolts: Bolt
material = 40Ni3, Ultimate tensile strength = 780 MPa, Yield point strength = 580
MPa, Endurance limit in bending = 260 MPa Fatigue stress concentration factor =
3.0, Determine the size of the bolts

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