DEPARTMENT OF MECHANICAL ENGINEERING

2023 – 2024 (Odd Semester)

20MEPC504 – Design of Machine Elements

Assignment – V (Answer Key)

Permanent and Temporary Joints

Date of Issue: 19.12.2023 (Tuesday)

1. Design a Knuckle joint to connect two circular rods subjected to an axial tensile force of
50kN. Select a suitable material with a factor of safety of 4. (CO 4) (K3)

Material ➔ C 30 Steel; From (DDB 1.11)

σyt = 400 N/mm2 σyc = 1.5 σyt = 600 N/mm2 τy = 0.5 σyt = 200 N/mm2
σt = (σyt /FS) = 100 N/mm 2
σc = (σyc /FS) = 150 N/mm2 τ = (τy /FS) = 50 N/mm2

1. Tensile Failure of Rods

𝛑
Tensile Load, 𝐏 = 𝐝𝟐 𝐱 𝛔𝐭 ➔ d = 30mm
𝟒

✓ Diameter of Pin, d1 = d = 30mm; Outer Diameter of Eye, d2 = 2d = 60mm;

✓ Diameter of knuckle pin head and collar, d3 = 1.5d = 45mm;

✓ Thickness of single eye or rod end, t = 1.25d = 38mm;

✓ Thickness of fork, t1 = 0.75d = 23mm; Thickness of pin head, t2 = 0.5d = 15mm;

2. Shear Failure of Knuckle Pin

𝛑
Shear Strength of Pin (Double Shear), 𝐏 = 𝟐 𝐱 𝐝𝟐𝟏 𝐱 𝛕 ➔ d1 = 25.23mm
𝟒

3. Bending Failure of Knuckle Pin

𝟑𝟐 𝐏 𝐭 𝐭
Maximum Bending Stress, 𝛔𝐛𝐭 = 𝐱 [ 𝟏 + ] ➔ d1 = 35.22mm
𝛑𝐝𝟑𝟏 𝟐 𝟑 𝟒

Taking Larger value of d1 = 40 mm

d2 = 80mm & d3 = 60mm

4. Tensile Failure of Eye

Tensile Strength of Eye, 𝐏 = (𝐝𝟐 − 𝐝𝟏 )𝐭 𝐱 𝛔𝐭 ➔ σt = 32.89 N/mm2;

 5. Shear Failure of Eye

Shear Strength of Eye, 𝐏 = (𝐝𝟐 − 𝐝𝟏 )𝐭 𝐱 𝛕 ➔  = 32.89 N/mm2;

6. Crushing Failure of Pin in Eye

Crushing Strength of Eye, 𝐏 = 𝐝𝟏 𝐱 𝐭 𝐱 𝛔𝐜 ➔ σC = 32.89 N/mm2;

7. Tensile Failure of Fork

Tensile Strength of Fork, 𝐏 = (𝐝𝟐 − 𝐝𝟏 )𝟐𝐭 𝟏 𝐱 𝛔𝐭 ➔ σt = 27.17 N/mm2;

8. Shear Failure of Fork

Shear Strength of Fork, 𝐏 = (𝐝𝟐 − 𝐝𝟏 )𝟐𝐭 𝟏 𝐱 𝛕 ➔  = 27.17 N/mm2;

9. Crushing Failure of Pin in Fork

Crushing Strength of Fork, 𝐏 = 𝐝𝟏 𝐱 𝟐𝐭 𝟏 𝐱 𝛔𝐜 ➔ σC = 27.17 N/mm2;

Dimensions of Knuckle Joint

✓ Diameter of the rod, d = 30mm; Diameter of Pin, d1 = 40mm;

✓ Outer Diameter of Eye, d2 = 80mm; Diameter of knuckle pin head and collar, d3 = 60mm;

✓ Thickness of single eye or rod end, t = 38mm;

✓ Thickness of fork, t1 = 23mm; Thickness of pin head, t2 = 15mm;

**********

2. Design a cotter joint to connect two MS rods for a pull of 20 kN. σt = 50 MPa;  = 40 MPa;
σC = 80 MPa; Draw a neat sketch of the joint designed.

1. Tensile Failure of Rods

𝛑
Tensile Load, 𝐏 = 𝐝𝟐 𝐱 𝛔𝐭 ➔ d = 23 mm;
𝟒

2. Tensile Failure of Spigot

𝛑
Tearing Strength of Spigot, 𝐏 = [ 𝐝𝟐𝟐 − 𝐝𝟐 𝐭] 𝐱 𝛔𝐭 ➔ d2 = 28mm & t = 7 mm; {t = d2/4}
𝟒

3. Crushing Failure of Rod or Spigot

Crushing Strength of Cotter, 𝐏 = 𝐝𝟐 𝐱 𝐭 𝐱 𝛔𝐜 ➔ σc = 102 N/mm2 > 80 N/mm2 Not safe

𝐏 = 𝐝𝟐 𝐱 𝐭 𝐱 𝛔𝐜 ➔ d2 = 32 mm & t = 8 mm;

4. Tensile Failure of Socket

𝛑
Tensile Strength of Socket, 𝐏 = {[𝟒 (𝐝𝟐𝟏 − 𝐝𝟐𝟐 )] − [(𝐝𝟏 − 𝐝𝟐 )𝐭]} 𝛔𝐭

0.785d12 – 8d1 – 948.25 = 0 ➔ d1 = 41 mm

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 5. Shear Failure of Cotter

Shear Strength of Cotter, 𝐏 = 𝟐𝐛𝐭 𝐱 𝛕 ➔ b = 32 mm

6. Crushing Failure of Socket End

Crushing Strength of Socket Collar, 𝐏 = (𝐝𝟒 − 𝐝𝟐 ) 𝐭 𝐱 𝛔𝐜 ➔ d4 = 64 mm

7. Shear Failure of Socket End

Shear Strength of Socket Collar, 𝐏 = 𝟐(𝐝𝟒 − 𝐝𝟐 )𝐜 𝐱 𝛕 ➔ c = 8 mm

8. Shear Failure of Spigot End

Shear Strength of Rod End, 𝐏 = 𝟐𝐚 𝐱 𝐝𝟐 𝐱 𝛕 ➔ a = 8 mm

9. Crushing Failure of Spigot Collar

𝛑
Crushing Strength of Spigot Collar, 𝐏 = 𝟒 (𝐝𝟐𝟑 − 𝐝𝟐𝟐 ) 𝐱 𝛔𝐜 ➔ d3 = 37 mm

10. Shearing Failure of Spigot Collar

Shear Strength of Spigot Collar, 𝐏 = 𝛑𝐝𝟐 𝐭 𝟏 𝐱 𝛕 ➔ t1 = 5 mm

11. Length of Cotter, l = 4d = 92 mm; & Taper for Cotter = 1 in 32 & Clearance = 2.5mm

12. Bending Failure of Cotter –

𝐏(𝐝𝟒 + 𝟎.𝟓𝐝𝟐 )
Bending Stress in Cotter, 𝛔𝐛 = ➔ σb = 156.25 N/mm2 > 50 N/mm2 Not safe
𝟐𝐭 𝐱 𝐛 𝟐

𝐏(𝐝𝟒 + 𝟎. 𝟓𝐝𝟐 )
𝛔𝐛 = ➔ 𝐛 = 𝟓𝟕 𝐦𝐦
𝟐𝐭 𝐱 𝐛 𝟐

**********

3. Determine the size of the weld for the eccentrically loaded member as shown in Figure 1
for steady and alternating load if the permissible shear stress is 80 N/mm2.

Figure 1

P 15000 15000 𝟖𝟏. 𝟔

Direct Shear Stress, τ1 = = = =
A 260 × t (260 × 0.707 × s) 𝐬

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 M
Bending Stress, σb =
ZW
M = P x e = 15000 x 250 = 3.75 x 106 N – mm b

From (DDB 11.5)

d
2 2
d 75
ZW = {[bd + ] × 𝐭} = [(55 × 75) + ] × 𝟎. 𝟕𝟎𝟕 × 𝐬 = 4242s
3 3
M 3.75 × 106 884
σb = = =
ZW 4242s s

𝛔𝐛 𝟐 𝟖𝟖𝟒 𝟐 𝟖𝟏. 𝟔 𝟐
𝛕 = √( ) + (𝛕𝟏 )𝟐 → 𝟖𝟎 = √( ) + ( ) → 𝐬 = 𝟓. 𝟔𝟐 𝐦𝐦
𝟐 𝟐×𝐬 𝐬
For Alternating Load, Kf = 2

𝛔𝐛 𝟐 𝟖𝟎 𝟖𝟖𝟒 𝟐 𝟖𝟏. 𝟔 𝟐
√ 𝟐 √
𝛕 = ( ) + (𝛕𝟏 ) → ( ) = ( ) + ( ) → 𝐬 = 𝟏𝟏. 𝟐𝟒 𝐦𝐦
𝟐 𝟐 𝟐×𝐬 𝐬

**********

4. Figure 2 shows a welded joint subjected to an eccentric load of 25 kN. Determine the uniform size
of the weld on the entire length of two legs. Take permissible shear stress for the weld material as
75 MPa.

Figure 2
P = 25 kN; τ = 75 N/mm2;
P 25000 𝟏𝟎𝟏
Primary Shear Stress , τ1 = = = 𝐍⁄𝐦𝐦𝟐
A (150 × 0.707s) + (200 × 0.707s) 𝐬
𝐓×𝐫
Secondary Shear Stress, 𝛕𝟐 =
𝐉𝐰
250 mm 25 kN

A
r θ
θ
G B τ2
τ1

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T = P x e = 25000 x 250 = 6.25 x 106 N – mm

Since the weld is unsymmetrical about both axis, From (DDB 11.5)
b
𝐛𝟐 𝐝𝟐
̅ = 𝐍𝐲 =
𝐗 ̅ = 𝐍𝐗 =
= 𝟑𝟐. 𝟏𝟒 𝐦𝐦 & 𝐘 = 𝟓𝟕. 𝟏𝟒 𝐦𝐦 d
𝟐(𝐛 + 𝐝) 𝟐(𝐛 + 𝐝)

GB = 150 – NY = 117.86 mm & AB = NX = 57.14 mm

𝐫 = √(𝐆𝐁)𝟐 + (𝐀𝐁)𝟐 = 𝟏𝟑𝟏 𝐦𝐦

From (DDB 11.5)
(b + d)4 − (6b2 d2 ) Cos θ = (GB / r) = (117.86 / 131)
JW = {[ ] × 𝐭} = 𝟏. 𝟔𝟏𝟕 × 𝟏𝟎𝟔 𝐬 𝐦𝐦𝟒
12(b + d)
𝐓 × 𝐫 𝟓𝟎𝟔. 𝟑𝟒
𝛕𝟐 = = 𝐍⁄𝐦𝐦𝟐
𝐉𝐰 𝐬

τ = √(τ1 )2 + (τ2 )2 + 2 τ1 τ2 cosθ → 𝐬 = 𝟕. 𝟗𝟖 𝐦𝐦

**********

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