Chapter 6

Design of Fasteners
Bolted Joints
6.1 Introduction
 A screw thread is formed by cutting a continuous helical groove on a cylindrical surface,
A screw made by cutting a single helical groove on the cylinder is known as single
threaded (or single-start) screw and if a second thread is cut in the space between the
grooves of the first, a double threaded (or double-start) screw is formed.
 The helical grooves may be cut either right hand or left hand.
 A screwed joint is mainly composed of two elements i.e., a bolt and nut.
 The screwed joints are widely used where the machine parts are required to be readily
connected or disconnected without damage to the machine or the fastening.

6.2 Advantages and Disadvantages of Screwed Joints

 Advantages
1. Screwed joints are highly reliable in operation.
2. Screwed joints are convenient to assemble and disassemble.
3. A wide range of screwed joints may be adopted to various operating conditions.
4. Screws are relatively cheap to produce due to standardization and highly efficient
manufacturing processes.
5. Requires less skilled labor.
 Disadvantages
1.The main disadvantage of the screwed joints is the stress concentration in the
threaded portions .
2. Less strength as compaired to welded joints.

6.3 Stresses in Screwed Fastening due to Static Loading

 The following stresses in screwed fastening due to static loading are important from the
subject point of view:
1. Internal stresses due to screwing up forces,
2. Stresses due to external forces, and
3. Stress due to combination of stresses at (1) and (2).
We shall now discuss these stresses, in detail, in the following articles.
1. Initial Stresses due to Screwing up Forces
 Tensile stress due to stretching of bolt. Since none of the above mentioned stresses are
accurately determined, therefore bolts are designed on the basis of direct tensile stress
with a large factor of safety in order to account for the indeterminate stresses.
 The initial tension in a bolt, based on experiments, may be found by the relation
Pi = 2840 d N
where Pi = Initial tension in a bolt, and
d = Nominal diameter of bolt, in mm.
 The above relation is used for making a joint fluid tight like steam engine, cylinder cover
joints etc.
 When the joint is not required as tight as fluid-tight joint, then the initial tension in a bolt
may be reduced to half of the above value. In such cases
Pi = 1420 d N
 The small diameter bolts may fail during tightening, therefore bolts of smaller diameter
(less than M 16 or M 18) are not permitted in making fluid tight joints.
 If the bolt is not initially stressed, then
P
Permissible Stress(σt) =
Cross −sectional area at bottom of the thread

P
Permissible Stress (σt) = 𝜋 𝑑𝑐 2
4

2. Torsional shear stress caused by the frictional resistance of the threads during its
tightening.
 The torsional shear stress caused by the frictional resistance of the threads during its
tightening may be obtained by using the torsion equation. We know that
𝜋
T = 16 (dc)3
Where
= Torsional shear stress,
T = Torque applied, and
dc = Minor or core diameter of the thread.
 It has been shown during experiments that due to repeated unscrewing and tightening
of the nut, there is a gradual scoring of the threads, which increases the torsional
twisting moment
3. Shear stress across the threads.
 The average thread shearing stress for the screw ( s) is obtained by using the
relation:

4. Compression or crushing stress on threads.

 The compression or crushing stress between the threads ( σc ) may be obtained by

using the relation:

𝑷
σc = 𝟐 𝟐
𝝅 (𝒅𝒐 − 𝒅𝒄 )
𝒏
𝟒
where
do = Major diameter,
dc= Minor diameter, and
n = Number of threads in engagement.

5. Bending stress if the surfaces under the head or nut are not perfectly parallel to the
bolt axis.
 When the outside surfaces of the parts to be connected are not parallel to each other,
then the bolt will be subjected to bending action. The bending stress (σb) induced in the
shank of the bolt is given by

Where ,
x = Difference in height between the extreme corners of the nut or head,
 l = Length of the shank of the bolt, and
E = Young’s modulus for the material of the bolt.

6.4 Bolts Uniform Strength

 When a bolt is subjected to shock loading, as in case of a cylinder head bolt of an
internal combustion engine, the resilience of the bolt should be considered in order to
prevent breakage at the thread.
 In an ordinary bolt shown in following Fig (a). the effect of the impulsive loads applied
axially is concentrated on the weakest part of the bolt i.e., the cross-sectional area at
the root of the threads.
 In other words, the stress in the threaded pan of the bolt will be higher than that in the
shank.
 Hence a great portion of the energy will be absorbed at the region of the threaded pan
which may fracture the threaded portion because of its small length.

 If the shank of the bolt is turned down to a diameter equal or even slightly less than the
core diameter of the thread (Dc) as shown in Fig. (b), then shank of the bolt will undergo
higher stress.
 This means that a shank will absorb a large portion of the energy. This gives us bolts of
uniform strength.
 The bolt, in this way, becomes stronger and lighter and it increases the shock absorbing
capacity of the bolt because of an increased modulus of resilience by increasing its
length.
 A second alternative method of obtaining bolt of uniform strength is shown in fig.(c).
 In this method, an axial hole is drilled through the head as far as the thread portion such
that the area of the shank becomes equal to the root area of the thread.
Let D = Diameter of the hole.
Do = Outer diameter of the thread, and
Dc= Root or core diameter of the thread.
6.5 Bolted Joints under Eccentric Loading

a. Eccentric Load Acting Parallel to the Axis of Bolts

 Consider a bracket having a rectangular base bolted to a wall by means of four bolts as
shown in above Fig.
 A little consideration will show that each bolt is subjected to a direct tensile
load of
W
Wt1 = ………..(a)
𝑛
Where
n is the number of bolts.

 Further the load W tends to rotate the bracket about the edge A. Due to this, each bolt
is stretched by an amount that depends upon its distance from the titling edge.
 Since the stress is a function of elongation, therefore each bolt will experience a
different load which also depends upon the distance from the tilting edge.
 Let ,
w = the load in a bolt per unit distance due to the turning effect of the bracket,
W1 and W 2 = the loads on each of the bolts at distances L 1 and L2 from the tilting
edge.
 Load on each bolt at distance L1,
W1 = w. L1
 and moment of this load about the tilting edge ,
= w. L1 x L1 = w (L1)2
 Similarly, load on each bolt at distance L2 ,
W2 = w. L2
 and moment of this load about the tilting edge ,
= w. L2 x L2 = w (L2)2
 Total moment of the load on the bolts about the titling edge
= 2 w (L1)2 + 2w (L2)2 …………………….(I)
…..(since There are two bolts each at distance of L1 and L2)
 Also the moment due to load W about the titling edge
= W.L ………………………(II)
 From equations (I) and (II), we have
W.L= = 2 w (L1)2 + 2w (L2)2
 Also

 It may be noted that the most heavily loaded bolts are those which are situated at the
greatest distance from the tilting edge.
 In the case discussed above, the bolts at distance L 2 are heavily loaded.

 Now the total tensile load on the most heavily loaded bolt,
Wt = W t1 + W t2

 If dc is the core diameter of the bolt and σt is the tensile stress for the bolt material,

then,
Wt
σt = 𝜋 𝑑𝑐 2
4

from above equation dc may be obtained

b.Eccentric Load Acting Perpendicular to the Axis of Bolts

 A wall bracket carrying an eccentric load perpendicular to the axis of the bolts is shown
in following Fig.
6.6 Design of Cylinder Covers

 The cylinder covers may be secured by means of bolts or studs, but studs are preferred.
 The possible arrangement of securing the cover with bolts and studs is shown in
following Fig.
 The bolts or studs, cylinder cover plate and cylinder flange may be designed as
discussed below

I. Design of bolts or studs

Let

D = Diameter of the cylinder,

p = Pressure in the cylinder,
dc= Core diameter of the bolts or studs,
n = Number of bolts or studs, and

σtb = Permissible tensile stress for the bolt or stud material.

  From this equation, the number of bolts or studs may be obtained, if the size of the bolt
or stud is known and vice-versa.
 Usually the size of the bolt is assumed. If the value of n as obtained from the above
relation is odd or a fraction, then next higher even number is adopted.
 The pitch circle diameter (Dp) is usually taken as
Dp = D + 2t + 3d1
 and outside diameter of the cover is kept as
Do = Dp + 3 d1 = D + 2 t + 6 d1
where t = Thickness of the cylinder wall.

Welded Joints
6.7 Introduction
 A welded joint is a permanent joint which is obtained by the fusion of the edges of the
two parts to be joined together, with or without the application of pressure and a filler
material.
 The heat required for the fusion of the material may be obtained by burning of gas (in
case of gas welding) or by an electric arc (in case of electric arc welding).
 The latter method is extensively used because of greater speed of welding.
 Welding is extensively used in fabrication as an alternative method for casting or forging
and as a replacement for bolted and riveted joints.
 It is also used as a repair medium e.g., to reunite metal at a crack, to build up a small
part that has broken off such as gear tooth or to repair a worn surface such as a bearing
surface.
6.8 Advantages and Disadvantages of Welded Joints over Riveted Joints
 Advantages
1. The welded structures are usually lighter than riveted structures. This is due to the reason,
that in welding, gussets or other connecting components are not used.
2. The welded joints provide maximum efficiency (may be 100%) which is not possible in
case of riveted joints.
3. Alterations and additions can be easily made in the existing structures.
4. As the welded structure is smooth in appearance, therefore it looks pleasing.
5. In welded connections, the tension members are not weakened as in the case of riveted
joints,
6. A welded joint has a great strength. Often a welded joint has the strength of the parent
metal itself.
7. Sometimes, the members are of such a shape (i.e., circular steel pipes) that they afford
difficulty for riveting. But they can be easily welded.
8. The welding provides very rigid joints. This is in line with the modem trend of providing
rigid frames,
9. It is possible to weld any part of a structure at any point. But riveting requires enough
clearance.
10. The process of welding takes less time than the riveting.

 Disadvantages
1. Since there is an uneven heating and cooling during fabrication, therefore the members may
get distorted or additional stresses may develop.
2. It requires a highly skilled labour and supervision.
3. Since no provision is kept for expansion and contraction in the frame, therefore there is a
possibility of cracks developing in it.
4. The inspection of welding work is more difficult than riveting work.

6.9 Strength of Transverse Fillet Welded Joints

 The transverse fillet welds are designed for tensile strength.
 Let us consider a single and double transverse fillet welds as shown in following Fig.
(a) and (b) respectively.
 In order to determine the strength of the fillet joint, it is assumed that the section of fillet
is a right angled triangle ABC with hypotenuse AC making equal angles with other two
sides AB and BC.
 The enlarged view of the fillet is shown in following Fig.

 The length of each side is known as leg or size of the weld and the perpendicular
distance of the hypotenuse froth the intersection of legs (i.e., BD) is known as throat
thickness.
 The minimum area of the weld is obtained at the throat BD. which is given by the
product of the throat thickness and length of weld.
 Let
t = Throat thickness (BD),
s = Leg or size of weld = thickness of plate, and
l = Length of weld,
 From above Fig. we find that the throat thickness as,
t= s x sin 45° = 0.707 (s)
 Therefore minimum area of the weld or throat area,
A = Throat thickness x Length of weld
= t x l = 0.707 (s x I)

 If σt is the allowable tensile stress for the weld metal, then the tensile strength of the

joint for single fillet weld,

P
σt =
0.707 s x l

Therefore P = 0.707 s x I x σt

for double fillet weld,

P = 2 [ 0.707 s x I x σt ]
6.10 Strength of Parallel Fillet Welded Joints