Automotive Department

Design of Machine Elements

AU-315
Assignment # 01

Course Teacher: Dr. Faraz Akber

Submitted By:

Name Roll No

 Faizan Samdani AU-19005

 Mujtaba Sheikh AU-19013

 Munaam Khan AU-19015

 Sheeraz Shahid AU-19022

Contents
Abstract .................................................................................................................................................... 3
Introduction .............................................................................................................................................. 4
Rivets ............................................................................................................................................................ 4
Methods of Riveting ................................................................................................................................ 5
Nomenclature For Rivets ....................................................................................................................... 6
Boiler ............................................................................................................................................................ 8
Types of Boiler and Classifications of Boiler: .......................................................................................... 8
Rivet Design and Material Selection Criteria: ......................................................................................... 9
Material For the Designed Riveted Joint ................................................................................................ 11
 High Carbon Steel ............................................................................................................................. 11
Properties of AISI-304 .......................................................................................................................... 12
Key Features Of AISI-304 .................................................................................................................... 13
Cost ............................................................................................................................................................. 15
Analytical Solution .................................................................................................................................... 16
FEA Analysis ............................................................................................................................................. 20
Abstract
The accompanying study includes FEA software and analytical solutions for designing and
evaluating riveted joints. The stresses on riveted joints are accumulated by analyzing forces
acting on a cross-section of the joint. To identify the causes of failure, a FEA tool is utilized. In
addition to FEA simulation, an analytical solution is used to verify the results. The material
is chosen based on a set of criteria outlined in the literature review. All the required parameters
are set according to the IBR and AISI tables of codes and standards.
Introduction
In the following report, Riveted joints are designed for boiler. Longitudinal and Circumferential
joint for a boiler is designed of a boiler whose diameter is 2.4m and is subjected to 1 N/mm 2.
The longitudinal joint is a triple riveted butt joint with an efficiency of 85% and the
circumferential joint is a double riveted lap joint with an efficiency of about 70%. The pitch in
the outer row of the rivets is to be double than in the inner rows and the width of the cover
plate is unequal. Suitable material is selected for riveted joints and corresponding values of
allowable stresses. The resistance in the rivets in double shear is 1.875 times that of single
shear. The failure of the riveted joints is checked analytically and through modern
computational tool.

Rivets
A rivet is a short cylindrical bar with a head integral to it. The cylindrical portion of the rivet is
called shank or body and lower portion of shank is known as tail, as shown in Fig. 9.1. The rivets
are used to make permanent fastening between the plates such as in structural work, ship
building, bridges, tanks and boiler shells. The riveted joints are widely used for joining light
metals. The fastenings (i.e.: joints) may be classified into the following two groups:
1. Permanent fastenings
2. Temporary or detachable fastenings.
Methods of Riveting
The function of rivets in a joint is to make a connection that has strength and tightness. The
strength is necessary to prevent failure of the joint. The tightness is necessary in order to
contribute to strength and to prevent leakage as in a boiler or in a ship hull. When two plates are
to be fastened together by a rivet as shown in Fig. 9.2 (a), the holes in the plates are punched and
reamed or drilled. Punching is the cheapest method and is used for relatively thin plates and in
structural work. Since punching injures the material around the hole, therefore drilling is used in
most pressure-vessel work. In structural and pressure vessel riveting, the diameter of the rivet
hole is usually 1.5 mm larger than the nominal diameter of the rivet. The plates are drilled
together and then separated to remove any burrs or chips so as to have a tight flush joint between
the plates. A cold rivet or a red-hot rivet is introduced into the plates and the point (i.e., second
head) is then formed. When a cold rivet is used, the process is known as cold riveting and when a
hot rivet is used, the process is known as hot riveting. The cold riveting process is used for
structural joints while hot riveting is used to make leak proof joints.

Essential Qualities of a Rivet

Essential Qualities of a Rivet According to Indian standard, ISO: 2998 – 1982 (Reaffirmed 1992), the
material of a rivet must have a tensile strength not less than 40 N/mm2 and elongation not less than 26
percent. The material must be of such quality that when in cold condition, the shank shall be bent on itself
through 180° without cracking and after being heated to 650°C and quenched, it must pass the same test.
The rivet when hot must flatten without cracking to a diameter 2.5 times the diameter of shank.
(Budynas & Nisbett)
Nomenclature For Rivets

𝑝𝑏 = Back pitch
C = Constant
d = Rivet Hole Diameter
d=Rivet Diameter
D = Internal diameter of boiler shell
L = Shell length section
m = Margin
n = Number of rivets
N= Number of rows
P = Steam pressure in boiler
p = Pitch
t = Thickness of the boiler shell
tc= Thickness of the Cover Plate
𝜎𝑡 = Permissible tensile stress
σL = Longitudinal stress
σC = Crushing stress
τ = Shearing stress
ηL= Efficiency of the longitudinal joint
η = Lap joint efficiency
ƞC = Efficiency of the circumferential joint
Boiler
Boilers are defined as
“Boiler is a closed vessel in which water or other liquid is heated, steam or vapor is
generated, steam is super-heated, or any combination thereof, under pressure or vacuum, for
use external to itself, by the direct application of energy from the combustion of fuels, from
electricity or nuclear energy. “

Types of Boiler and Classifications of Boiler:

There are following Boilers Types:
1. According to the position of water and hot gasses

 Fire Tube Boiler

 Water Tube Boiler

2. According to Axis of Shell

 Horizontal Boiler
 Vertical Boiler
3. According to the position of the boiler
 External Fired Boiler
 Internally Fired Boiler
4. According to the pressure

 Low-Pressure Boiler
 High-Pressure Boiler
5. According to the method of circulation
 Natural Circulation Boiler
 forced Circulation Boiler
6. According to use of boilers

 Mobile Boiler
 Stationary Boiler
7. According to drums

 Single drum Boiler

 Multi drum Boiler
8. According to the nature of drought
 Forced drought Boiler
 Natural drought Boiler
9. According to furnace

 Single furnace Boiler

 Dual furnace Boiler
10. According to fuel firing
 Solid fuel-fired Boiler
 Liquid fuel-fired Boiler
 Gaseous fuel-fired Boiler

(Thermodyne Engineering, n.d.)

Rivet Design and Material Selection Criteria:

 Rivet shear and tensile strength:

o The rivet selected and the number of rivets used in the application should equal or
exceed the joint strength requirements. Typical ultimate shear and tensile
strengths are listed in the catalog. Testing is recommended before final rivet
selection and use in your product.

 Rivet body material:

Should be compatible with the materials to be joined to resist galvanic corrosion
which may result in reduction of joint strength. If dissimilar materials are widely
separated on the galvanic chart, it is advisable to separate them with a dielectric
material such as paint or other coating.
 Rivet Grip Range:
Select the rivet grip range which includes the total thickness of materials to be joined.
Please note that the rivet barrel length is not the grip range.

 Rivet Hole Size:

Recommended hole sizes are listed for each rivet. An undersized hole will not
allow insertion of the rivet body; an oversize hole will reduce shear and tensile
strengths, and may cause improper rivet setting, all of which promote joint failure.

 Rivet Head Style: Various head types are offered to accommodate different assembly
needs. The most popular is the buttonhead, whose lower-profile head is twice the
diameter of the rivet body. This provides adequate bearing surface for nearly all
applications. The large flange rivet provides greater bearing surface for fastening soft or
brittle facing materials. The countersunk rivet is available for applications where a flush
appearance is required. And the closed-end is ideal for roofing, marine, electric or
electronics applications.

 Corrosion or Heat Resistance - the primary reason for specifying stainless. The specifier
needs to know the nature of the environment and the degree of corrosion or heat
resistance required.

 Mechanical Properties - with particular emphasis on strength at room, elevated, or low

temperature. Generally speaking, the combination of corrosion resistance and strength is
the basis for selection.

 Fabrication Operations - and how the product is to be made is a third-level consideration.

This includes forging, machining, forming, welding, etc.

 Total Cost - in considering total cost, it is appropriate to consider not only material and
production costs, but the life cycle cost including the cost-saving benefits of a
maintenance-free product having a long-life expectancy.

o (Nickel Development Institute)

Material For the Designed Riveted Joint

 High Carbon Steel

AISI-304

AISI 304 is an austenitic stainless-steel grade that belongs to the 300 series.
 What does AISI stand for in stainless steel?
AISI stands for American Iron and Steel Institute, which developed a standardized numbering
system for stainless steel together with SAE International (a standards organization).
 Is AISI 304 the same as SS 304?
AISI 304, SS 304, SAE 304, and SUS 304 are all different representations of the same material,
depending on where it is referenced. SS stands for "stainless steel", SUS stands for "steel use
stainless" (Japanese standard), and AISI/SAE refer to the standard organizations that developed
the numbering system.
 Is AISI 304 magnetic?
Being an austenitic stainless steel, AISI 304 is theoretically non-magnetic. In reality, it is only
slightly magnetic. Its nickel content is what helps lower its responsiveness to external magnetic
fields.
Examples & applications of austenitic stainless steels, 304 the most common stainless steel
contains 18 wt.% chromium and 8 wt.% nickel and therefore is often referred to as 18/8. It is
used for many applications including cutlery, kitchen equipment, food processing equipment,
automotive and aerospace structural components and marine fasteners.

COMPOSITION:
 Iron 66.74 - 71.24% (Balance)

Chromium 17.5 - 19.5%

Nickel 8 - 10.5%

Manganese 2%

Silicon 1%

Nitrogen 0.11%

Carbon 0.07%

Phosphorus 0.05%

Sulphur 0.03%

(AMBICA, n.d.)

Properties of AISI-304

The table below shows some of the most common material properties of AISI 304.

304 304 Annealed

Properties
(Typical values at 20°C) (Typical values at 20°C)

Density 8 g/cm³
 Elastic Modulus 193 GPa 200 GPa

Hardness, Brinell 215 HB

Tensile Strength 500-700 MPa 590 MPa

Yield Strength 190 MPa 240 MPa

Elongation 40%

Coefficient of Thermal 1.72E-5 1/K

Expansion

Thermal Conductivity 16.2 W/(m·K)

Melting Point 1450°C

Specific Heat Capacity 500 J/(kg·K)

Electrical Resistivity 0.73 x 106 Ω·m

(AZO Materials, n.d.)

Key Features Of AISI-304

 Corrosion Resistance
AISI 304 is highly corrosion resistant to most oxidizing acids. However, corrosion can occur in
environments containing chlorides. 304 stainless steel is not as corrosion-resistant as 316
stainless steel.
  Machinability:

Stainless steel 304 has good machinability. Machining can be enhanced by using the
following rules:

 Cutting edges must be kept sharp. Dull edges cause excess work hardening.
 Cuts should be light but deep enough to prevent work hardening by riding on the
surface of the material.
 Chip breakers should be employed to assist in ensuring swarf remains clear of the
work
 Low thermal conductivity of austenitic alloys results in heat concentrating at the
cutting edges. This means coolants and lubricants are necessary and must be used in
large quantities.

(AZO Materials, n.d.)

 Weldability:
Has good weldability. Welding method can be used often, both before welding without heat
treatment after welding. Large section size steel intergranular corrosion after welding sensitive

 Durability:
The main benefit of 304 stainless steel is its durability. It also allows for ease of fabrication and
cleaning, meaning that it is simple to maintain. Finally, it is available in a wide range of finishes
and appearances.
 Stainless Steel 304 Price in INR (per Price in USD Price in Euro
Origin
price per kg kg) (per kg) (per kg)

SS 304 price per kg in

Indian Rs 190/- $2.68 €2.41
India

SS 304 price per kg in

Japanese Rs 245/- $3.46 €3.11
Japan

SS 304 price per kg in

European Rs 295/- $4.16 €3.74
UK / Europe

SS 304 price per kg in

USA Rs 345/- $4.87 €4.37
USA

ss 304 sheet price per

Indian Rs 190/- $2.68 €2.41
kg

Cost

(Steel Tube, 2022)

Analytical Solution

Given:
Pressure (P) = 1 N/mm2
Longitudinal efficiency (ƞL) = 85% = 0.85
Circumferential efficiency (ƞC) = 70% = 0.70
Tensile stress (σt) = 170 MPa = N/mm2
Shear stress (τ) = 154 MPa = 154 N/mm2
Compressive stress (σc) = 110 MPa = 110 N/mm2
1. Design Of Longitudinal Joint:

1. Thickness of boiler shell.

𝑃. 𝐷
t= + 1 𝑚𝑚
2 𝜎𝑡 ∗ 𝜂𝐿
t = 9.3 mm ≈ 10 mm
2. Diameter of Rivet.
d = 6√𝑡
d = 18.97 mm
From Table 9.3, we see that according to IS: 1928 – 1961 (Reaffirmed 1996), the standard
diameter of the rivet hole (d) is 19 mm and the corresponding diameter of the rivet is 18 mm.

3. Pitch of rivet.
Triple riveted double strap butt joint Pitch of the rivet is in the outermost row
Tearing resistance of plate per pitch length
Pt = (p-d) * t * σt
Pt = (p-19) * 1700 → (i)
Since the pitch in the outer row is twice the pitch of the inner row and the joint is double riveted,
therefore for one pitch length there will be three rivets in double shear (i.e. n = 4). It is given that
the strength of rivets in double shear is 1.8 times that of single shear, therefore
Shearing strength of the rivets per pitch length
𝜋
Ps = n * 1.875 * 4 * d2 * τ

Ps = 327.47 KN → (ii)
From equations (i) and (ii), we get
(p-19) * 1700 = 327.47
p = 192 mm
According to I.B.R., the maximum pitch,
𝑝𝑚𝑎𝑥 = 𝐶 * t + 41.28 mm
From Table 9.5, we find that for 5 rivets per pitch length and for double strap butt joint, the value
of C is 6.
𝑝𝑚𝑎𝑥 = 102 mm
Since the value of pmax is less than p, therefore we shall adopt the value of
p = pmax = 102 mm
Pitch in the inner row (p,)
𝑝
p, = 2

p, = 51 mm
4. Distance between rows of rivet.
According to I.B.R., the distance between the rows of rivets,
𝑝𝑏 = 0.2 p + 1.15 d
𝑝𝑏 = 42.25 mm
5. Thickness of butt strap.
According to I.B.R., the thickness of double butt straps of unequal width,
i- For wide butt strap
𝑡1 = 0.75 t
𝑡1 = 7.5 mm
ii- For narrow butt strap
 𝑡2 = 0.625 t
𝑡2 = 6.25 mm
6. Margin.
We know that the margin,
m = 1.5 d
m = 28.5 mm
Efficiency:
A- Tearing resistance
Pt = (p-d) * t * σt
Pt = 141 KN
B- Shear resistance
𝜋
Ps = n * 1.875 * 4 * d2 * τ

Ps = 327 KN
C- Crushing resistance
Pc = n * d * t * σc
Pc = 448 KN
The joint may also fail by tearing off the plate between the rivets in the second row. This is only
possible if the rivets in the outermost row gives way (i.e. shears). Since there are four rivet holes
per pitch length in the second row and one rivet is in the outer most row, therefore combined
tearing and shearing resistance
𝜋
= (p-d) * t * σt + 4 * d2 * τ

= 152.46 KN
From above, we see that strength of the joint
= 152.46 KN
Strength of the unriveted or solid plate,
P = p * t * σt
P = 173.4 KN

∴ Efficiency of the joint,

 𝑙𝑒𝑎𝑠𝑡 𝑜𝑓 𝑃𝑡 , 𝑃𝑠 𝑜𝑟 𝑃𝑐
ƞ=
𝑃
ƞ = 82%
Since the efficiency of the designed joint is close to the given efficiency, therefore the design is
satisfactory.

2. Design of circumferential joint

 Thickness of the shell and diameter of rivet.
The thickness of the boiler shell and the diameter of the rivet will be same as for longitudinal
joint.
 Number of rivet (n).
𝜋
Shearing resistance = n * 4 * d2 * τ → (i)

Total shearing resistance on circumferential

𝜋
= 4 * D2 * P → (ii)

Comparing eq (i) and (ii) we get

𝐷 2 ∗𝑃
n= 𝑑2 ∗ 𝜏

n = 105.66 ≈ 106 rivets

 Number of rivet per row.
106
= 2

= 53 rows
 Pitch of rivet.
If the efficiency of the longitudinal joint is known, then the efficiency of the circumferential joint
may be obtained. Knowing the efficiency of the circumferential lap joint (ηc), the pitch of the
rivets for the lap joint (p1) may be obtained by using the relation
𝜋 ( 𝐷+𝑑 )
P1 = 57

P1 = 143.38 ≈ 144 mm
According to I.B.R., the maximum pitch,
𝑝𝑚𝑎𝑥 = 𝐶 * t + 41.28 mm
From Table 9.5, we find that for 5 rivets per pitch length and for double strap butt joint, the value
of C is 6.
 𝑝𝑚𝑎𝑥 = 102 mm
Since the value of pmax is less than p1, therefore we shall adopt the value of
P1 = pmax = 102 mm
 Efficiency.
𝑃1 −𝑑
ȠC = 𝑃1

ȠC = 72.06%
 Distance between rows of rivet.
𝑝𝑏 = 0.33 𝑝 + 0.67 𝑑
𝑝𝑏 = 46.39 ≈ 47 mm
 Margin.
m = 1.5 d
m = 28.5 mm
 Overlap.
= (No. of rows of rivet - 1) pb + m
= 75.5 mm

FEA Analysis
Conclusion
The design of the rivet joints has been verified not only using an analytical approach but also
using the FEA analysis of it. By seeing the Safety of Factor Plot as shown in both FEA analysis,
it is evident that our joint lies within safe region and design in a way that it does not let metal
plates fail.
We are very thankful to our course teacher who challenged us to use modern computational tools
for the designing of machine elements. We got to learn about a lot of things and about FEA in
particular.

Thankyou!