Elements of Mechanical Engineering

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2. Design of Joints and Power Screw vi. Socket failure in shearing.

2.1 Design of Joints, Design of cotter joints., Design of vii. Rod ends failure in shear.
Knuckle joints, Design of turn buckle. viii. Spigot collar failure to crush.
2.2 Design of Power Screw, Basic concept of power ix. Spigot collar failure in shear.
screw, Thread profiles used in power screw, Relative x. Cotter failure in bending.
merits and demerits. Torque required to raise & lower
B. Cotter Joint Applications:
load by square threaded screws (No Derivation).
Stresses in Power Screws

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2.3 Welded joints: Introduction, Types of welded joints,
Merits and demerits.
2.4 Riveted Joints: Introduction, Types of Riveted Joints
Merits & Demerits.

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2.1.1 COTTER JOINT
Cotter Joint: " A cotter joint is a temporary joint and
used to connect two coaxial rods or bars which are

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subjected to axial tensile and or compressive forces."
It consist of
i) Spigot : It is the male part of the joint , it has a
rectangular slot for passing the cotter through it. Spigot
has a collar which rests against the socket end.
ii) Socket : It is the female part of the joint, it also has a ep i.It is used for connecting piston rod with the tail or
pump rod
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rectangular slot for passing the cotter through it. It has a
circular hole in which a spigot fits..
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iii) Cotter : It is a wedge shaped piece of metal which

actually connects two parts which are non rotating.
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ii.It is also used for connecting the piston rod and the
cross-head of the steam engine.
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Various methods of failures in the cotter joint are

discussed below:
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A. Failure modes of Cotter joint:

Spigot:
i. Failure of rod in tension.igot failure under stress
in the weakest section.
ii. Rod or cotter failure in crushing.
iii. Socket failure under tension in the slot. iii.Valve rod in stem
iv. Shear failure in shear. iv.It is used for connecting piston rod with the tail or
v. Socket collar failure to crush. pump rod

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v. It is used in bicycles for connecting the pedal to D. State the advantages of cotter joint.
the sprocket wheel. i. Easy assembling and dismantling.
ii. Strong grip force: Due to wedge action there is
a very strong tightening force which prevents
loosening of parts.
iii. Simple to design and manufacture.

2.1.2 KNUCKLE JOINT

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A knuckle Joint is a mechanical component that is used

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to join the two components under tensile loads. It is also
known as the Forked pin joint. For example Tractor and
trolley. The trolley is being attached to the tractor with
the help of a knuckle joint.

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vi. This joint is used between the pistons rod and
the tail of the pump rod.
vii. Cotter’s joints are used between the slide
spindle and the fork of the valve mechanism.

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viii. Cotter and Dowell arrange to join two parts of a
flywheel.
ix. Foundation bolt: mainly used for fastening

x.
foundation and construction heavy machines
In an automobile engine, the cotter joint is used
to connect the extension of the piston rod ep
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xi. with the connecting rod in the crosshead.
xii. The Cotter joint has historically been used to
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connect connecting rods to steam engines and

pumps of dumping mines.
xiii. It is used in bicycles to connect the paddle to the
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sprocket wheel.
i. Single eye
xiv. Use a wet air pump to join a tail rod with the
ii. Double-eye or fork
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piston rod.
iii. Knuckle pin
xv. It is used to connect two rods of equal diameter
iv. Taper pin
subjected to axial forces.
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v. Collar
C. Cotter joint taper: why and how much?
A. Applications of knuckle joint:
Cotter is a flat wedge shaped metal piece which is used
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i. To connect tractor and trolley,

to connect two rods which transmit the force but without
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ii. Tie rod joint of roof truss.

rotation. The force may be axial and of tensile or
iii. Link of a cycle chain
compressive nature. Cotter is fitted in the tapered slot
iv. Pump rod joint.
and remains in its position because of wedge action.
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Because of taper, B. Materials for Knuckle Joint.

i. It is simple to remove the cotter and dismantle Steel or Wrought Iron.
the joint parts.
ii. Taper ensures tightness of the joint in operation C. Function of split pin in knuckle joint.
and it prevents slackening of the parts. i. It holds a collar.
Generally the value of taper on cotter is 1 in 48 to 1 in ii. Prevent lifting or ejecting the knuckle pin from
24. the joint.

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D. Failures in Knuckle Joints: v. The knuckle joint’s construction is simple to

Single Eye:
i. Failure of rod in Tension.
Failure of single eye in tension.
ii. Failure of Single eye in crushing.
iii. Failure of Single eye in Shearing.
Double Eye:
i. Failure of double eye / Fork in tension.
build.
vi. This joint has fewer pieces, which makes it less
expensive and more reliable.
vii. This provides for angular momentum between
rods and is mostly used to extend the tool’s life.
F. Knuckle Joint Disadvantages:

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ii. Failure of double eye / Fork in crushing. It has some disadvantages too and those are:

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iii. Failure of double eye / Fork in Shearing. i. The angular movement can be done in only one
Knuckle Pin: plane or axis.
i. Failure due to Shear. ii. It can not withstand large compressive loads
which is a major drawback.

ii. Failure due to Bending.
Knuckle Joint Application:
The following application of Knuckle Joints are:
i. The very first use of the Knuckle joint is to
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iii. Compare to universal joint it has less flexibility.
2.1.3 TURN BUCKLE
A turnbuckle also called adjustable joint or bottle screw

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connect the tractor and trolley. or stretching screw is mainly used for adjusting the
ii. It is also used in robotic arms, cranks, and tanks. tension or adjusting length in the cables, rods or tie rods.
iii. This joint can be used in the windshield wipers of
the vehicles.
iv. Used to join the coaches of the train easily.
v. It has application in the valve mechanism of a ep
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reciprocating engine.
vi. It also connects the connecting rod between
wheels of locomotives. Fig. shows Turn Buckle, Let
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vii. Used to the joint between the tie rod joint of a dc = Core diameter of rod.
roof truss and bridge structure. d = Outer diameter of rod.
D = Outer diameter of coupler at end.
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viii. Another application is Tie rod joint of the jib

crane. D1 = Inner diameter of coupler at centre.
ix. Knuckle joint also used in Link of roller chain, D2 = Outer diameter of coupler at centre.
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bicycle chain, and chain straps of watches and so l = Length of threaded portion.
on. L = Total length of coupler.
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x. This joint is mainly used in the mechanical and Parts of Turnbuckle

automobile sectors whose axis lies on the same i. Tie rod (dc, d)
ii. Coupler Nut (D, l)
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line (Joint supports skeleton for wheel assembly).

iii. Coupler (D1, D2, L)
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E. Knuckle Joint Advantages:

The following advantages of Knuckle Joint are: Step 1. Decide the design Load (Pd)
i. Knuckle joints can bear significant tensile strains. For threaded portion the design load is taken 30% more
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Even with variable material thickness and tensile than the given load to account for friction in threads
strength, it may provide excellent repetitive Pd=1.3 P
accuracy.
Step 2. Design of tie rod (dc, d) –
ii. They have a high degree of mechanical stiffness.
a) Tensile Failure of rod Considering tensile failure of
iii. They have a straightforward design and are simple
rod, We know that Area resisting tearing
to set up. π
iv. The knuckle joint is simple to put together and A= 4
d2
take apart. Tensile Strength of the Rod

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2.2 Design of Power Screw:

A. Basic concept of power screw:

Calculate ‘dc’ A power screw is a mechanical device used for
By using empirical relation convening rotary motion into linear motion and
Calculate d=1.15 dc transmitting power. A power screw is also called a
Step 3. Design of coupler nut (l, D) translation screw. It uses helical translatory motion of
a) Tensile Failure of coupler nut Considering tensile failure the screw thread in transmitting power rather than

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of coupler nut, clamping the machine components. The main

We know that Area resisting tearing
Tensile Strength of the Rod
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applications of power screws are as follows:
i. to raise the load. e.g.. screw-jack;
ii. to obtain accurate motion in machining
operations, e.g., lead-screw of lathe;

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iii. to clamp a work piece, e.g., a vice; and
iv. to load a specimen, e.g., universal testing
Calculate ‘D’ machine.
b) Shear Failure of coupler nut considering share failure o

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There are three essential parts of the power screw, viz.,
coupler nut, screw, nut and a part to hold either the screw or the nut
We know that Area resisting tearing in its place. Depending upon the holding arrangement,

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A= (π x dc x l) power screws operate in two different ways. In some
Shear Strength of the Rod cases, the screw rotates in its bearing, while the nut has
axial motion. The lead screw of the lathe is an example
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of this category. In other applications, the nut is kept
Calculate ‘l’ stationary and the screw moves in an axial direction. A
Step 4. Design of coupler (D1, D2, L) screw jack and machine vice are examples of this
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a) By using empirical relation decide D1 category.

D1=d + 6 mm
B. Thread profiles used in power screw:
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b) Tensile Failure of coupler considering tensile failure o

i. Square thread
coupler,
ii. Acme or trapezoidal thread
We know that Area resisting tearing
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iii. Buttress thread

Square Thread:
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Tensile Strength of the Rod

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Calculate ‘D2’
a) By using empirical relation decide L
L=6xd
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A square thread, as shown in Fig., is adapted for the

A. Application of Turn Buckle:
transmission of power in either direction. This thread
i. It is used in tie rod in crane
Results in maximum efficiency and minimum radial or
ii. It is used in electric poles to support it.
bursting pressure on the nut.
iii. It is used in telegraph wires
iv. It is used in automobile chassis. Application:
v. It is used in railway track changing mechanisms. The square threads are employed in
i. Screw Jack

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ii. Mechanical Presses Buttress Thread:

iii. Clamping devices.
iv. Feed Screws.
Merits / Advantages:
i. Transmission of power in both directions.
ii. Higher Efficiency.
iii. Radial & Bursting Pressure on nut is minimum.
iv. Low friction

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Demerits / Disadvantages:

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i. Difficult to manufacture.
ii. Less strong than ACME threads. A buttress thread, as shown in Fig., is used when large
iii. Screw requires replacement. forces act along the screw axis in one direction only.

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iv. More cost. This thread combines the higher efficiency of square
thread and the ease of cutting and the adaptability to a
Acme or Trapezoidal Thread:
split nut of acme thread. It is stronger than other threads
because of greater thickness at the base of the thread.

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The buttress thread has limited use for power
transmission. It is employed as the thread for light jack

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screws and vices.
Application:
The buttress threads are employed in
i. Light screw jacks
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ii. Machine Vices
Merits / Advantages:
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i. Higher Efficiency.
ii. Easy to manufacture.
An acme or trapezoidal thread, as shown in Fig., is a iii. The axial wear at the thread surface can be
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modification of square thread. The slight slope given to compensated by means of a split-type nut.
its sides lowers the efficiency slightly than square thread iv. More strong than Square threads.
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and it also introduces some bursting pressure on the nut, Demerits / Disadvantages:
but increases its area in shear. i. Transmission of power in one direction only.
Application:
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C. Torque required to raise & lower load by

The Acme or trapezoidal are employed in
square threaded screws (No Derivation).
i. Lead screws of machine tools.
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ii. Bench Vices. Torque required to raise the load

Merits / Advantages:
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i. Easy to manufacture.
ii. More strong than Square threads.
Tr= Torque required to raise the load. N-mm
iii. Split type nuts can be used to compensate for
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P = Load to be lifted, N
wear & tear.
Φ = Friction angle,
Demerits / Disadvantages:
α = Helix angle,
i. Efficiency is less than square threads.
d = Mean diameter of the screw. mm
ii. Radial & Bursting Pressure on nut affects the
performance. To find Φ (Friction Angle) if μ is given.
iii. The axial wear at the thread surface can be μ = Coefficient of friction, between the screw and
compensated by means of a split-type nut. nut

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Since μ=tan Φ
Φ = tan-1 ( μ)

To find 𝛂 (Helix Angle) where

tan 𝛂 =
𝑝 W = Axial load on the screw,
π𝑥𝑑
n = Number of threads in engagement,
p = Pitch of the screw, mm
dc = Core or root diameter of the screw,
do = Outside or major diameter of nut or screw, and

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Torque required to raise the load
t = Thickness or width of thread.

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G. Bearing pressure
Tl= Torque required to lower the load. N-mm

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In the above expression, if Φ < α the torque required to
lower the load will be negative.
where d = Mean diameter of screw,
In other words, the load will start moving downward
t = Thickness or width of screw = p / 2, and
without the application of any torque. Such a condition

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n = Number of threads in contact with the nut
is known as overhauling of screws.
= height of nut/pitch of threads = h/p
If however, the torque required to lower the load will be

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positive, indicating that an effort is applied to lower the
2.3 Welded joints:
load. Such a screw is known as selflocking screw.
Introduction:A welded joint is a permanent joint
If the efficiency is more than 50%, then the screw is said
which is obtained by the fusion of the edges of the
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to be overhauling.
two parts to be joined together, with or without the
If the efficiency is less than 50%, then the screw is said
application of pressure and a filler material. The heat
to be Selflocking..
required for the fusion of the material may be
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D. Conditions for Overhauling: obtained by burning of gas (in case of gas welding) or
Efficiency is more than 50% (ղ > 50%) by an electric arc (in case of electric arc welding).
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if Φ (Friction Angle ) is less than α (Helix Angle) The latter method is extensively used because of
Φ<α greater speed of welding. Welding is extensively used
in fabrication as an alternative method for casting or
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E. Conditions for Selflocking: forging and as a replacement for bolted and riveted
Efficiency is less than 50% (ղ < 50%) joints. It is also used as a repair medium e.g. to
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if Φ (Friction Angle ) is more than α (Helix Angle) reunite metal at a crack, to build up a small part that
Φ>α has broken off such as gear tooth or to repair a worn
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surface such as a bearing surface.

F. Stresses in Power Screws
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Direct tensile or compressive stress due to an axial A. Types of welded joints:

load Following two types of welded joints,
𝑃
Direct stress (tensile or compressive) = i. Lap joint or fillet joint
𝐴
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ii. Butt joint

Torsional shear stress

i. Lap Joint or fillet joint

Shear stress due to axial load

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The lap joint or the fillet joint is obtained by ii. The welded joints provide maximum efficiency
overlapping the plates and then welding the edges of the (may be 100%) which is not possible in case of
plates. The cross-section of the fillet is approximately riveted joints.
triangular. iii. Alterations and additions can be easily made in
The fillet joints may be the existing structures.
i. Single transverse fillet, iv. As the welded structure is smooth in appearance,
ii. Double transverse fillet, and therefore it looks pleasing.
iii. Parallel fillet joints. v. In welded connections, the tension members are

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The fillet joints are shown in Fig. A single transverse not weakened as in the case of riveted joints.

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fillet joint has the disadvantage that the edge of the plate vi. A welded joint has a great strength. Often a
which is not welded can buckle or warp out of shape. welded joint has the strength of the parent metal
ii. Butt Joint itself.

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vii. 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.
viii. The welding provides very rigid joints. This is in

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The butt joint is obtained by placing the plates edge to line with the modern trend of providing rigid
edge as shown in Fig. In butt welds, the plate edges do frames.
not require beveling if the thickness of plate is less than ix. It is possible to weld any part of a structure at any
5 mm. On the other hand, if the plate thickness is 5 mm
to 12.5 mm, the edges should be beveled to V or
U-groove on both sides. ep point. But riveting requires enough clearance.
x. The process of welding takes less time than the
riveting.
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The butt joints may be Disadvantages
i. Square butt joint, i. Since there is an uneven heating and cooling
during fabrication, therefore the members may
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ii. Single V-butt joint

iii. Single U-butt joint, get distorted or additional stresses may develop.
iv. Double V-butt joint, and ii. It requires a highly skilled labour and
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v. Double U-butt joint. supervision.

iii. Other types of welded Joint iii. Since no provision is kept for expansion and
contraction in the frame, therefore there is a
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The other type of welded joints are corner joint, edge

joint and T-joint as shown in Fig. possibility of cracks developing in it.
iv. The inspection of welding work is more difficult
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than riveting work.

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2.4 Riveted Joints:

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A. Introduction:
A rivet is a short cylindrical bar
B. Advantages and Disadvantages of Welded Joints
with a head integral to it. The
over Riveted Joints
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cylindrical portion of the rivet is

Following are the advantages and disadvantages of
called shank or body and the lower
welded joints over riveted
portion of shank is known as tail.
joints.
The rivets are used to make
Advantages
permanent fastening between the
i. The welded structures are usually lighter than
plates such as in structural work,
riveted structures. This is due to the reason, that
ship building, bridges, tanks and
in welding, gussets or other connecting
components are not used.

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boiler shells. The riveted joints are widely used for

joining light metals.

B. Types of Riveted Joints:

2.4.1 Types of Riveted Joints
Following are the two types of riveted joints, depending
upon the way in which the plates are connected.
i. Lap joint

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ii. Butt joint.

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i. Lap joint

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A lap joint is that in which one plate overlaps the other
and the two plates are then riveted together.
There are different types of riveted lap joints depending C. Advantages of Riveted Joints
i. It is more reliable
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upon the number of rows of the rivets.
i. Single riveted joint ii. It can also be used for non-ferrous metals
ii. Double riveted joint. iii. Parts assembled by Riveted joint do not have any
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A single riveted joint is that in which there is a single thermal after effects
row of rivets in a lap joint as shown in Fig. A double iv. Its quality inspection is easy and cheap
riveted joint is that in which there are two rows of rivets v. When parts are dismantled riveted parts have less
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in a lap joint as shown in Fig. damage compared to welded parts

ii. Butt joint
D. Disadvantages of Riveted joints
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A butt joint is that in which the main plates are kept in

i. Due to holes plates become weak
alignment butting (i.e. touching) each other and a cover
ii. Labor cost is more
plate (i.e. strap) is placed either on one side or on both
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iii. Overall cost of riveted joints is more.

sides of the main plates. The cover plate is then riveted
iv. They have more weight than welded joints.
together with the main plates. Butt joints are of the
v. Riveting process creates more noise.
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following two types:

vi. Stress concentration near holes
i. Single strap butt joint
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ii. Double strap butt joint.

In a single strap butt joint, the edges of the main plates
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butt against each other and only one cover plate is

placed on one side of the main plates and then riveted
together.
In a double strap butt joint, the edges of the main plates
butt against each other and two cover plates are placed
on both sides of the main plates and then riveted
together.