Mechanical Design

Selected Topics

Dr. Amr Shaaban

Assistant Professor at
Ain Shams University, Egypt.
Founder of
Design Online Academy.

https://www.facebook.com/designonlineacademy
 The Connection Bolt material
Joint material
Bolt type
Design of Bolted Number of bolts
Bolt size
Connections
The Load Shear Load
Axial Load
Load Factor
Safety factor

Results Initial tension/Pre-stress

Tightening torque
Stresses
Margin of safety

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Fasteners Designation

Bolt’s head ≈ 0.7d Md*L*b Md*L*b* b1

Nut’s head ≈ 0.8d
Core diameter ≈ 0.85d M: Metric
Across flat ≈ 2d d: Outer diameter
Hole clearance ≈ 1.1d L: Total length
From hole’s center to edge ≈ 1.1d b: Threaded length
Washer diameter ≈ 2d b1 : Length of engaged thread in studs.
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Fasteners Designation

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Fasteners Designation

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Tightening Torque Concept

T2: Friction torque between

bolt ‘s head and joint

T: TIGHTENING TORQUE

T1: Friction torque between bolt

and nut connection

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Tightening torque calculations
α Helix angle Tan α =p/∏. dm

µ Coefficient of friction 0.2-0.25

β Inclination angle β=30⁰ (fasteners)

p Pitch Defined by bolt’s designation

dm Bolt mean diameter

rm1 Bolt mean radius rm1=dm/2

rm2 Flat mean radius rm2=1.5d+(d+2)/4

µ̀ Inclined Coefficient of friction µ̀= µ/ cosβ

Fa Axial load on bolt (pre-tension) Following slide

Friction torque consumed

T1 between threads
Friction torque consumed
T2 between flat surfaces

T Tightening torque

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Manual Calculation Of Initial Tension
F
Pmax

Pbolt

Pex
Pi

CJ Cb Pjoint

Pr

ΔL
λ
ΔL J ΔL b λ
Manual Calculation Of Bolt And Joint Stiffness

Ab1
C: Stiffness (N/mm) Lb1
E: Young’s modulus (Gpa)
A: Area (mm2)
L: Length (mm)
Lb2 Ab2

AJ1
Lb1 LJ1

AJ2
Lb2 LJ2

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 Manual bolt’s pre-stress and working stress calculation
T
ASSEMBLY STRESSES
n Safety factor 1.5-2.5
T2
dc Core diameter ≈ 0.85d
Ac Core Area

σy Yield stress Depends on bolt’s material (+)

Normal stress due to
σ initial tension
T1
τ Shear stress due to T1
Tap bolt T.D N.F.D
Combines stress due to
τcomb normal and shear
(Von mises‘s theory)
Allowable shear stress WORKING STRESSES
(depends on bolt’s grade)
τall τall should be ≥ τcomb
Pall should be ≥ Pmax

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Dynamic analysis for bolted connections

F
Pmax

Pmin

Pex-max
Pi

Pex-min
Pr-max

Pr-min

Cb CJ
ΔL

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Soderberg ‘s theory for fatigue

σvar •Based on the max and min values of the

working load, the mean and variance
σen stresses are calculated, and hence, line
OA can be drawn.
•Based on the bolt’s grade selected
through the static analysis, determine
yield and endurance stress, and hence,
draw the soderberg’s line. Point (B) that
B lays on the line represents the critical
point after which failure occurs.

A •If point (A) lays on the safe zoon, then

the bolt’s grade is accepted, and the
safety factor is simply (OB/OA).
σvar
SAFETY ZONE •If point (A) lays out the safe zone, then
o the bolt should be upgraded.
σmean σy σmean
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Applications
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BRACKETS
F1 F2

F2

F1

Tilting edge

W.L = F1 . L1 + F2 . L2
Pex = (F2/n)+(W/n)
Pex = (F2/n)+(W/µ.n) F1 / L1 = F2 / L2
Tilting load Direct normal

Tilting load Direct shear

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BRACKETS

40cos60*175 +40sin60*100 = 2F1 *60 + 2F2 *(120+60)

Tilting edge
F1 / 60 = F2 / (120+60)

Pex = (F2) )+(40sin60/n) +(40cos60/ µn)

Tilting load Direct normal Direct shear

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WORK BENCH PRESS

P*(150+400) = 2F *300

Pex = F+(p/2)

Tilting edge Tilting load Direct normal

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JIB CRANE

Tilting edge

W . 200 = F1 . 80 + F2 . (160+80)

F1 / 80 = F2 / (160+80)
Pex = F2/2
FOR ONE BOLT

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STEEL STRUCTURES

Ps : Direct shear force on bolt=60/6=10KN

F1,2,3,.. : Due to tilting moment (M=P.e) about G.

Pex = Rmax /µ

Rmax: The max resultant force of the 6 bolts

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STEEL STRUCTURES

Ps : Direct shear force on bolt=60/6=10KN

F1,2,3,.. : Due to tilting moment (M=60*200) about G.
Pex = Rmax /µ

Rmax: The max resultant force of the 6 bolts

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PRESSURE VESSELS

Pex = P.A/n

P: Pressure inside vessel

n: number of bolts
A: projected area of the cover

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•Vessel’s inner diameter = 150mm.
•Vessel’s wall thickness = 12mm.
•Number of studs recommended = 8 of M12*1.25.
•Bolt’s pitch circle diameter = 200mm.
•Pressure inside vessel in working status = 2Mpa.
•The residual load in the connection should be 80% of external load.

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