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Problem Specification
Construction
Selection of Materials
General Considerations
The coupler and the rods are provided with ISO metric coarse threads.
Coarse Threads are preferred because of the following advantages:
The rods are tightened by applying force on the wrench handle and
rotating the hexagonal coupler. The expression for torque required to tighten
the rod with specific tension P can be derived by suitable modification of the
equation derived for the trapezoidal threads. The torque required to
overcome thread friction in case of trapezoidal threads is given by Equation.
Or =0.098Pd
The above expression is used to find out torsional moment at each end of
the coupler.
The free body diagram of forces acting on the rods and the coupler is
shown in Fig. 02. Each rod is subjected to a tensile force P and torsional
moment . In the initial stages, it is not possible to find out torsional
moment. Considering only tensile force,
P=A
Where, A is tensile stress area of the treaded portion of the rod and is
permissible tensile stress. The rod is made of steel 30C8 ( = 400Pa) and
factor of safety is 5. Therefore,
75KN= A=937.5
From table, ISO metric coarse screw thread of M36 designation is suitable
for the rod (stress area = 817 ).For M36 size, the core diameter ( as
per table is 31.093 mm.
Trial No.01
d = 36 mm and = 31.093 mm
= =
98.77 Mpa or N /
= 264,600 N-mm
= =
44.83 N /
= 66.69988 N /
And,
= =
= 2.9985
The factor of safety is less than the required value of 5. The next size
of ISO metric coarse thread is M42 with 36.479 mm as minor diameter (
and 4.5 mm pitch. The stress area is
Trial no. 02
d = 42 mm and = 36.479 mm
= =
71.76 Mpa or N /
= 308,700 N-mm
= =
32.38754 N /
= 48.33575862 N /
And,
= =
= 4.1377
The factor of safety is slightly less than the required value of 5. The
next size of ISO metric coarse thread is M48 with as minor
diameter ( and 6.5 mm pitch. The stress area is
Trial no. 03
d = 48 mm and =45.802 mm
= =
49.36 Mpa or N /
= 352,800 N-mm
= =
21.116N /
The principal shear stress is given by,
= 32.48 N /
And,
= =
= 6.15745
=P
Where,
= = = 40 N /
Therefore,
= 75KN
= 13. 569276mm
This length is too small compared with the nominal diameter of 42 mm.
In practice, the length l varies from d to 1.25d. Or,
l = d = 48mm
From (i) and (ii) the length of threaded portion l is assume as60mm.
DESIGN OF COUPLER
The two ends of the coupler are called coupler nuts. As shown in Fig.
03, the coupler nuts are integral with the coupler. The outer and inner
diameter of the coupler nuts are D and d respectively and length is denoted
by l. It acts as a hollow rod. Considering tension,
P=
75KN =
Therefore,
= = 40 N /
Substitute the above value in Equation.
75KN =
Or, D = 68.49 mm or 70 mm
From the two result of diameter, it is decided that the dimension for D
should be 70 mm.
The coupler nut is subjected to direct tensile stress as well as torsional shear
stress due to torque
= 352,800 N-mm
r= = = 35mm
J= = = 1,836,023.716
= r = = 6.7254 N /
= 36.785 N /
Coupler is made of cast iron. Cast iron is brittle material. For brittle
materials, maximum principal stress theory is applicable. The maximum
principal stress is given by,
=
=
= 37.9757 N /
( )= = = 5.2665
d + 10 = 48 mm + 10 = 58 mm
=2 ( 58mm ) = 116 mm