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This connection has been designed to carry a load which varies between 0 and 12,000 pounds-per-bolt. Determine the factor-of-safety of the connection which has been preloaded to 10,000 pounds. The bolt is a 5/8"-11UNC-Grade 4 bolt, 2.25-inches long with rolled threads. In working this problem, we will assume the thread has a machine finish and will use a stress concentration factor of 3.0 for rolled threads. k surface S ult Se 0.73 k size ksi .k S . k . ult size e 2 S e = 1.034 10 4 ksi 0.85 ke 1 3

100000 k surface

The endurance limit has now been determined using techniques from the chapter on fatigue and data given in the problem statement. The next step is determine the proof strength of the bolt, the preload, bolt load, and clamped member loads. Following that, the loads will be checked against the criteria for tensile (positive) total bolt load and compressive (negative) clamped member loads. Finally, the fatigue life will be checked using the factor of safety equation given in your notes. From the Table 14-6 (page 914 of Norton) we can find the properties for a class 4 bolt: 65ksi = proof strength 100 ksi = yield strength 115 ksi = ultimate strength 0.2260 in2 = stress area

As a first check, verify the preload stress load is less than the proof stress. At Fi i 0.2260 10000 Fi At square pounds 4 i = 4.425 10 psi inches

This stress is less that the proof stress (65-ksi). We can, therefore, continue with our calculations. The next step is to evaluate the stiffness of the components, the clamped members and the bolt. For these calculations, note the material of the clamped members is #25 cast iron. We will need to find the stiffness (Young's Modulus) for that material. The clamped length of the joint is 1.5 inches, and the bolt diameter 5/8-inch. Because the modulus of elasticity for steel is different than that for cast iron, we can not make the assumption the member stiffness is eight times that of the bolt. #25 CI Steel Length Diameter 30 . 10 0.625 E . d2 . b 4 .l E . .d2 . m 2 l

6

E = 12,000,000 psi, member E = 30,000,000 psi, bolt l = 1.5 inches d = 0.625 inch 12 . 10

6

Eb d kb km

psi inch

Em l

psi inch 6 lb in lb in

1.50

k b = 6.136 10

7 k m = 1.963 10

Next, the minimum (preload), mean, maximum, and alternating stresses are calculated. This is done to check the factor of safety in fatigue as well as compare the maximum stress to the proof stress and ultimate stress of the bolt. As mentioned in class, for now we do not determine and check the clamped member stresses. We need to know more about surface fatigue and compressive stresses in fatigue to do this, which is beyond the scope of our current course. P min P mean min mean max 0 pounds P min 2 kb kb kb kb kb kb kb kb km P . min 2 .A t P max P max P alt Fi At Fi At Fi At 12000 P max 2 4 min = 4.425 10 mean = 5.057 10 max = 5.689 10 4 psi P min pounds

P . mean k m At

psi

P . max k m At

psi

alt

P . alt km At P max . kb kb km

3 alt = 6.321 10

psi

F bmax bmax

Fi

F bmax = 1.286 10

pounds

F bmax At

4 bmax = 5.689 10

psi

At this point, we see the maximum bolt stress is less than the allowable proof stress; and, we can continue on with our calculations. For this case we need to check the minimum external load against the criteria for flange separation. The maximum bolt load is use for strength calculations. Fb,min > 0 Fm,max < 0

kb kb km Fi C) Fi

F bmin F mmax

P min .C P max . ( 1

pounds

pounds

From these calculations, the criteria has been satisfied. There is a positive load in the bolt and a negative (compressive) load in the clamped members. The next step is to evaluate the factor of safety in fatigue using equation number 14.16 on page 924 of Norton. S e. S ult S e . mean min S ult . alt

Nf

min

N f = 0.827

This factor of safety, which indicates negative margin of safety in fatigue, is unsatisfactory. We have several options to improve the design so we have a positive margin of safety. Among these are: (1) Use a stronger bolt. (2) Use a larger bolt. (3) Use more bolts to decrease the external load/bolt. (4) Change the clamped member material to a stronger material such as steel.

For this example, we will select option (4), use steel members with a modulus of 30E+06 modulus. This will affect the portion of the external load carried by the members and bolt. We need modify only the equations involving the member stiffness determination; all others will remain the same. Eb Em d km kb P min P mean min 30 . 10

6 6

30 . 10 0.625

12000 P max

P alt Fi At

P . min 2 .A t

4 min = 4.425 10

mean

kb kb kb kb kb kb Fi

P . mean k m At

Fi At Fi At

mean = 4.72 10

psi

max

P . max k m At

max = 5.015 10

psi

alt

P . alt km At P max . kb kb km

3 alt = 2.95 10

psi

F bmax bmax

pounds

F bmax At kb

psi

kb

km P max . ( 1 P min .C C) Fi Fi

F mmax F bmin

pounds pounds

This calculation indicates we have a positive load for the clamping force, meaning the joint separates. The factor of safety will also be checked, just to determine the effect of the material change. S ult min . Nf Se N f = 1.771 S e . mean min S ult . alt

This value is acceptable. The design, is, however, unacceptable because the joint separates. Further further calculations, such as increasing the size of the bolts, or increasing the number of bolts are required. The only remaining step is to run a hand calculation to verify the computer results. Remember, in computer-aide-analysis, we need to verify our program to avoid "GIGO". Which can be a very embarrassing event to incur, especially during a design review.

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