Design of Joint

S K Mondal’s Chapter 1

1. Design of Joint

Theory at a glance (IES, IAS, GATE & PSU)

Cotters
x In machinery, the general term “shaft” refers to a member, usually of circular cross-
section, which supports gears, sprockets, wheels, rotors, etc., and which is subjected to
torsion and to transverse or axial loads acting singly or in combination.
x An “axle” is a non-rotating member that supports wheels, pulleys, and carries no
torque.
x A “spindle” is a short shaft. Terms such as line-shaft, head-shaft, stub shaft,
transmission shaft, countershaft, and flexible shaft are names associated with special
usage.

A cotter is a flat wedge-shaped piece of steel as shown in figure below. This is used to connect
rigidly two rods which transmit motion in the axial direction, without rotation. These joints
may be subjected to tensile or compressive forces along the axes of the rods.

Examples of cotter joint connections are: connection of piston rod to the crosshead of a steam
engine, valve rod and its stem etc.

Figure- A typical cotter with a taper on one side only

A typical cotter joint is as shown in figure below. One of the rods has a socket end into which
the other rod is inserted and the cotter is driven into a slot, made in both the socket and the
rod. The cotter tapers in width (usually 1:24) on one side only and when this is driven in, the
rod is forced into the socket. However, if the taper is provided on both the edges it must be less
than the sum of the friction angles for both the edges to make it self locking i.e. D1  D 2  E1  E2
where D1 , D2 are the angles of taper on the rod edge and socket edge of the cotter respectively
and E1 , E2 are the corresponding angles of friction. This also means that if taper is given on

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one side only then D  E1  E2 for self locking. Clearances between the cotter and slots in the
rod end and socket allows the driven cotter to draw together the two parts of the joint until the
socket end comes in contact with the cotter on the rod end.

d d1 d2
d3

Figure- Cross-sectional views of a typical cotter joint

Figure- An isometric view of a typical cotter joint

Design of a cotter joint

If the allowable stresses in tension, compression and shear for the socket, rod and cotter be
V t , V c and W respectively, assuming that they are all made of the same material, we may write
the following failure criteria:

1. Tension failure of rod at diameter d

S
d 2V t P
4

Fig. Tension failure of the rod

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2. Tension failure of rod across
slot

§S 2 ·
¨ 4 d1  d1t ¸ V t P
© ¹

Fig. Tension failure of rod across slot

3. Tensile failure of socket
across slot
§S ·
©
 2

¨ 4 d2  d1   d2  d1  t ¸ V t
2

¹
P

Fig. Tensile failure of socket across slot

4. Shear failure of cotter

2btW P

Fig. Shear failure of cotter

5. Shear failure of rod end

2l1d1W P

Fig. Shear failure of rod end

6. Shear failure of socket end

2l  d3  d1 W P

Fig. Shear failure of socket end

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7. Crushing failure of rod or
cotter

d1tV c P

Fig. Crushing failure of rod or cotter

8. Crushing failure of socket or

rod

 d3  d1  tV c P

Fig. Crushing failure of socket or rod

9. Crushing failure of collar

S
4
d 4
2
 d12 V c P

Fig. Crushing failure of collar

10. Shear failure of collar

S d1t1W P

Fig. Shear failure of collar

Cotters may bend when driven into position. When this occurs, the bending moment cannot be
correctly estimated since the pressure distribution is not known. However, if we assume a
triangular pressure distribution over the rod, as shown in figure below, we may approximate the
loading as shown in figure below.

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Figure-Bending of the cotter

P § d3  d1 d1 ·
This gives maximum bending moment  ¸ and
2 ¨© 6 4¹

P § d3  d1 d1 · b § d  d1 d1 ·
 ¸ 3P ¨ 3  ¸
2 ¨© 6 4 ¹2 © 6 4¹
The bending stress, V b  3 2
tb tb
12
Tightening of cotter introduces initial stresses which are again difficult to estimate.
Sometimes therefore it is necessary to use empirical proportions to design the joint. Some
typical proportions are given below:

d1 = 1.21.d d4 = l = l1 = 0.75d
1.5.d

d2 = 1.75.d t = 0.31d t1 = 0.45d

d3 = 2.4 d b = 1.6d c = clearance

A design based on empirical relation may be checked using the formulae based on failure
Mechanisms.

Question: Design a typical cotter joint to transmit a load of 50 kN in tension or compression.

Consider that the rod, socket and cotter are all made of a material with the following
allowable stresses:

Allowable tensile stress ( ǔy )= 150 MPa

Allowable crushing stress (ǔc) = 110 MPa

Allowable shear stress (Ǖy) = 110 MPa.

Answer: Refer to figures

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d d1 d2
d3

S
Axial load P  d 2V y . On substitution this gives d=20 mm. In general
4
Standard shaft size in mm is
6 mm to 22 mm diameter 2 mm in increment
25 mm to 60 mm diameter 5 mm in increment
60 mm to 110 mm diameter 10 mm in increment
110 mm to 140 mm diameter 15 mm in increment
140 mm to 160 mm diameter 20 mm in increment
500 mm to 600 mm diameter 30 mm in increment

We therefore choose a suitable rod size to be 25 mm.

Refer to figure
§S 2 ·
For tension failure across slot ¨ d  d1t ¸ V y P . This gives
©4 ¹
d1t = 1.58x10-4m2. From empirical relations we may take t=0.4d i.e. 10 mm and this
gives d1= 15.8 mm. Maintaining the proportion let d1= 1.2 d = 30 mm.

Refer to figure
­§ S 2 · ½
The tensile failure of socket across slot ®¨ d2  d12 ¸   d2  d1  t ¾ V y P
¯© 4 ¹ ¿
This gives d2 = 37 mm. Let d2 = 40 mm

Refer to figure above

For shear failure of cotter 2btW = P. On substitution this gives b = 22.72 mm.

Let b = 25 mm.

Refer to figure
For shear failure of rod end 2l1d1W = P and this gives l1 = 7.57 mm. Let l1 = 10 mm.

Refer to figure
For shear failure of socket end 2l(d2-d1)W = P and this gives l = 22.72 mm. Let l = 25
mm.

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Refer to figure
For crushing failure of socket or rod (d3-d1)tVc = P. This gives d3 = 75.5 mm. Let d3 = 77
mm.

Refer to figure
S
For crushing failure of collar
4
d 2
4 
 d12 V c P . On substitution this gives d4 = 38.4
mm. Let d4 = 40 mm.

Refer to figure

For shear failure of collar Sd1t1W = P which gives t1 = 4.8 mm. Let t1 = 5 mm.

Therefore the final chosen values of dimensions are

d = 25 mm; d1 = 30 mm; d2 = 40 mm; d3 = 77 mm; d4 = 40 mm; t = 10 mm; t1 = 5 mm; l =

25 mm; l1 = 10 mm; b = 27 mm.

Knuckle Joint
A knuckle joint (as shown in figure below) is used to connect two rods under tensile load. This
joint permits angular misalignment of the rods and may take compressive load if it is guided.
d3
d2

t1
d t d
t1 t2
t2

d1

Figure- A typical knuckle joint

These joints are used for different types of connections e.g. tie rods, tension links in bridge
structure. In this, one of the rods has an eye at the rod end and the other one is forked with
eyes at both the legs. A pin (knuckle pin) is inserted through the rod-end eye and fork-end eyes
and is secured by a collar and a split pin.

Normally, empirical relations are available to find different dimensions of the joint and they
are safe from design point of view. The proportions are given in the figure above.
d = diameter of rod
d1 = d t = 1.25d

d2 = 2d t1 = 0.75d
d3 = 1.5.d t2 = 0.5d

Mean diameter of the split pin = 0.25 d

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However, failures analysis may be carried out for checking. The analyses are shown below
assuming the same materials for the rods and pins and the yield stresses in tension,
compression and shear are given by ǔt, ǔc and Ǖ.

1. Failure of rod in tension:

S
d 2V t P
4
2. Failure of knuckle pin in double sheer:
S
2 d12W P
4
3. Failure of knuckle pin in bending (if the pin is loose in the fork)
Assuming a triangular pressure distribution on the pin, the loading on the pin is shown in
figure below.

Equating the maximum bending stress to tensile or compressive yield stress we have
§t t·
16P ¨ 1  ¸
Vt ©3 4¹
S d13

Figure- Bending of a knuckle pin

4. Failure of rod eye in shear:

(d2 - d1) tW = P
5. Failure of rod eye in crushing:
d1tVc = P

6. Failure of rod eye in tension:

(d2 - d1)tVt = P

7. Failure of forked end in shear:

2(d2 - d1)t1W = P

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8. Failure of forked end in tension:
2(d2 - d1)t1Vt = P

9. Failure of forked end in crushing:

2d1t1ǔc = P

The design may be carried out using the empirical proportions and then the analytical
relations may be used as checks.

2P
For example using the 2nd equation we haveW . We may now put value of d1 from
S d12
Wy
empirical relation and then find FACTOR OF SAFTEY, (F.S.) = which should be more
W
than one.

Q. Two mild steel rods are connected by a knuckle joint to transmit an axial
force of 100 kN. Design the joint completely assuming the working stresses for
both the pin and rod materials to be 100 MPa in tension, 65 MPa in shear and
150 MPa in crushing.
d3
d2

t1
d t d
t1 t2
t2

d1

Refer to figure above

S
For failure of rod in tension, P d 2V y . On substituting P = 100 kN, ǔy = 100 MPa we
4
have d= 35.6 mm. Let us choose the rod diameter d = 40 mm which is the next standard size.

We may now use the empirical relations to find the necessary dimensions and then
check the failure criteria.

d1= 40 mm t= 50 mm
d2 = 80 mm t1= 30 mm;
d3 = 60 mm t2= 20 mm;

Split pin diameter = 0.25 d1 = 10 mm

To check the failure modes:

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§ S ·
1. Failure of knuckle pin in shear: P ¨ 2 ˜ d12 ¸ Wy ,which gives Ǖy = 39.8
© 4 ¹
MPa. This is less than the yield shear stress.

§t t·
16P ¨ 1  ¸
2. For failure of knuckle pin in bending: V y
© 3 4 ¹ . On substitution
S d13
this gives ǔy = 179 MPa which is more than the allowable tensile yield stress of 100
MPa. We therefore increase the knuckle pin diameter to 55 mm which gives ǔy = 69
MPa that is well within the tensile yield stress.

3. For failure of rod eye in shear: (d2 - d1)tǕ = P. On substitution d1 = 55mm Ǖ = 80

MPa which exceeds the yield shear stress of 65 MPa. So d2 should be at least 85.8
mm. Let d2 be 90 mm.

4. for failure of rod eye in crushing: d1 t ǔc = P which gives ǔc = 36.36 MPa that is
well within the crushing strength of 150 MPa.

5. Failure of rod eye in tension: (d2 - d1)tǔt = P. Tensile stress developed at the rod
eye is then ǔt = 57.14 MPa which is safe.

6. Failure of forked end in shear: 2(d2-d1)t1Ǖ = P. Thus shear stress developed in

the forked end is Ǖ = 47.61 MPa which is safe.

7. Failure of forked end in tension: 2(d2 -d1)t1ǔy = P. Tensile strength developed in

the forked end is then ǔy= 47.61 MPa which is safe.

8. Failure of forked end in crushing: 2d1t1ǔc = P which gives the crushing stress
developed in the forked end as ǔc = 42 MPa. This is well within the crushing
strength of 150 MPa.

Therefore the final chosen values of dimensions are:

d1 = 55 mm t = 50 mm
d2 = 90 mm t1= 30 mm; and d = 40 mm
d3 = 60 mm t2= 20 mm;

Keys
In the assembly of pulley, key and shaft, Key is made the Weakest so that it is cheap and easy
to replace in case of failure.

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Figure- (a) Square

F S or rectangular
r key. (b) Sq
quare or reectangular keyk with on ne end
roounded; alsso available with both ends round ded. (c) Squuare or rectaangular key y with
gib head. (d d) Woodrufff key; alsso available e with flatttened botttom. (e) Ta apered
reectangular key; Ł = hu ub length, h = height; taper
t is 1¼8 in for 12 in
n or 1 for 100
1 for
m
metric sizes. (f) Tapered
d gib-head k
key; dimensiions and tap per same ass in (e).

Rectan
ngular and sq
quare ke
ey
1. Rectangular sunk key:: A rectangu
ular sunk key n in figure below. The usual
k is shown
pro
oportions of this key aree:

Width of key, (w)) =d/4

Thickn
ness of keyy, (t) = 2w / 3 = d / 6

Whhere d = Diaameter of th
he shaft or d
diameter of the
t hole in the
t hub.
Thee key has ta
aper 1 in 100 on the toop side only.

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Figu
ure-. Rectan
ngular sunk
k key.

2.. Square su unk key: The

T only diffference betw
ween a rectangular sun
nk key and a square su
unk
keey is that its width and
d thickness are
a equal, i..e.

w=t=d/4

3.. Gib-head key: It is a rectangula ar sunk keyy with a heaad at one en

nd known as
a gib head d. It
is usually prrovided to fa
acilitate thee removal oof key. A gib
b head key is shown in figure below
annd its use in
n shown in figure
f below
w.

Figure- Giib-head key.

he usual prooportions off the gib hea

Th ad key are:
Width,
W (w
w) =d/4
Thicknes
T ss at larg
ge end, ( t ) =2w
w/3=d/6

Iff a square keey of sides d/4

d is used then.
t In that case, for shear failuree we have

§d · d
¨ 4 u l ¸W x 2 T
© ¹
8T
o Wx
or [Where W x the yield is streess in shear and l is thee key length
h.]
d2
ld
Q.
Q A heat treated stteel shaft of
o tensile y
yield strength of 350 MPa has a diameter
r of
50 mmm. The shafft rotates at 1000 rp pm and transmits 10 00 kW thr
rough a geear.
Select an
a approp priate key for
f the gea ar.

So
olution: Coonsider a re
ectangular key of widtth (w), thickkness (t) an
nd length (L
L) as shown
n in
figure below.
b The key
k may faill (a) in shear or (b) in crrushing.

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Figure
d
Shear failure
e: The failu
ure criterio
on is Wy ˜ w˜ L˜
2

§ 2S N ·
Wh
here torque
e transmittted is, T  Poweer / ¨ ¸
© 60 ¹
N being
b in rpm
m, w, L and d are the wwidth, lengthh and diameter of the shaft
s respecctively
andd Ǖy is the yield
y stress in
i shear of tthe key matterial. Takin
ng Ǖy to be half
h of the tensile
t
yield stress annd substituting the valu
ues in abovee equations and we hav ve wL = 2.19 9 x 10-
4 m2.

t˜ L d
ushing faillure
Cru Vc ˜ ˜
2 2

Flat ke
ey
A flat key y, as shown n in figure below
b ed for light load beca
is use ause they deepend entirrely on
friction forr the grip. The
T sides of
o these key ys are paralllel but the top is sligh
htly tapered
d for a
tight fit. Theses
T keys have aboutt half the thickness of sunk keys.

Flat key Saddlee key

Saddle
e key
A saddle key, shown n in figure above,
a is very similar to
t a flat key y except thaat the bottom
m side
is concavee to fit the shaft
s surfacce. These keeys also havve friction g
grip and therefore cann not be
used for heavy
h loads. A simple pin
p can be u used as a keey to transmmit large toorques. Veryy little
stress conccentration occurs
o in the
e shaft in th
hese cases. This
T is showwn in figuree above.

Tange
ent Key

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Figure- Tangent
T Key
Feather
F key
A feather keyy is used whhen one com
mponent slid
des over anoother. The k
key may be fastened
f either
too the hub or the shaft and
a the keywway usuallyy has a slidin
ng fit.

Figure- feather
f key
Woodru
W uff key
A woodrufff key is a form
fo of sunk
k key wherre the key shape
s is tha
at of a trun
ncated disc,, as
sh
hown in figuure below. It
I is usually
y used for shafts
s less than
t about 60 mm dia ameter and the
ke ut in the shaft using a milling cuttter, as shown in the figure
eyway is cu f below
w. It is wid
dely
ussed in machhine tools and
a automoobiles due tto the extraa advantagge derived from
f the exxtra
deepth.

Figure- Woodruff
W key
y

The main ad
dvantages of a woodruff key ar
re as follow
ws:

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1. It accommodates itself to any taper in the hub or boss of the mating piece.
2. It is useful on tapering shaft ends. Its extra depth in the shaft prevents any tendency
to turn over in its keyway.
The main dis-advantages of a woodruff key are as follows:
1. The depth of the keyway weakens the shaft.
2. It can not be used as a feather.

Circular (Pin) Keys

Significantly lower stress concentration factors result from this type of key as compared to
parallel or tapered keys. A ball end mill can be used to make the circular key seat.

Splines
Splines are essentially stub by gear teeth formed on the outside of the shaft and on the inside
of the hub of the load-transmitting component. Splines are generally much more expensive to
manufacture than keys, and are usually not necessary for simple torque transmission. They
are typically used to transfer high torques. One feature of a spline is that it can be made
with a reasonably loose slip fit to allow for large axial motion between the shaft and
component while still transmitting torque. This is useful for connecting two shafts where
relative motion between them is common, such as in connecting a power takeoff (PTO) shaft of
a tractor to an implement.

Stress concentration factors are greatest where the spline ends and blends into the shaft, but
are generally quite moderate.

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ƒ Splines ca
an be thoug
ght of
as a series of axial
keyways with mating
m
keys ma achined on nto a
shaft.

ƒ There are two major types

of nes
splin used in
industry: 1) straight--sided
splines, and
a 2) invvolute
splines.

ƒ Splines pprovide a more

uniform circumfereential
transfer oof torque to the
shaft than
n a key.

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Spline Manufacturing Methods

Splines are either “cut” (machined) or rolled. Rolled splines are stronger than cut splines due
to the cold working of the metal. Nitriding is common to achieve very hard surfaces which
reduce wear.

Welded joints
A welded joint is a permanent joint which is obtained by the fusion of the edges of the two
parts to be joined together, with or without the application of pressure and a filler material.
The heat required for the fusion of the material may be obtained by burning of gas (in case of
gas welding) or by an electric arc (in case of electric arc welding). The latter method is
extensively used because of greater speed of welding.

Welding is extensively used in fabrication as an alternative method for casting or forging and
as a replacement for bolted and riveted joints. It is also used as a repair medium e.g. to reunite
metal at a crack, to build up a small part that has broken off such as gear tooth or to repair a
worn surface such as a bearing surface.

Types of welded joints:

Welded joints are primarily of two kinds:

(a) Lap or fillet joint

Obtained by overlapping the plates and welding their edges. The fillet joints may be single
transverse fillet, double transverse fillet or parallel fillet joints (see figure below).

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Figurre- Differentt types of la

ap joints

(b
b) Butt Joints
Formed by b placing the
t plates edge to edgee and weldin ng them. GGrooves are sometimes cut
k plates) on the edges before
(for thick b weld ding to the shape of th
ding. Accord he grooves, the
butt jointts may be off different ty
ypes, e.g.
x Squarre butt jointt
x Singlee V-butt join nt, double V-butt
V joint
x Singlee U-butt join nt, double U-butt
U joint
x Singlee J-butt joinnt, double J--butt joint
x Singlee bevel-butt joint, double bevel buttt joint.

Th hematically shown in fiigure below

hese are sch

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Figure- Diffferent typess of butt join

nts

There are
e other typ pes of weld ded joints, for examp
ple,
x Corrner joint (ssee figure beelow)
x Edg ge or seal jo
oint ( see fig
gure below)
x T-jooint (see fig
gure below)

Weldin
ng sym
mbol
A welding symbol hass following basic
b elemen
nts:

1. Reference
R line.
2. Arrow.
A
3. Basic
B weld symbols
s (lik
ke fillet, butt joints etc.))
4. Dimensions
D
5. Supplement
S tary symbols.
6. Finish
F symb bols
7. Tail.
T
8. Specification
S n processes

These welding symbols are placeed in standa

ard locationss (see figuree below)

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Example: If the desiredd weld is a fillet

f weld off size 10 mm
m to be done on each siide of Tee jooint
with
w convex contour,
c thee weld symbbol will be as following

Figure- Tee joint

Design
D of a bu
utt joint
he main faiilure mechanism of wellded butt joint is tensille failure. T
Th Therefore the strength of
o a
bu
utt joint is
P V t At
Where
W Vt = allowable tensile stren
ngth of the w
weld material.
t =th
hickness of the
t weld
ngth of the weld.
l =len
Foor a square butt joint t is equal too the thickn
ness of the plates.
p In geeneral, this need not bee so
(ssee figure beelow).

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Figu
ure- butt jointt

Design
n of tra
ansvers
se fillet joint
Consider a single tran nsverse join
nt as shownn in figure below.
b The g
general streess distributtion in
the weld metal
m is veryy complicated. In desig
gn, a simple procedure is used assu uming that entire
load P acts as shear force
f on the a, which is the smallesst area of th
e throat area he cross secttion in
a fillet weld. If the filllet weld ha ht, (h, say), then the crross section of the
as equal basse and heigh
hl
throat is easily
e seen to
t be . With
W the aboove consideration the p
permissible load carried by a
2
transverse
e fillet weld is
P = W s .Athroaat
WhereW s = allowablee shear stresss
Athroat = th
hroat area.
For a doub ble transverrse fillet join wable load iss twice that of the singlle fillet jointt.
nt the allow

Figu
ure- Enlarge view of filllet welding

Design
n of parallel fillet join
nt
Consider a parallel filllet weld as shown in fiigure below. Each weld
d carries a lo
oad P 2 . It is
i easy
to see from
m the streng
gth of materrial approacch that the maximum
m sshear occurss along the throat
area (try to
t prove it).. The allowable load ca
arried by ea
ach of the joint is W s At , wheere the
lh
throat area At . The d is P = 2W s At.
T total alllowable load
2

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In
n designing a weld joinnt the desig gn variables are h and l. They can n be selected d based on the
abbove design
n criteria. When
W a comb bination of ttransverse and paralleel filled joint required (see
(
fig
gure below) the allowabble load is

P 2W s At  W s Atc
Where
W At = throat arrea along th
he longitudinal direction.
Act = throa ng the transverse directtion.
at area alon

Figure
Design
D of circu
ular fille
et weld
d subjec
cted to torsion
n
Consider a circular
c shaaft connecteed to a platte by meanss of a fillet joint as sh
hown in figgure
beelow. If the shaft is sub bjected to a torque, sheear stress develops
d in the
t weld inn a similar way
w
ass in paralleel fillet join
nt. Assumin ng that the weld thick mpared to the
kness is verry small com
diiameter of the
t shaft, th he maximum m shear strress occurs in the throaat area. Thus, for a giv
ven
toorque the maximum she ear stress in
n the weld is
i
§d ·
T ¨  tthroat ¸
W max ©2 ¹
Jp
Where
W T = torque app plied.
d = outer diameter
d off the shaft
t throat = throat
t thickn ness
Jp = polarr moment off area of thee throat secttion.
S ª
 d  2t throat   d4 º
4

32 ¬ ¼

Page 22 of 263
 Des
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nt
S K Monda
M al’s Chapte
er 1
d
T
2 2T
When t thhroat  d, W max
S 3 S tthroat d 2
tthroat d
4
The throatt dimension
n and hence weld dimen
nsion can bee selected frrom the equation
2T
W max
m
S tthroaat d 2

Fig.

Q. A pllate 50 mmm wide an nd 12.5 mmm thick is to be welded to an nother pla

ate by
means of para allel fillet welds.
w The
e plates are
e subjectedd to a load
d of 50 kN.. Find
the length
l of th
he weld. Assume
A allo
owable sheear strengtth to be 56 MPa.

Solution. In a paralllel fillet wellding two lin

nes of weldiing are to b
be provided. Each line shares
s
50 p
a loa
ad of P kN
k 25 kN . Maximum s shear stresss in the parrallel fillet weld
w is , where
w t
2 lt
12.5 p
= thrroat length mm . Since
S d W s 56 u 106 . Hence
H the miinimum len ngth of the weld
w is
2 lt
25 u 103 u 2
0.5mm . How
50 wever somee extra len
ngth of the weld is to
o be provid
ded as
56 u 12.5
1 u 103
allow
wance for sttarting or stopping
s of the bead. A usual allowance of 12.5 mm iss kept.
(Note
e that the allowance haas no connecction with th
he plate thiickness)

Q. Two plates 20 00 mm wiide and 10 0 mm thic ck are to be welded by mea ans of

nsverse wellds at the ends. If th
tran he plates ar
re subjecte
ed to a loa
ad of 70 kN
N, find
the size
s of the weld assum
ming the aallowable tensile
t stre
ess 70 MPaa.

Solution: According to the design principlee of fillet (transverse) joint the weld is dessigned
assumming maxim mum shear stress occu
urs along th he throat arrea. Since teensile stren
ngth is
speciified the she
ear strength
h may be caalculated ass half of ten gth, i.e. ,W s ¬= 35
nsile streng
MPa. Assuming there are tw
wo welds, eeach weld ca
arries a load a the size of the
d of 35 kN and
weld is calculate
ed from

§ 10
1 u 10 3 ·
35 u 103 lu¨ 3 u 106
¸ u 35
© 2 ¹
Or l = 141.42 m
mm.

Page 23 of 263
 Design of Joint
S K Mondal’s Chapter 1
Adding an allowance of 12.5 mm for stopping and starting of the bead, the length of the
weld should be 154 mm.

Q. A 50 mm diameter solid shaft is to be welded to a flat plate and is required to

carry a torque of 1500 Nm. If fillet joint is used foe welding what will be the
minimum size of the weld when working shear stress is 56 MPa.

Solution. According to the procedure for calculating strength in the weld joint,

2T
Ws
S tthroat d 2
Where the symbols have usual significance. For given data, the throat thickness is 6.8
mm. Assuming equal base and height of the fillet the minimum size is 9.6 mm. Therefore
a fillet weld of size 10 mm will have to be used.

Q. A strap of mild steel is welded to a plate as shown in the following figure.

Check whether the weld size is safe or not when the joint is subjected to
completely reversed load of 5 kN.

Fig.

Solution. As shown in the figure the joint is a parallel fillet joint with leg size as 9 mm and
the welding is done on both sides of the strap. Hence the total weld length is 2(50) = 100
mm.

In order to calculate the design stress the following data are used

kï1 = 2.7 (parallel fillet joint, refer table 3) (there is required a table to solve the
problem……)
w = 0.9 cm

K = -1 for completely reversed loading

The value of the allowable fatigue stress (assuming the weld to be a line) is then
358 u 0.9
V 1 214.8 kgf/cm = 214800 N/m (approx).The design stress is Therefore
1.5

Page 24 of 263
 Des
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S K Monda
M al’s Chapte
er 1
214800
V 1, d 79556 N/m . Since
e the totall length off the weld
d is 0.1 m,
m the max
ximum
2..7
fluctuating
g load allow
wable for thee joint is 795
55.6 N. Thee joint is theerefore safe.

Thread
ded fas
steners

Bo olt - Threaaded fastenner designeed to pass

th
hrough holes in mating g members and to be
seecured by tightening
t a nut from
m the end
oppposite the head
h of the bolt.

Fig.

Sccrew - Thrreaded fasttener desig gned to be

in
nserted throough a holee in one meember and
in
nto a threadeed hole in a mating meember.

Fig.

Bolts

Machine Scre
ews

Page 25 of 263
 Desig
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S K Mo
ondal’’s C
Chapter
r1

Sheet
S M
Metal an
nd Lag Screws
S s

F
Figure-Sheet
t metal screews are often
n self-tapping.

Thread
T Profiles
s

Th
he pitch line or diameter is located
d at ½ the h
height of the
e theoreticall sharp v-th
hread profilee.
Thread
T Series
Thread Seriies - groupss of diamete
er-pitch commbinations distinguishe
d ed from eacch other by the
nu
umber of th
hreads per in
nch applied to a specificc diameter.

Page 26 of 263
 Design of Joint
S K Mondal’s Chapter 1

M-Series
Metric system of diameters, pitches, and tolerance/allowances.

Tensile Stress Area

The average axial stress in a fastener is computed using a “tensile stress area”.

F F { Axial Force
V ave
At Dr { Root Diameter

Dp { Pitch Diameter
2
S ª Dr  Dp º
At « » At { Tensile Stress Area
4¬ 2 ¼
Vave { Average axial stress

Length of Engagement (Equal Strength Materials)

If the internal thread and external thread material have the same strength, then
Tensile Strength (External Shear Strength (Internal
Thread) Thread)
Fmax Fmax
Vt 0.5V t
At As,i ˜ Le

Where
Fmax V t At 0.5V t As ,i Le
2 At
Le
As,i

Bolt/Nut Design Philosophy

ANSI standard bolts and nuts of equal grades are designed to have the bolt fail before the
threads in the nut are stripped.

The engineer designing a machine element is responsible for determining how something
should fail taking into account the safety of the operators and public. Length of engagement is
an important consideration in designing machine elements with machine screws.

Objective Questions (For GATE, IES & IAS)

Page 27 of 263
 Design of Joint
S K Mondal’s Chapter 1
Previous 20-Years GATE Questions

Keys
GATE-1. Square key of side "d/4" each and length l is used to transmit torque "T"
from the shaft of diameter "d" to the hub of a pulley. Assuming the length
of the key to be equal to the thickness of the pulley, the average shear
stress developed in the key is given by [GATE-2003]
4T 16T 8T 16T
(a) (b) 2 (c) 2 (d) 3
ld ld ld Sd
GATE-1. Ans. (c) If a square key of sides d/4 is used then. In that case, for shear failure we
§d · d
have ¨ u l ¸ Wx T
©4 ¹ 2
8T
or Wx [Where W x is the yield stress in shear and l is the key length.]
ld 2

GATE-2. A key connecting a flange coupling to a shaft is likely to fail in[GATE-1995]

(a) Shear (b) tension (c) torsion (d) bending
GATE-2. Ans. (a) Shear is the dominant stress on the key

Welded joints
GATE-3. A 60 mm long and 6 mm thick fillet weld carries a steady load of 15 kN
along the weld. The shear strength of the weld material is equal to 200
MPa. The factor of safety is [GATE-2006]
(a) 2.4 (b) 3.4 (c) 4.8 (d) 6.8
GATE-3. Ans. (b)
Strength of material
Factorofsafety
Actual load or strength on material
200(in MPa) 200(in MPa)
3
3.4
15 u 10 58.91(in MPa)
6
60 u u 106 (in MPa)
cos 45o

Threaded fasteners

Page 28 of 263
 Design of Joint
S K Mondal’s Chapter 1
GATE-4. A threaded nut of M16, ISO metric type, having 2 mm pitch with a pitch
diameter of 14.701 mm is to be checked for its pitch diameter using two or
three numbers of balls or rollers of the following sizes [GATE-2003]
(a) Rollers of 2 mm I (b) Rollers of 1.155 mm I
(c) Balls of 2 mm I (d) Balls of 1.155 mm I
GATE-4. Ans. (b)

Previous 20-Years IES Questions

Cotters
IES-1. Assertion (A): A cotter joint is used to rigidly connect two coaxial rods carrying
tensile load.
Reason (R): Taper in the cotter is provided to facilitate its removal when it fails
due to shear. [IES-2008]
(a) Both A and R are true and R is the correct explanation of A
(b) Both A and R are true but R is NOT the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-1. Ans. (b) A cotter is a flat wedge shaped piece of rectangular cross-section and its
width is tapered (either on one side or both sides) from one end to another for an
easy adjustment. The taper varies from 1 in 48 to 1 in 24 and it may be increased up
to 1 in 8, if a locking device is provided. The locking device may be a taper pin or a
set screw used on the lower end of the cotter. The cotter is usually made of mild
steel or wrought iron. A cotter joint is a temporary fastening and is used to connect
rigidly two co-axial rods or bars which are subjected to axial tensile or compressive
forces.

IES-2. Match List I with List II and select the correct answer using the code given
below the Lists: [IES 2007]
List I List II
(Application) (Joint)
A. Boiler shell 1. Cotter joint
B. Marine shaft coupling 2. Knuckle joint
C. Crosshead and piston road 3. Riveted joint
D. Automobile gear box 4. Splines
(gears to shaft) 5. Bolted Joint
Code: A B C D A B C D
(a) 1 4 2 5 (b) 3 5 1 4
(c) 1 5 2 4 (d) 3 4 1 5
IES-2. Ans. (b)

IES-3. Match List-I (Parts to be joined) with List-II (Type of Joint) and select the
correct answer using the code given below: [IES-2006]
List-I List -II
A. Two rods having relative axial motion 1. Pin Joint
B. Strap end of the connecting rod 2. Knuckle Joint
C. Piston rod and cross head 3. Gib and Cotter Joint
D. Links of four-bar chain 4. Cotter Joint
A B C D A B C D
(a) 1 3 4 2 (b) 2 4 3 1

Page 29 of 263
 Desig
gn of Joint
S K Mo
ondal’’s C
Chapter
r1
(c)) 1 4 3 2 (d) 2 3 4 1
IE
ES-3. Ans. (d)
(

IE
ES-4. Ma atch List I with List II and sele
ect the corrrect answeer. [IES-199
94]
Liist I (Typess of joints) Listt II (An element of th
he joint)
A. Riveted jo oint 1. Pin
B. Welded jo oint 2. Sttrap
C. Bolted joiint 3. Loock washe er
D.. Knuckle joint
j 4. Fillet
Codes: A B C D A B C D
(a)) 4 3 2 1 (b) 2 3 4 1
(c)) 2 4 3 1 (d) 2 4 1 3
IE
ES-4. Ans. (c)
(

IE
ES-5. n a gib and cotter join
In nt, the gib and cotterr are subje ected to [IES-200
06]
(a)) Single shear only (b) doublle shear onlly
(c)) Single shea
ar and crush
hing (d) doublle shear andd crushing
IE
ES-5. Ans. (d)
(

IE
ES-6. Ma atch List I (Items inn joints) wwith List III (Type of failure) an
nd select the
t
coorrect answ wer using the
t codes given
g below w the Listss: [IES-2004]
Liist I L
List II
A. Bolts in bolted
b join
nts of engin ne 1.Doubletra ansverse shhear
cylinder cover platte
B. Cotters in n cotter joiint 2. Torsional shear
C Rivets in lap
l joints 3 Single traansverse shhears
D.. Bolts holdding two fllanges in 4. Tension
a flange coupling
c
A B C D A B C D
(a)) 4 1 3 2 (b) 4 2 3 1
(c)) 3 1 4 2 (d) 3 2 4 1
ES-6. Ans. (a)
IE (

IE
ES-7. n a cotter joint, the width of the cotter
In r at the ce entre is 500 mm and its
th
hickness is s 12 mm. The T load a
acting on the
t cotter
r is 60 kN.. What is the
t
sh
hearing str ress develo oped in thee cotter? [IES-200
04]
(a)) 120 N/mm
m2 (b) 100 N/m
mm2 (cc) 75 N/mm2 (d)) 50 N/mm2
IE
ES-7. Ans. (d)
( It is
i a case of double
d shea
ar.
Load 60 u 103
Shear streess 50N / mm2
2 u Area
a 2 u 50 u 12
2

Page 30 of 263
 Design of Joint
S K Mondal’s Chapter 1
IES-8. The spigot of a cotter joint has a diameter D and carries a slot for cotter.
The permissible crushing stress is x times the permissible tensile stress for
the material of spigot where x > 1. The joint carries an axial load P. Which
one of the following equations will give the diameter of the spigot?
[IES-2001]
P x 1 P x 1 2 P x 1 2P
(a) D 2 (b) D 2 (c) D (d) D x 1
SVt x SVt x S Vt x SVt
IES-8. Ans. (b)

IES-9. Match List-l (Machine element) with List-II (Cause of failure) and select
the correct answer using the codes given below the lists: [IES-1998]
List-I List-II
A. Axle 1. Shear stress
B. Cotter 2. Tensile/compressive stress
C. Connecting rod 3. Wear
D. Journal bearing 4. Bending stress
Code: A B C D A B C D
(a) 1 4 2 3 (b) 4 1 2 3
(c) 4 1 3 2 (d) 1 4 3 2
IES-9. Ans. (b)
x In machinery, the general term “shaft” refers to a member, usually of circular
cross-section, which supports gears, sprockets, wheels, rotors, etc., and which is
subjected to torsion and to transverse or axial loads acting singly or in combination.
x An “axle” is a non-rotating member that supports wheels, pulleys, and carries no
torque.
x A “spindle” is a short shaft. Terms such as line-shaft, head-shaft, stub shaft,
transmission shaft, countershaft, and flexible shaft are names associated with
special usage.

IES-10. The piston rod and the crosshead in a steam engine are usually connected
by means of [IES-2003]
(a) Cotter joint (b) Knuckle joint (c) Ball joint (d) Universal joint
IES-10. Ans. (a)

IES-11. A cotter joint is used when no relative motion is permitted between the
rods joined by the cotter. It is capable of transmitting [IES-2002]
(a) Twisting moment (b) an axial tensile as well as compressive load
(c) The bending moment (d) only compressive axial load
IES-11. Ans. (b)

IES-12. Match List I with List II and select the correct answer using the codes
given below the lists: [IES-1995]
List I List II
(Different types of detachable joints) (Specific use of these detachable joints)
A. Cotter joint 1. Tie rod of a wall crane
B. Knuckle joint 2. Suspension bridges
C. Suspension link joint 3. Diagonal stays in boiler
D. Turn buckle (adjustable joint) 4. Cross-head of a steam engine
Codes: A B C D A B C D
(a) 4 2 3 1 (b) 4 3 2 1
(c) 3 2 1 4 (d) 2 1 4 3

Page 31 of 263
 Desig
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ondal’’s C
Chapter
r1
IE
ES-12. Ans.. (a)

IE
ES-13. Ma atch List I with Lisst II and select s the correct an nswer usin ng the cod des
givven below the lists: [IES-1993]
List I (Tyype of jointt)
A. Cotter joint
B. Knuckle joint
C. Turn buck kle
D.. Riveted jo oint
List II (MMode of join nting mem mbers)
1. Connects two rods or o bars per rmitting sm mall amoun nt of flexib bility
2. Rigidly co onnects two memberss
3. Connects two rods havingh thre
eaded ends
4. Permanen nt fluid-tight joint be etween two o flat piece es
5. Connects two shaftss and transsmits torqu ue
Coodes: A B C D A B C D
(a) 5 1 3 2 (b) 2 1 3 4
(c) 5 3 2 4 (d) 2 3 1 4
IE
ES-13. Ans. (b) A cotter is a flat wedge-shap ped piece of steel. This is used to connect
c rigiidly
wo rods whicch transmit motion in tthe axial dirrection, with
tw hout rotation. These joiints
ma ay be subjeccted to tensiile or comprressive forcees along thee axes of thee rods.
Coonnection off piston rod to the crosss-head of a steam engin ne, valve rood and its sttem
etcc are examp ples of cotterr joint.

IE
ES-14. Asssertion (A A): When th he coupler oof a turn buuckle is turned in one direction both
b
the connectin ng rods eith her move closer or mov ve away froom each oth her depend ding
uppon the direcction of rotaation of the coupler. [IES-19996]
Re eason (R): A turn bucckle is used d to connectt two roundd rods subjeected to tensile
loaading and reequiring sub bsequent addjustment foor tightenin
ng or looseniing.
(a)) Both A and d R are indiividually truue and R is the correct explanation
n of A
(b)) Both A and d R are indiividually truue but R is not
n the corrrect explana ation of A
(c)) A is true but R is falsee
(d)) A is false but
b R is truee
IE
ES-14. Ans.. (b)

Fig. Tu
urnbuckle

Keys
K
IE
ES-15. In
n the assem mbly of pulley, key an
nd shaft [IES-1993; 199
98]
(a)) pulley is made
m the weeakest (b) key iss made the weakest

Page 32 of 263
 Des
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o Join
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S K Monda
M al’s Chapte
er 1
(c) Key is made
m the strrongest (d) all the threee are dessigned for equal
streng
gth
IES-15. Ans.
A (b) Key
y is made the
t weakestt so that it is cheap an
nd easy to replace
r in ccase of
failure.

IES-16. Match List-I (Type of keys) with Listt-II (Chara acteristic) and selec ct the
correct an nswer usin ng the code es given beelow the Liists: [IES--1997]
List-I L
List-II
A. Woodru uff key 1. Loose fittting, light duty
B. Kenned dy key 2. Heavy du uty
C. Feather key 3. Self-align
ning
D. Flat ke ey 4. Normal in ndustrial use
u
Code: A B C D A B C D
(a) 2 3 1 4 (b) 3 2 1 4
(c) 2 3 4 1 (d) 3 2 4 1
IES-16. Ans.
A (b) A feeather key iss used whenn one compoonent slidess over anoth
her. The key
y may
be fastened d either to the hub or th
he shaft andd the keywaay usually has
h a slidingg fit.

Fig. feather keyy

IES-17. Match List-I with List-II and

d select thhe correctt answer using the code
given beloow the lists: [IES--2008]
List-I (Key
y/splines) List-III (Applicaation)
A. Gib heaad key 1. Sellf aligning
B. Woodru uff key 2. Faccilitates re
emoval
C. Paralle
el key 3. Moostly used
D. Spliness 4. Axial movem ment possib
ble
Code: A B C D A B C D
(a) 1 2 3 4 (b) 1 2 4 3
(c) 2 1 3 4 (d) 2 1 4 3
IES-17. Ans.
A (c)

IES-18. A spur ge ear transmmitting pow wer is con nnected to o the shaftt with a kkey of
rectangullar section n. The type (s) of stressses develo oped in the
e key is far
re.
(a) Shear stress
s alone (b) beearing stresss alone [IES--1995]
(c) Both sh
hear and beaaring stressees (d) sh
hearing, bearing and beending stresses.
IES-18. Ans.
A (c) Key
y develops booth shear an
nd bearing stresses.
s

IES-19. Assertion (A): The effect of keeyways on a shaft is to reduce its load carrying
capacity an nd to increase its torsioonal rigidity
y. [IES--1994]
Reason (R R): Highly lo ocalized streesses occur at or near tthe corners of keyways..
(a) Both A and R are individually y true and R is the correect explanattion of A
(b) Both A and R are individually y true but R is not the ccorrect explanation of A
(c) A is true but R is faalse
(d) A is falsse but R is true
t
IES-19. Ans.
A (d)

Page 33 of 263
 Design of Joint
S K Mondal’s Chapter 1
IES-20. Which key is preferred for the condition where a large amount of impact
torque is to be transmitted in both direction of rotation? [IES-1992]
(a) Woodruff key (b) Feather key (c) Gib-head key (d) Tangent key
IES-20. Ans. (d)

IES-21. What is sunk key made in the form of a segment of a circular disc of
uniform thickness, known as? [IES-2006]
(a) Feather key (b) Kennedy key (c) Woodruff key (d) Saddle key
IES-21. Ans. (c)

IES-22. What are the key functions of a master schedule? [IES-2005]

1. To generate material and capacity requirements
2. To maintain valid priorities
3. An effective capacity utilization
4. Planning the quantity and timing of output over the intermediate time
horizons
Select the correct answer using the code given below:
(a) 1, 2 and 3 (b) 2, 3 and 4 (c) 1, 3 and 4 (d) 1, 2 and 4
IES-22. Ans. (b)

IES-23. A square key of side d/4 is to be fitted on a shaft of diameter d and in the
hub of a pulley. If the material of the key and shaft is same and the two are
to be equally strong in shear, what is the length of the key? [IES-2005]
Sd 2Sd 3Sd 4 Sd
(a) (b) (c) (d)
2 3 4 5
IES-23. Ans. (a)

IES-24. Which one of the following statements is correct? [IES-2004]

While designing a parallel sunk key it is assumed that the distribution of
force along the length of the key
(a) Varies linearly (b) is uniform throughout
(c) varies exponentially, being more at the torque input end
(d) varies exponentially, being less at torque output end
IES-24. Ans. (c) Parallel sunk key. The parallel sunk keys may be of rectangular or square
section uniform in width and thickness throughout. It may be noted that a parallel
key is a taperless and is used where the pulley, gear or other mating piece is
required to slide along the shaft. In designing a key, forces due to fit of the key are
neglected and it is assumed that the distribution of forces along the length of key is
uniform.

IES-25. Match List-I (Device) with List-II (Component/Accessory) and select the
correct answer using the codes given below the Lists: [IES-2003]
List-I List-II
(Device) (Component/Accessory)
A. Lifting machine 1. Idler of Jockey pulley
B. Fibre rope drive 2. Sun wheel
C. Differential gear 3. Sheave
D. Belt drive 4. Power screw
Codes: A B C D A B C D
(a) 4 3 1 2 (b) 3 4 1 2
(c) 4 3 2 1 (d) 3 4 2 1
IES-25. Ans. (c)

Page 34 of 263
 Des
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S K Monda
M al’s Chapte
er 1
IES-26. A pulley is connec cted to a power tra ansmissionn shaft of diameter d by
means of a rectangu ular sunk k key of widdth wand leength ‘l’. The
T width of
o the
key is tak
ken as d/4.. For full p power tran nsmission, the shear ring strenggth of
the key is
s equal to the
t torsionnal shearinng strength
h of the sha aft. The ra
atio of
the length
h of the key to the diameter of the shaft ((l/d) is [IES--2003]
S S S
(a) (b) (c) (d) S
4 2 2
IES-26. Ans.
A (c)
§d ·
Shearing strength of key:F
k W. ¨ .l ¸
©4 ¹
d §d · d
T) =F.
Torque(T W. ¨ .l ¸ .
2 ©4 ¹ 2
T W
Torsional shearing, 4
Sd d
32 2
W
or T Sd3 u
16
For samee strength
§d · d W
W. ¨ .l ¸ . Sd3 u
©4 ¹ 2 16
l S
or
d 2

IES-27. Assertion (A): A Woo odruff key iss an easily adjustable

a k
key.
Reason (R R): The Woo odruff key aaccommodattes itself to any taper in the hub oor boss
of the matiing piece. [IES--2003]
(a) Both A and R are individually y true and R is the correect explanattion of A
(b) Both A and R are individually y true but R is not the ccorrect explanation of A
(c) A is true but R is faalse
(d) A is falsse but R is true
t
IES-27. Ans.
A (b)

The main advantages

a of a woodruuff key are as
a follows:
1. It accommmodates itsself to any taper in the hub or bosss of the mating piece.
2. It is usefful on taperring shaft en
nds. Its extrra depth in the
t shaft prrevents any
tendency too turn over in its keywa ay.
The main dis-advanta
d ages of a wooodruff key are
a as follow ws:
1. The deptth of the key yway weakeens the shafft.
2. It can noot be used as
a a feather.

Page 35 of 263
 Design of Joint
S K Mondal’s Chapter 1
IES-28. The key shown in the above
figure is a
(a) Barth key

(b) Kennedy key

(c) Lewis key

(d) Woodruff key

[IES-2000]
IES-28. Ans. (a)

IES-29. Match List I (Keys) with List II (Characteristics) and select the correct
answer using the codes given below the Lists: [IES-2000]
List I List II
A. Saddle key 1. Strong in shear and crushing
B. Woodruff key 2. Withstands tension in one direction
C. Tangent key 3. Transmission of power through frictional
resistance
D. Kennedy key 4. Semicircular in shape
Code: A B C D A B C D
(a) 3 4 1 2 (b) 4 3 2 1
(c) 4 3 1 2 (d) 3 4 2 1
IES-29. Ans. (d)

IES-30. Match List-I with List-II and select the correct answer using the code
given below the Lists: [IES-2009]
List-I List-II
(Description) (shape)
A. Spline 1. Involute
B. Roll pin 2. Semicircular
C. Gib-headed key 3. Tapered on on side
D. Woodruff key 4. Circular
Code: A B C D A B C D
(a) 1 3 4 2 (b) 2 3 4 1
(c) 1 4 3 2 (d) 2 4 3 1
IES-30. Ans. (c)

IES-31. The shearing area of a key of length 'L', breadth 'b' and depth 'h' is equal to
(a) b x h (b) Lx h (c) Lx b (d) Lx (h/2) [IES-1998]
IES-31. Ans. (c)

Splines
IES-32. Consider the following statements: [IES-1998]
A splined shaft is used for
1. Transmitting power
2. Holding a flywheel rigidly in position
3. Moving axially the gear wheels mounted on it
4. Mounting V-belt pulleys on it.
Of these statements
(a) 2 and 3 are correct (b) 1 and 4 are correct

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 Design of Joint
S K Mondal’s Chapter 1
(c) 2 and 4 are correct (d) 1 and 3 are correct
IES-32. Ans. (d)

Welded joints
IES-33. In a fillet welded joint, the weakest area of the weld is [IES-2002]
(a) Toe (b) root (c) throat (d) face
IES-33. Ans. (c)

IES-34. A single parallel fillet weld of total length L and weld size h subjected to a
tensile load P, will have what design stress? [IES 2007]
P P
(a) Tensile and equal to (b) Tensile and equal to
0.707Lh Lh
P P
(c) Shear and equal to (d) Shear and equal to
0.707Lh Lh
IES-34. Ans. (c)

1
Throat, t = h cos450 = h = 0.707h
v2
P P
T= =
Lt 0.707Lh
IES-35. Two metal plates
of thickness ’t’
and width 'w' are
joined by a fillet
weld of 45° as
shown in given
figure. [IES-1998]
When subjected to a pulling force 'F', the stress induced in the weld will be
F F F sin 45o 2F
(a) o
(b) (c) (d)
wt sin 45 wt wt wt
IES-35. Ans. (a)

IES-36. A butt welded joint, subjected to

tensile force P is shown in the
given figure, l = length of the
weld (in mm) h = throat of the
butt weld (in mm) and H is the
total height of weld including
reinforcement. The average
tensile stress ǔt, in the weld is
given by [IES-1997]
P P P 2P
 a  Vt ¬¬¬¬¬¬¬¬¬¬¬¬¬ b  Vt ¬¬¬¬¬¬¬¬¬¬¬¬  c  Vt ¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬  d  ¬Vt ¬¬¬
Hl hl 2hl Hl
IES-36. Ans. (b)

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 Design of Joint
S K Mondal’s Chapter 1
IES-37. In the welded joint shown in the given
figure, if the weld at B has thicker fillets
than that at A, then the load carrying
capacity P, of the joint will
(a) increase
(b) decrease
(c) remain unaffected
(d) exactly get doubled
[IES-1997]
IES-37. Ans. (c)

IES-38. A double fillet welded joint with parallel fillet weld of length L and leg B is
subjected to a tensile force P. Assuming uniform stress distribution, the
shear stress in the weld is given by [IES-1996]
2P P P 2P
(a) ¬¬ (b) ¬¬ (c) (d)
B.L 2.B.L 2.B.L B.L
IES-38. Ans. (c)

IES-39. The following two figures show welded joints (x x x x x indicates welds),
for the same load and same dimensions of plate and weld. [IES-1994]

The joint shown in

(a) fig. I is better because the weld is in shear and the principal stress in the weld is
not in line with P
(b) fig. I is better because the load transfer from the tie bar to the plate is not direct
(c) fig. II is better because the weld is in tension and safe stress of weld in tension is
greater than that in shear
(d) fig. II is better because it has less stress concentration.
IES-39. Ans. (c) Figure II is better because the weld is in tension and safe stress of weld in
tension is greater than shear.

IES-40. Assertion (A): In design of double fillet welding of unsymmetrical sections with
plates subjected to axial loads lengths of parallel welds are made unequal.
Reason (R): The lengths of parallel welds in fillet welding of an unsymmetrical
section with a plate are so proportioned that the sum of the resisting moments of
welds about the centre of gravity axis is zero. [IES-2008]
(a) Both A and R are true and R is the correct explanation of A
(b) Both A and R are true but R is NOT the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-40. Ans. (a) Axially loaded unsymmetrical welded joints

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 Design of Joint
S K Mondal’s Chapter 1
P1
W
A1
P1 WA1
P1 W u t u I1
P2 W u t u I2
P1 y1 P2 y 2
WtI1 y1 WtI2 y 2
I1 y1 I2 y 2

IES-41. Two plates are joined together by means of

single transverse and double parallel fillet
welds as shown in figure given above. If the size
of fillet is 5 mm and allowable shear load per
mm is 300 N, what is the approximate length of
each parallel fillet?
(a) 150 mm

(b) 200 mm

(c) 250 mm

(d) 300 mm
[IES-2005]
IES-41. Ans. (b) 300 u 100  2l  15000 or l 200

IES-42. A circular rod of diameter d is welded to a flat plate along its

circumference by fillet weld of thickness t. Assuming Ǖw as the allowable
shear stress for the weld material, what is the value of the safe torque that
can be transmitted? [IES-2004]
2 2 2
Sd Sd Sd
(a) Sd 2 .t.W w (b) .t.Ww (c) .t.Ww (d) .t.Ww
2 2 2 2
IES-42. Ans. (b)
Shear stress WW
Shear fore WW u Sdt
d Sd 2
Torque  T  WW u Sdt u .tWW
2 2

IES-43. A circular solid rod of diameter d welded to a rigid flat plate by a circular
fillet weld of throat thickness t is subjected to a twisting moment T. The
maximum shear stress induced in the weld is [IES-2003]
T 2T 4T 2T
(a) (b) (c) (d)
Std 2 Std 2 Std 2 Std 3
§d·
T. ¨ ¸
T.r ©2¹ 2T
IES-43. Ans. (b) W 3
J Std Std 2
4

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 Design of Joint
S K Mondal’s Chapter 1
IES-44. The permissible stress in a filled weld is 100 N/mm2.
The fillet weld has
equal leg lengths of 15 mm each. The allowable shearing load on weldment
per cm length of the weld is [IES-1995]
(a) 22.5 kN (b) 15.0 kN (c) 10.6 kN (d) 7.5 kN.
IES-44. Ans. (c) Load allowed = 100 x 0.707 x 10 x15 = 10.6 kN

Threaded fasteners
IES-45. A force ‘F’ is to be transmitted through a square-threaded power screw
into a nut. If ‘t’ is the height of the nut and ‘d’ is the minor diameter, then
which one of the following is the average shear stress over the screw
thread? [IES 2007]
2f F F 4F
(a) (b) (c) (d)
Sdt Sdt 2Sdt Sdt
IES-45. Ans. (b)

IES-46. Consider the case of a square-

threaded screw loaded by a nut as
shown in the given figure. The
value of the average shearing
stress of the screw is given by
(symbols have the usual meaning)
2F F
(a) (b)
Sd r h Sd r h
2F F
(c) d 
Sdh Sdh
[IES-1997]
IES-46. Ans. (b)

IES-47. Assertion (A): Uniform-strength bolts are used for resisting impact loads.
Reason (R): The area of cross-section of the threaded and unthreaded parts is
made equal. [IES-1994]
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-47. Ans. (c) A is true and R is false.

IES-48. How can shock absorbing capacity of a bolt be increased? [IES 2007]
(a) By tightening it property
(b) By increasing the shank diameter
(c) By grinding the shank
(d) By making the shank diameter equal to the core diameter of thread
IES-48. Ans. (d)

IES-49. The number of slots is a 25 mm castle nut is [IES-1992]

(a) 2 (b) 4 (c) 6 (d) 8
IES-49. Ans. (c)

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 Design of Joint
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Answers with Explanation (Objective)

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