DESIGN OF MACHINE ELEMENTS

Submitted to School of Mechanical and Building Sciences VIT University, Vellore 632 014

SLOT-D1 TOPIC

DESIGN OF KNUCKLE JOINT

SUBMITTED BY:VIKAS PORWAL(11BME0138) ASHISH JAISWAL(11BME0268)

Knuckle joint :A knuckle joint is a mechanical joint used to connect two rods which are under a tensile load, when there is a requirement of small amount of flexibility, or angular moment is necessary. There is always axial or linear line of action of load. However, if the joint is guided, the rods may support a compressive load. A knuckle joint may be readily disconnected for adjustments or repairs.

Applications:1.Tie rod joint of roof truss. 2.Tension link in bridge structure. 3.Link of roller chain. 4.Tie rod joint of jib crane. 5.The knuckle joint is also used in tractor. 6. Valve rod joint with eccentric rod. 7. Tension link in bridge structure.

Material used for manufacturing of knuckle joint:1. Mild steel 2. Wrought iron

Dimensions of Various Parts of the Knuckle Joint

KNUCKLE JOINT
The knuckle joint assembly consist of following major components : 1.Single eye. 2.Double eye or fork. 3.Knuckle pin.

The dimensions of various parts of the knuckle joint are fixed by empirical relations as given below. It may be noted that all the parts should be made of the same material i.e. mild steel or wrought iron. If d is the diameter of rod, then diameter of pin, d1 = d Outer diameter of eye, d2 = 2 d Diameter of knuckle pin head and collar, d3 = 1.5 d Thickness of single eye or rod end, t = 1.25 d Thickness of fork, t1 = 0.75 d Thickness of pin head, t2 = 0.5 d Other dimensions of the joint are shown in Figure.

The modes of failure of knuckle joint are :

1. Failure of solid rod in tension. 2. Failure of knuckle pin in shear. 3. Failure of single eye or rod end in tension. 4. Failure of single eye or rod end in shear. 5. Failure of single eye or rod end in crushing. 6. Failure of forked end in tension. 7. Failure of forked end in shear. 8. Failure of forked end in crushing.

Consider a knuckle joint as shown in given Figure, Let P = Tensile load acting on the rod, d = Diameter of the rod, d1 = Diameter of the pin, d2 = Outer diameter of eye, t = Thickness of single eye, t1 = Thickness of fork. t , and c = Permissible stresses for the joint material in tension, shear and crushing respectively. In determining the strength of the joint for the various methods of failure, it is assumed that 1. There is no stress concentration, and 2. The load is uniformly distributed over each part of the joint.

Due to these assumptions, the strengths are approximate, however they serve to indicate a well proportioned joint.

1.Failure of solid rod in tension.

Since the rods are subjected to direct tensile load, therefore tensile strength of the rod,

Equating this to the load (P) acting on the rod, we have

t

From this equation, diameter of the rod ( d ) is obtained.

2. Failure of the knuckle pin in shear

Since the pin is in double shear, therefore cross-sectional area of the pin under shearing
2 1

and the shear strength of the pin Equating this to the load (P) acting on the rod, we have 2 P 1
2 1

From this equation, diameter of the knuckle pin (d1) is obtained. This assumes that there is no slack and clearance between the pin and the fork and hence there is no bending of the pin. But, in

actual practice, the knuckle pin is loose in forks in order to permit angular movement of one with respect to the other, therefore the pin is subjected to bending in addition to shearing. By making the diameter of knuckle pin equal to the diameter of the rod (i.e., d1 = d), a margin of strength is provided to allow for the bending of the pin. In case, the stress due to bending is taken into account, it is assumed that the load on the pin is uniformly distributed along the middle portion (i.e. the eye end) and varies uniformly over the forks as shown in Figure below.

Distribution of load on the pin

Thus in the forks, a load P/2 acts through a distance of t1 / 3 from the inner edge and the bending moment will be maximum at the centre of the pin. The value of maximum bending moment is given by

From this expression, the value of d1 may be obtained.

3. Failure of the single eye or rod end in tension

The single eye or rod end may tear off due to the tensile load. We know that area resisting tearing = (d2 d1) t Tearing strength of single eye or rod end = (d2 d1) t t Equating this to the load (P) we have P = (d2 d1) t t From this equation, the induced tensile stress (t) for the single eye or rod end may be checked. In case the induced tensile stress is more than the allowable working stress, then increase the outer diameter of the eye (d2).

4. Failure of the single eye or rod end in shearing

The single eye or rod end may fail in shearing due to tensile load. We know that area resisting shearing = (d2 d1) t Shearing strength of single eye or rod end = (d2 d1) t Equating this to the load (P), we have P = (d2 d1) t From this equation, the induced shear stress () for the single eye or rod end may be checked.

5. Failure of the single eye or rod end in crushing

The single eye or pin may fail in crushing due to the tensile load. We know that area resisting crushing = d1 t Crushing strength of single eye or rod end = d1 t c Equating this to the load (P), we have P = d1 t c From this equation, the induced crushing stress (c) for the single eye or pin may be checked. In case the induced crushing stress in more than the allowable working stress, then increase the thickness of the single eye (t).

6. Failure of the forked end in tension

The forked end or double eye may fail in tension due to the tensile load. We know that area resisting tearing = (d2 d1) 2 t1 Tearing strength of the forked end = (d2 d1) 2 t1 t Equating this to the load (P), we have P = (d2 d1) 2t1 t From this equation, the induced tensile stress for the forked end may be checked.

7. Failure of the forked end in shear

The forked end may fail in shearing due to the tensile load. We know that area resisting shearing = (d2 d1) 2t1 Shearing strength of the forked end = (d2 d1) 2t1 Equating this to the load (P), we have P = (d2 d1) 2t1 From this equation, the induced shear stress for the forked end may be checked. In case, the induced shear stress is more than the allowable working stress, then thickness of the fork (t1) is increased.

8. Failure of the forked end in crushing

The forked end or pin may fail in crushing due to the tensile load. We know that area resisting crushing = d1 2 t1 Crushing strength of the forked end = d1 2 t1 c Equating this to the load (P), we have P = d1 2 t1 c From this equation, the induced crushing stress for the forked end may be checked.

Note: From the above failures of the joint, we see that the
thickness of fork (t1) should be equal to half the thickness of single eye (t / 2). But , in actual practice t1 > t / 2 in order to prevent deflection or spreading of the forks which would introduce excessive bending of pin.

Design procedure of knuckle joint

The empirical dimensions as discussed above have been formulated after wide experience on a particular service. These dimensions are of more practical value than the theoretical analysis. Thus, a designer should consider the empirical relations in designing a knuckle joint. The following procedure may be adopted : 1. First of all, find the diameter of the rod by considering the failure of the rod in tension. We know that tensile load acting on the rod,
t

where

d = Diameter of the rod, and t = Permissible tensile stress for the material of the rod.

2. After determining the diameter of the rod, the diameter of pin (d1) may be determined by considering the failure of the pin in shear. We know that load, 2 P 1 A little consideration will show that the value of d1 as obtained by the above relation is less than the specified value (i.e. the diameter of rod). So fix the diameter of the pin equal to the diameter of the rod.

3. Other dimensions of the joint are fixed by empirical relations as discussed before.

4. The induced stresses are obtained by substituting the empirical dimensions in the relations as discussed in the equations of failure points. In case the induced stress is more than the allowable stress, then the corresponding dimension may be increased.

EXAMPLE:Let, load to be transmitted (P) =150kN t = 75MPa = 60MPa c =150MPa design the knuckle joint for given specifications. SOLUTION The joint is designed by considering the various methods of failure as discussed below : 1. Failure of the solid rod in tension Let d = Diameter of the rod. We know that the load transmitted (P), 2 150 103 d d2 = 150 103 / 59 = 2540 or d = 50.4 say 52 mm Ans. Now the various dimensions are fixed as follows : Diameter of knuckle pin, d1 = d = 52 mm Outer diameter of eye, d2 = 2 d = 2 52 = 104 mm

Diameter of knuckle pin head and collar, d3 = 1.5 d = 1.5 52 = 78 mm Thickness of single eye or rod end, t = 1.25 d = 1.25 52 = 65 mm Thickness of fork, t1 = 0.75 d = 0.75 52 = 39 say 40 mm Thickness of pin head, t2 = 0.5 d = 0.5 52 = 26 mm 2. Failure of the knuckle pin in shear Since the knuckle pin is in double shear, therefore load (P), 2 150 103 1
2

= 4248 =150 103/4248 =35.3 MPa

3. Failure of the single eye or rod end in tension The single eye or rod end may fail in tension due to the load. We know that load (P), 150 103 = (d2 d1) t t = (104 52) 65 t = 3380 t t = 150 103 / 3380 = 44.4 N / mm2 = 44.4 MPa

4. Failure of the single eye or rod end in shearing The single eye or rod end may fail in shearing due to the load. We know that load (P), 150 103 = (d2 d1) t = (104 52) 65 = 3380 = 150 103 / 3380 = 44.4 N/mm2 = 44.4 MPa

5. Failure of the single eye or rod end in crushing The single eye or rod end may fail in crushing due to the load. We know that load (P), 150 103 = d1 t c = 52 65 c = 3380 c c = 150 103 / 3380 = 44.4 N/mm2 = 44.4 MPa

6. Failure of the forked end in tension The forked end may fail in tension due to the load. We know that load (P), 150 103 = (d2 d1) 2 t1 t = (104 52) 2 40 t = 4160 t t = 150 103 / 4160 = 36 N/mm2 = 36 MPa

7. Failure of the forked end in shear The forked end may fail in shearing due to the load. We know that load (P), 150 103 = (d2 d1) 2 t1 = (104 52) 2 40 = 4160 = 150 103 / 4160 = 36 N/mm2 = 36 MPa

8. Failure of the forked end in crushing The forked end may fail in crushing due to the load. We know that load (P), 150 103 = d1 2 t1 c = 52 2 40 c = 4160 c c = 150 103 / 4180 = 36 N/mm2 = 36 MPa From above, we see that the induced stresses are less than the given design stresses, therefore the joint is safe.

Stress analysis of fork

Units
Unit system: Length/Displacement Temperature Angular velocity Stress/Pressure SI mm Kelvin rad/s N/m^2

Material Properties
No. 1 Body Name Solid Body fork(Cut-Extrude6) Material Wrought Stainless Steel Mass 0.731199 kg Volume 9.13999e-005 m^3

Material name: Description: Material Source: Material Model Type: Default Failure Criterion: Application Data:

Wrought Stainless Steel

Linear Elastic Isotropic Max von Mises Stress

Property Name Elastic modulus Poisson's ratio Shear modulus Mass density Tensile strength Yield strength Thermal expansion coefficient Thermal conductivity Specific heat

Value 2e+011 0.26 7.9e+010 8000 5.1702e+008 2.0681e+008 1.1e-005

Units N/m^2 NA N/m^2 kg/m^3 N/m^2 N/m^2 /Kelvin

Value Type Constant Constant Constant Constant Constant Constant Constant

19 500

W/(m.K) J/(kg.K)

Constant Constant

Loads and Restraints

Fixture
Restraint name Fixed-1 <fork> Selection set on 2 Face(s) fixed. Description

Load
Load name Force-1 <fork> Selection set on 1 Face(s) apply normal force -1.5e+005 N using uniform distribution on 2 Face(s) apply normal force -1.5e+005 N using uniform distribution Loading type Sequential Loading Description

Force-2 <fork>

Sequential Loading

Reaction Forces
Selection set Entire Body Units N Sum X -0.543427 Sum Y -0.307434 Sum Z -85702.5 Resultant 85702.5

Free-Body Forces
Selection set Entire Body Units N Sum X 3.70368e-005 Sum Y -0.0630307 Sum Z 0.143353 Resultant 0.156598

Free-body Moments
Selection set Entire Body Units N-m Sum X 0 Sum Y 0 Sum Z 0 Resultant 1e-033

Study Results

Default Results

Name Stress1

Type VON: von Mises Stress

Min 1.40795e+007 N/m^2 Node: 13770

Location (16.558 mm, 11.3076 mm, 19.1602 mm) (3.73517e-015 mm, 17.5 mm, 16.2316 mm)

Max 1.75826e+009 N/m^2 Node: 19585 0.973815 mm Node: 71

Location (18.2665 mm, 16.9286 mm, 10.1394 mm) (31.5613 mm, 5.03197e-005 mm, -61.6298 mm)

Displacement1

URES: Resultant Displacement

0 mm Node: 549

Strain1

ESTRN: Equivalent Strain

5.77976e-005 Element: 5953

(17.1524 mm, -11.7353 mm, 18.6719 mm)

0.00456444 Element: 3193

(-18.1257 mm, -17.6481 mm, 9.59889 mm)

Fork-Study 1-Stress-Stress1

Fork-Study 1-Displacement-Displacement1

Fork-Study 1-Strain-Strain1

Material Properties
No. 1 Body Name SolidBody 1(CutExtrude1) SolidBody 1(CutExtrude6) SolidBody 1(Revolve1) Material Wrought Stainless Steel Wrought Stainless Steel Wrought Stainless Steel Mass 0.926753 kg Volume 0.000115844 m^3

0.731199 kg

9.13999e-005 m^3

0.55292 kg

6.9115e-005 m^3

Material name: Description: Material Source: Material Model Type: Default Failure Criterion: Application Data:

Wrought Stainless Steel

Linear Elastic Isotropic Max von Mises Stress

Property Name Elastic modulus Poisson's ratio Shear modulus Mass density Tensile strength Yield strength Thermal expansion coefficient Thermal conductivity Specific heat

Value 2e+011 0.26 7.9e+010 8000 5.1702e+008 2.0681e+008 1.1e-005

Units N/m^2 NA N/m^2 kg/m^3 N/m^2 N/m^2 /Kelvin

Value Type Constant Constant Constant Constant Constant Constant Constant

19 500

W/(m.K) J/(kg.K)

Constant Constant

Loads and Restraints

Fixture
Restraint name Fixed-1 <fork-1> Selection set on 1 Face(s) fixed. Description

Load
Load name Force-1 <eye-1> Selection set on 1 Face(s) apply normal force -1.5e+005 N using uniform distribution on 1 Face(s) apply normal force -1.5e+005 N using uniform distribution Loading type Sequential Loading Description

Force-2 <fork-1>

Sequential Loading

Reaction Forces
Selection set Entire Body Units N Sum X 0.198853 Sum Y -0.791847 Sum Z -0.117023 Resultant 0.824778

Free-Body Forces
Selection set Entire Body Units N Sum X -0.00489192 Sum Y 0.00129189 Sum Z -0.317051 Resultant 0.317092

Free-body Moments
Selection set Entire Body Units N-m Sum X 0 Sum Y 0 Sum Z 0 Resultant 1e-033

Study Results

Name Stress1

Type VON: von Mises Stress

Min 643068 N/m^2 Node: 29789

Location (1.37842 in, 1.00716 in, -1.95428 in)

Max 7.33743e+008 N/m^2 Node: 28404 0.152514 mm Node: 16007

Location (0.498811 in, 0.2048 in, -0.159804 in) (0.293518 in, 0.253227 in, 2.37843 in)

Displacement1

URES: Resultant Displacement

0 mm Node: 15813

(-1.57449 in, -0.0420505 in, -0.811472 in)

Strain1

ESTRN: Equivalent Strain

1.14457e-005 Element: 24314

(1.30129 in, 0.144692 in, -0.378905 in)

0.00269573 Element: 14102

(-1.11751 in, 0.229582 in, -0.182911 in)

Assem2-Study 1-Stress-Stress1

Assem2-Study 1-Displacement-Displacement1

Assem2-Study 1-Strain-Strain1