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door hinges
Contents
The failure modes for the lug are listed below. The numbers
correspond with the labeled sections from the above figure:
3. Bearing failure
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Bearing failure
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w = ݓwidth
Tension failure across the net section occurs over the cross-section
highlighted in red in the figure below:
The ultimate tensile load is the load that would result in tensile
failure across the net section, and is given by:
where Stuܵ௧௨ is the ultimate tensile strength of the lug material. The
equation above assumes a uniform tensile stress over the cross-
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ܲ௧௨
FStu=PtuFapp
ܵܨ௧௨ =
ܨ
Shear tear out occurs over the two shear planes highlighted in red
in the figure below:
where Lspܮ௦ is the length of the shear plane and t ݐis the lug
thickness. A simple and conservative approach is to calculate the
length of a single shear plane as:
ܮ௦ = ܽ
Lsp=a
ܦ
Lsp=a+Dp2(1−cos(ϕ))−Z
ܮ௦ = ܽ + (1 − cos(߶)) − ܼ
2
where ϕ߶ is the shear plane locating angle of 40° and Zܼ is the loss
in shear plane length due to the curvature at the end of the lug.
This loss is calculated as:
Z=r−r2−(Dp2sin(ϕ))2−−−−−−−−−−−−−−−√
ܦ
ଶ
ܼ = ݎ− ඨ ݎଶ − ቆ sin(߶)ቇ
2
Note that if the lug end is flat then r ݎis infinity and Zܼ is zero.
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The ultimate shear load is the load that would result in shear tear
out along the two planes, and is given by:
ܲ௦௨
FStu=PsuFapp
ܵܨ௧௨ =
ܨ
Bearing occurs between the surface of the pin and the inner
surface of the hole in the lug, as shown in the figure below:
Note that since the length of the bearing surface is equal to the
the length of the bearing surface is also equal to 1/π1/ߨ times the
circumference of the pin
The ultimate bearing load is the load that would result in bearing
failure, and is given by:
ܲ௨
FSbru=PbruFapp
ܵܨ௨ =
ܨ
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Pin on bushing
Bushing on lug
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For axially loaded lugs, the Air Force method evaluates the lug for
bearing failure, shear-out failure, hoop tension failure, and failure
across the net section. Three of the failure modes are actually
combined into a single failure mode -- the "bearing strength"
accounts for bearing, shear-out, and hoop tension. This is
consistent with Bruhn and Melcon & Hoblit.
D = ܦhole diameter
e݁ = edge distance
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w = ݓwidth
t = ݐthickness
ܲ௨. = อ
1.304ܨ௬. ݐܦ otherwise
ܨ௨. and Fbry.Lܨ௬. are the lug ultimate and yield bearing
where D ܦis the hole diameter and t ݐis the lug thickness. Fbru.L
ܽ
KaDStu
ܵ ܭ௧௨ ܵܭ௧௨
KStu
Ultimate Bearing Stress, Fbru.Lܨ௨. :
ܦ
ܽ
KaDSty
ܵ ܭ௧௬ ܵܭ௧௬
KSty
Yield Bearing Stress, Fbry.Lܨ௬. :
ܦ
The equation for ultimate bearing load can be condensed down to:
Pbru.L=K⋅min(Stu,1.304Sty)⋅Dt⋅∣∣∣aD1if e/D<1.5otherwise
if ݁/ < ܦ1.5
ܲ௨. = ⋅ ܭmin (ܵ௧௨ , 1.304ܵ௧௬ ) ⋅ ⋅ ݐܦቮ
1 otherwise
For ratios of e/D݁/ ܦless than 1.5, the hole is close to the edge of
the lug and so shear-out and hoop tension are likely to be the most
critical failure modes. For larger values of e/D݁/ܦ, the hole is
spaced farther from the edge and so bearing is likely to be the
critical failure mode.
The factor K ܭin the equations above is the allowable axial load
coefficient which accounts for the interaction effects between the
different failure modes (bearing, shear-out, and hoop tension). The
plot is used for D/t≤5ܦ/ ≤ ݐ5, which is the most common case. If
value of K ܭis read off of one of the following two plots. The first
D/t>5ܦ/ > ݐ5 then the lug is thin, and in that case the value of Kܭ
is read off of the second plot below. (Note 2)
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If there is a bushing in the lug, then the bearing strength for the
bushing must be calculated. The bushing ultimate load is given by:
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The net-section ultimate load accounts for tension failure across the
net section and is calculated by:
ܲ௨. = อ
1.304ܨ௬. ( ݓ− ݐ)ܦ otherwise
where w ݓis the width and D ܦis the hole diameter. Fnu.Lܨ௨. and
Fny.Lܨ௬. are the ultimate and yield net-section stresses,
respectively, and are given by the following equations:
The equation for net section ultimate load can be condensed down
to:
The factor Knܭ in the equations above is the net tension stress
coefficient which is a knock-down on the allowable stresses. The
value of Knܭ is determined by interpolating between the following
plots:
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The design ultimate load for an axially loaded lug is the minimum of
the ultimate bearing load, the ultimate bushing load, and the
ultimate net-section load:
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where h1ℎଵ , h2ℎଶ , h3ℎଷ , and h4ℎସ are failure planes of interest. If
the lug is symmetric, then the values for these dimensions can be
easily obtained from the dimensions for an axially loaded lug:
6
hav=63/h1+1/h2+1/h3+1/h4
ℎ௩ =
3/ℎଵ + 1/ℎଶ + 1/ℎଷ + 1/ℎସ
ܲ௧௨. = อ
1.304ܨ௬. ݐܦ otherwise
ܨ௨. and Fbry.Lܨ௬. are the lug ultimate and yield bearing
where D ܦis the hole diameter and t ݐis the lug thickness. Fbru.L
where Ktruܭ௧௨ and Ktryܭ௧௬ are the transverse ultimate and yield
load coefficients and are determined from the following plot:
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ܲ௧௨. = ܲ௨.
Ptru.B=Pu.B
In an obliquely loaded lug, the applied load has both axial and
transverse components, as shown in the figure below:
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For an obliquely loaded lug, the applied load should be broken out
into the axial and transverse components, Paxܲ௫ and Ptrܲ௧ , and
the strengths in the axial and transverse directions should be
calculated as discussed in the previous sections. An allowable load
curve can then be defined which takes the form of an interaction
equation, and is given below:
ܲ௫.௨௧ ܲ௧.௨௧
(Pax.ultPu.L.B)1.6+(Ptr.ultPtru.L.B)1.6=1
ଵ. ଵ.
ቆ ቇ +ቆ ቇ =1
ܲ௨.. ܲ௧௨..
The allowable load curve defines the limits at which the lug is
expected to fail -- it defines the ultimate load for a given
combination of applied axial and transverse load. In the equation
above, Pax.ultܲ௫.௨௧ is the axial component of the ultimate load,
Ptr.ultܲ௧.௨௧ is the transverse component of the ultimate load,
Pu.L.Bܲ௨.. is the design strength under axial load, and Ptru.L.B
ܲ௧௨.. is the design strength under transverse load. The allowable
load curve is shown below:
In the figure above, the values along the y-axis are the ratios of the
transverse applied load to the transverse strength, and the values
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along the x-axis are the ratios of the axial applied load to the axial
strength.
ܲ௫ ܲ௧
Rax=PaxPu.L.B Rtr=PtrPtru.L.B
ܴ௫ = ܴ௧ =
ܲ௨ .. ܲ௧௨..
The point for the applied load with coordinates of (Rax,Rtr)(ܴ௫ , ܴ௧
) should be plotted. Any point that falls within the allowable load
curve has a factor of safety ≥ 1 with respect to the ultimate load.
Rtrܴ௧ is 0 and the point (Rax,Rtr)(ܴ௫ , ܴ௧ ) lies along the x-axis,
Note that if the applied load is completely axial, then the value for
For an applied load with both axial and transverse components, the
the point (Rax,Rtr)(ܴ௫ , ܴ௧ ), and then through the allowable load
ultimate load is calculated by drawing a line from the origin, through
݉= =
ܴ௫ ܲ௧௨ .. ܲ௫
The ultimate load ratios are given by the intersection of the load line
with the allowable load curve. These ultimate ratios can then be
used to calculate the ultimate load values in the axial and
transverse directions.
ܲ௫.௨௧ ܲ௧.௨௧
Rax.ult=Pax.ultPu.L.B Rtr.ult=Ptr.ultPtru.L.B
ܴ௫.௨௧ = ܴ௧.௨௧ =
ܲ௨.. ܲ௧௨..
It should be noted that the equation for the slope given above
disagrees with the slope specified in the Air Force Manual. A
discussion is given in the Appendix.
where αߙ is the angle of the applied load with respect to the axial
direction. (Note 4) The equation defining the allowable load curve
can then be solved for the ultimate axial load, with the relationship
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Pax.ult=⎛⎝⎜⎜1(1Pu.L.B)1.6+(tan(α)Ptru.L.B)1.6
ܲ௫.௨௧ ܲ௧.௨௧ 1
(Pax.ultPu.L.B)1.6+(Ptr.ultPtru.L.B)1.6=1
ଵ. ଵ.
ቆ ቇ +ቆ ቇ =1 ܲ௫.௨௧ = ⎛ ⎞
ܲ௨.. ܲ௧௨.. ⎜ ⎟
→
ଵ. ଵ.
൬ ൰ +൬ ൰
ଵ ୲ୟ୬ (ఈ)
⎝ ೠ.ಽ.ಳ
ೝೠ.ಽ.ಳ ⎠
Pult=P2ax.ult+P2tr.ult−−−−−−−−−−−√
ܲ௨௧ = ටܲ௫.௨௧
ଶ
+ ܲ௧.௨௧
ଶ
ܲ௨௧
FS=PultPapp
= ܵܨ
ܲ
It is important for the pin in the joint to be strong enough that it will
distribute the load evenly over the lugs. Even though a weak pin will
not commonly break in practice, excessive flexure of the pin will
cause the load to "peak up" near the shear planes such that the
outer edges of the lugs see high loads and the inner portions of the
lugs are relatively unloaded. This can cause the material around
the holes on the outer surfaces of the lugs to stretch far enough to
initiate a fracture, and the lug will fail at a lower load than predicted.
One effect that helps the situation is that as the load concentrates
near the shear planes, the bending arm is reduced, and therefore
the bending moment in the pin is reduced. However, a study cited
by Molcon and Hoblit found that this decrease in bending moment
is "seldom more than 25 percent and usually much less."
Since bending in the pin affects the strength of the lug, it is critical
to account for the pin strength when analyzing the joint. In this
section, a method for calculating the allowable load for a double
shear joint is presented. An example of a double shear joint is
shown below:
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In a double shear joint, there are two outer (female) lugs, a single
inner (male) lug, and a pin.
where Pult.Mܲ௨௧.ெ is the ultimate load for the male lug and Pult.F
ܲ௨௧.ி is the ultimate load for a single female lug. Since there are 2
The shear strength and the bending strength of the pin should both
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be calculated.
ߨ
Pus.P=2(π4D2p)Ssu.P
The ultimate bending load is the applied load that would result in
bending failure of the pin, and is calculated by:
2ܯ௨.
Pub.P=2Mu.PLarm
ܲ௨. =
ܮ
ݐଵ ݐଶ
Larm=(t12+t24+g)
ܮ = ൬ + + ݃൰
2 4
where t1ݐଵ is the thickness of a single female lug, t2ݐଶ is the
thickness of the male lug, and g݃ is the gap between the male and
female lugs when the male lug is centered between the female
lugs.
ߨܦଷ
Mu.P=πD3P32⋅kb.P⋅Stu.P
Once the pin strengths are calculated, determine whether the pin is
ܲ௨. ) is greater than either the pin ultimate shear load (Pus.P)(
strong or weak in bending. If the pin ultimate bending load (Pub.P)(
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Yes → Strong
Pub.P≥Pu.J.nomܲ௨. ≥ ܲ௨.. or Pub.P≥Pus.P Pin
ܲ௨. ≥ ܲ௨௦. ? No → Weak
Pin
If the pin is strong, the joint strength will be limited by either the pin
shear strength or by the nominal joint strength. In the case of a
strong pin, the pin ultimate bending load is calculated assuming
that the load distributes evenly over the full width of the lugs:
ܲ௨. =
16ቀ భ + మ + ݃ቁ
௧ ௧
ଶ ସ
For a strong pin, the pin bending does not affect the joint strength
and the ultimate joint load is equal to the nominal ultimate joint
load:
ܲ௨. = ܲ௨..
Pu.J=Pu.J.nom
If the pin is weak in bending, then the load will not be distributed
evenly over the lug widths. Instead, the load will concentrate toward
the shear planes, and the inner portions of the lugs will be relatively
unloaded. Because of this, the lugs will fail at a lower load than
predicted.
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The ultimate load is reduced for the lugs (the lugs fail at a lower
load).
The moment arm for the pin is reduced, which increases the pin's
ultimate bending load (the pin fails at a higher load).
ܲ௨. =
16ቀ భ + మ + ݃ቁ
ଶ ଶ
where, in the equation above, b1ܾଵ and 2b22ܾଶ were substituted for
t1ݐଵ and t2ݐଶ from the previous pin bending equation.
The trick is to find the values of b1ܾଵ and b2ܾଶ that result in the
"balanced design" ultimate load. To determine the balanced design
ultimate load, reduce the bearing widths of each of the lugs until the
ultimate load for the lugs are equal to one other as well as equal to
the ultimate bending load of the pin. This requires an iterative
process.
Once the balanced design ultimate load is found, the ultimate joint
load and the pin ultimate bending load are each equal to the
balanced load:
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Strong pin: ܲ = ܲ
Pu.J=Pu.J.nom
௨ . ௨..
Weak pin: ܲ = ܲ
Pu.J=Pbalanced
௨. ௗ
The overall ultimate load accounting for both the ultimate joint load
and the ultimate pin shear load is calculated by:
ܲ௨௧
FS=PultPapplied
= ܵܨ
ܲௗ
3. Bearing failure
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The dimensions of interest for the lug analysis are shown in the
figure below:
beܾ = net width (distance between the edge of the hole and the
edge of the lug in the transverse direction)
=R−0.5Dh = ܴ − 0.5ܦ
aܽ = distance from the edge of the hole to the edge of the lug
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The lug strength is reduced as the fit between the pin and the hole
is loosened. The lug strength is not much affected as long as the
pin and hole are a relatively tight fit. ASME defines a strength
reduction factor that can be used to account for the pin-to-hole
clearance as:
ܥ = ተ
1 − 0.275ට1 − మ otherwise
మ
where Dpܦ is the pin diameter and Dhܦ is the hole diameter.
A shear plane locating angle, ϕ߶, is used to locate the two planes
along which shear tear out occurs, as shown in the figure:
ܦ
ϕ=55∘DpDh
߶ = 55 ∘
ܦ
The term beܾ is referred to as the net width and is the distance
between the edge of the hole and the edge of the lug in the
transverse direction, as shown in the figure:
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• beff.2=4tܾ.ଶ = 4ݐ
the net width beܾ , the effective
width is driven down). This limit
can be ignored if the lug is
stiffened or constrained against
buckling.
beff.3=0.6beStuStyDhbe−−−√
ܾ.ଷ = 0.6ܾ ௌ ට
ௌೠ
This equation is empirical, fitted
•
to test results.
Design
Condition
Factor
Design Category A lifters (predictable loads, accurately
Ndܰௗ =
defined or non-severe environmental conditions, no
2.00
more than 20,000 load cycles)
Ndܰௗ = Design Category B lifters (unpredictable loads,
3.00 uncertain or severe environmental conditions)
A service class is used to account for fatigue life and is defined
based on the table below:
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The ultimate tensile load is the load that would result in tensile
failure across the net section, and is given by:
ܣ௧ = 2 ⋅ ܾ ⋅ ݐ
At=2⋅t⋅beff
where beffܾ is the effective width and t ݐis the lug thickness.
The allowable tensile load is based on the design factor, Ndܰௗ , and
is given by:
ܲ௧.௨
Pt=Pt.u1.20Nd
ܲ௧ =
1.20ܰௗ
Note that the allowable tensile load is based on the design factor
multiplied by 1.20. ASME requires the design factor for some of the
strength calculations to be higher than the nominal value. The
factor of safety is given by:
ܲ௧.௨
FSt=Pt.uFapp
ܵܨ௧ =
ܨ
The ultimate single plane fracture load is the load that would result
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in failure along the plane collinear with the applied load, and is
given by:
ܦ 0.92ܾ
Ab=[1.13(R−Dh2)+0.92be1+be/Dh]⋅t
ܲ.௨
Pb=Pb.u1.20Nd
ܲ =
1.20ܰௗ
ܲ.௨
FSb=Pb.uFapp
ܵܨ =
ܨ
The ultimate double plane shear load is the load that would result in
shear tear out along the two planes, and is given by:
ܦ
Av=2⋅[a+Dp2(1−cos(ϕ))−Z]⋅t
Z=r−r2−(Dp2sin(ϕ))2−−−−−−−−−−−−−−−−√
ܦ
ଶ
ܼ = ݎ− ඨ ݎଶ − ቆ sin (߶)ቇ
2
Note that if the lug end is flat then r ݎis infinity and Zܼ is zero.
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ܲ௩.௨
Pv=Pv.u1.20Nd
ܲ௩ =
1.20ܰௗ
ܲ௩.௨
FSv=Pv.uFapp
ܵܨ௩ =
ܨ
The ultimate bearing load is the load that would result in bearing
failure on either the lug or the pin. This ultimate load is dependent
on the number of load cycles that the connection will be subjected
to, and is given by:
ܲ.௨ = อ
0.63 ⋅ ܵ௧௬. ⋅ ܣ for Service Class 1 or higher
ܲ.௨
Pp=Pp.uNd
ܲ =
ܰௗ
ܲ.௨
FSp=Pp.uFapp
ܵܨ =
ܨ
The Air Force Manual specifies to calculate the factor of safety for
an obliquely loaded lug by drawing a line from the origin that
intersects with the allowable load curve, where the slope of the line
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is given by:
ܲ௨.
m=Pu.LPtru.L
݉=
ܲ௧௨.
where Pu.Lܲ௨. is the ultimate load for an axially loaded lug and
Ptru.Lܲ௧௨. is the ultimate load for a transversely loaded lug.
The problem with using the above equation for the slope is that the
intersection line is the same regardless of the angle of the applied
force. This problem is illustrated in the figure below:
݉= =
ܲ௫ /ܲ௨. ܲ௧௨. ܲ௫
It should be noted that the figure showing the lug with the clevis pin
does not accurately depict the relative sizing. The clevis pin should
be a relatively tight fit in the lug. Per ASME, the pin diameter should
be at least 90% of the lug hole diameter to avoid a reduction in the
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joint strength.
The variable names used in the Axial Load Coefficient plot from the
Air Force Manual are inconsistent with the rest of the variable
names throughout the manual. This plot originated in Melcon &
Hoblit, and the variable names from the plot were not updated to
match. The Air Force Manual uses the variable e݁ for edge
distance (center of hole to edge of lug) and aܽ for the distance
between the edge of the hole to the edge of the lug. However, the
plot uses aܽ for the edge distance (center of hole to edge of lug).
ܴ௧ ܴ௧.௨௧
RtrRax=Rtr.ultRax.ult
=
ܴ௫ ܴ௫.௨௧
⋅ = ⋅
ܲ௧௨.. ܲ௫ ܲ௧௨.. ܲ௫.௨௧
ܲ௧ ܲ௧.௨௧
PtrPax=Ptr.ultPax.ult
=
ܲ௫ ܲ௫.௨௧
The load components are related by the angle of the applied load:
ܲ௧ ܲ௧.௨௧
tan(α)=PtrPax=Ptr.ultPax.ult
tan (ߙ) = =
ܲ௫ ܲ௫.௨௧
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ܲ௫.௪ ܲ௧.௪ 1
(Pax.allowPu.L.B)1.6+(Ptr.allowPtru.L.B)1.6=(1FS)1.6
ଵ. ଵ. ଵ.
ቆ ቇ +ቆ ቇ =ቆ ቇ
ܲ௨.. ܲ௧௨.. ܵܨ
FS=⎛⎝⎜⎜1(Pax.allowPu.L.B)1.6+(Ptr.allowPtru.L.B)1.6⎞⎠⎟⎟0.625
.ଶହ
1
⎛ = ܵܨ ⎞
⎜ ೌೣ.ೌೢ ଵ. ଵ.
⎟
൬ ൰ +൬ ൰
ೝ.ೌೢ
⎝ ೠ.ಽ.ಳ ೝೠ.ಽ.ಳ ⎠
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