diameter of the eye is 56mm, thickness of the eye 20mm and the fork thickness

MIO220S TUTORIAL 03 16mm. If a factor of safety of 5 was used and all parts are made of the same
material being of the composition 0.38% carbon steel. Determine:
COTTERED, KNUCKLE & CLAW COUPLINGS a) the ultimate tensile stress (1)
[With Reference to Hamilton – “Machine Design for Engineering Technicians” the ultimate shear stress (1)
Drotsky & Terblanche – “Mechanical Engineering Design”] the ultimate compressive stress (1)
b) Using the calculated ultimate stresses and factor of safety of 6, design
for a load of 110kN:
1. A cylindrical cottered joint is used to connect two tie-rods. All the parts are
i) the rod diameter (2)
made of the same type of steel having the following ultimate tensile, shearing ii) the pin diameter (2)
and compressive strengths of 430MPa, 320MPa and 655MPa respectively. iii) the outside diameter of the eye (2)
Using a safety factor of eight, calculate the following dimensions for the joint so iv) the thickness of the eye (1)
that the tie-rods and the joint may safely carry a load of 17kN being tensile of
[10]
compressive.

(i) diameter of the tie-rods 4. Design a suitable knuckle joint to connect two rods subjected to a pull of
(ii) the mean breadth (b) of the rectangular sectioned cotter, given that the 70kN, given the following information :
thickness (t) = 8mm
(iii) diameter of the enlarged rod-end Ultimate tensile stress = 430MPa
(iv) outside diameter of the socket-end at the cotter hole Ultimate compressive stress = 600MPa
(v) outside diameter of the enlarged portion of the socket-end. Ultimate shear stress = 340MPa
(vi) Sketch the outcome this cottered joint. Factor of safety = 5
[20] Make assumptions where necessary giving references to substantiate your
answers.
Sketch the designed joint in pencil with all the appropriate dimensions.
2. A cottered joint is required to connect two circular rods subjected to
[15]
Compressive and Tensile loads. The dimension of the cotter are : width = 80mm
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& thickness = 20mm. The safe working stresses are  = 40MPa ; T = 50MPa;
C = 90MPa. 5. A solid shaft of 0.75m long, acts as an intermediate shaft between an electric
From first principles, find : motor and a crusher. The shaft is mounted symmetrically between two bearings
a) Safe load spaced at 600mm apart. On the motor side, it is fitted with a claw coupling,
b) Diameter of rod at extremities having 3 claws, and on the crusher side it is fitted with a flange coupling such
c) Diameter of pierced rod that the shaft transmits torque only. The shaft is to transmit 135kW with a
d) OD of socket possible overload of 42% at 900rpm.
e) Diameter of shoulder on rod end Find:
f) Diameter of shoulder on socket end
(a) A suitable shaft diameter, if the Ult for the shaft material is 320MPa.
g) Make a neat free-hand sketch of the your design with all the relevant
dimensions Use a factor of safety of 5.
[20] (b) The total angle of twist for the shaft, using the Modulus of Rigidity =
80GPa.
(c) The maximum shear strain.

3. A knuckle joint subjected to a load of 60kN has a pin diameter of 30mm. Each
of the two rods connected by the joint has a diameter of 30mm. The outside
 Design a claw coupling indicating how the two shafts i.e.(motor and (a) Calculate the safe load.
intermediate shafts) are possibly aligned, using the following claw arrangement (b) Design the complete joint.
information. (c) Produce a free-hand sketch of two views of the joint showing all the
The 0 .D. of the claws = 2.5 x d dimensions.
The I.D. of the claws = 1.25 x d
Shaft diameter = d
Allowable Crushing in claws = 15MPa 8. Design a hollow shaft for a conveyor belt in a large kitchen. The shaft has to
Allowable  in keys = 55MPa transmit a torque of 8ONm @ 600 rpm. On one side of the hollow shaft is a
Allowable Crushing in keys = 120MPa knuckle joint which is joined to a solid shaft. On the other end is a flexible
coupling which is also connected to a hollow shaft. If there is a 80kN pull on
Find: the knuckle joint and the Ultimate Stress are: T = 440MPa;  = 400MPa;
(d) The O.D. & I.D. of the claws. C = 800Pa.
(e) The height of the claws.
(f) The size and length of the rectangular key on the fixed side. DESIGN ALL THE COMPONENTS REQUIRED FOR THIS SHAFT!
Any information that is omitted in this question must be assumed from
[20]
textbooks. Use your
own material choice for the components, giving reasons and references for all
decisions made.
6. A shaft on which a claw coupling is positioned transmits 30kW at 200rpm. The
shaft is supported by two bearings mounted on the floor. The claw coupling has
[20]
four jaws, the external and internal diameters of which are 127mm and 76mm
respectively. The depth of the claws is 25mm.
Calculate
a) the diameter of the shaft, (allowable stress due to twisting
should not exceed 55MPa).
b) the length of the keys, (assume a standard key; allowable
stress due to shearing 48MPa and the bearing stress 117MPa). COMMENT ON ALL YOUR FINAL OUTCOMES TO
c) the diameter of the shaft of the operating mechanism, (assume THESE PROBLEMS i.e. Are the results feasible and
the effective length of the hand-operated lever to be 380mm
and the maximum force applied 270N. Calculate for twisting tangible!
only and assume an allowable stress of 31MPa).
d) the size of the pins of circular cross-section fixing the
operating handles and levers in position, (allowable  =
170MPa).
e) the average bearing and shearing stresses in the claws.
ENJOY! ENJOY! ENJOY!
7. A cottered joint is required to connect two 32mm diameter steel rods by means
of a single sleeve with enlarged flanges and two cotters. Stresses in the rods are
ENJOY! ENJOY! ENJOY!
limited to the following: T = 110MPa,  = 60MPa and C = 150MPa. It is
not possible to enlarge the rod ends but the connecting collar and cotter are made
of a high quality steel of which the stress limits exceed that of the rods by 50%.