DESIGN OF COTTERS

INTRODUCTION

 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
 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 cotter is usually made of mild steel or wrought iron

 It is usually used in connecting a piston rod to the crosshead

of a reciprocating steam engine
TYPES OF COTTER JOINTS

Following are the three commonly used cotter joints to

connect two rods by a cotter:
1. Socket and spigot cotter joint,

2. Sleeve and cotter joint, and

3. Gib and cotter joint

 SOCKET AND SPIGOT COTTER JOINT

 In this joint, one end of the rods (say A) is provided with a

socket type of end as shown and the other end of the other rod
(say B) is inserted into a socket
 The end of the rod which goes into a socket is also called
spigot.
 A rectangular hole is made in the socket and spigot.
SOCKET AND SPIGOT COTTER JOINT

 A cotter is then driven tightly through a hole in order to make

the temporary connection between the two rods.
 The load is usually acting axially, but it changes its direction
and hence the cotter joint must be designed to carry both the
tensile and compressive loads.
 The compressive load is taken up by the collar on the spigot
 DESIGN OF SOCKET AND SPIGOT
COTTER JOINT

P = Load carried by the rods; d = Diameter of the rods; d1 =

Outside diameter of socket; d2 = Diameter of spigot or inside
diameter of socket; d3 = Outside diameter of spigot collar; t1 =
Thickness of spigot collar; d4 = Diameter of socket collar; c =
Thickness of socket collar; b = Mean width of cotter; t =
Thickness of cotter; l = Length of cotter; a = Distance from the
end of the slot to the end of rod;
DESIGN OF SOCKET AND SPIGOT
COTTER JOINT
σt = Permissible tensile stress for the rods material,
τ = Permissible shear stress for the cotter material, and
σc = Permissible crushing stress for the cotter material.
 The dimensions for a socket and spigot cotter joint may be
obtained by considering the various modes of failure:
1. Failure of the rods in tension
The rods may fail in tension due to the tensile load P.
Area resisting tearing = (π/4)d2
Tearing strength of the rods = (π/4)d2 × σt
Equating this to load (P), we have P = (π/4)d2 × σt
From this equation, diameter of the rods (d) may be determined
 DESIGN OF SOCKET AND SPIGOT
COTTER JOINT
2. Failure of spigot in tension across the weakest
section (or slot)
Since the weakest section of the spigot is that
section which has a slot in it for the cotter, as
shown, therefore:
Area resisting tearing of the spigot across the slot

and tearing strength of the spigot across the slot

Equating this to load (P), we have

From this equation, the diameter of spigot (d2)
may be determined
DESIGN OF SOCKET AND SPIGOT COTTER
JOINT

3. Failure of the rod or cotter in crushing

We know that the area that resists crushing
of a rod or cotter = d2 × t
∴ Crushing strength = d2 × t × σc
Equating this to load (P), we have
P = d2 × t × σ c
From this equation, the induced crushing
stress may be checked
DESIGN OF SOCKET AND SPIGOT COTTER
JOINT
4. Failure of the socket in tension across the slot
The resisting area of the socket across the slot:

∴ Tearing strength of the socket across the slot:

Equating this to load (P), we have:

From this equation, outside diameter of socket (d1)

may be determined
DESIGN OF SOCKET AND SPIGOT
COTTER JOINT
5. Failure of cotter in shear
Considering the failure of cotter in shear as shown.
Since the cotter is in double shear, therefore
shearing area of the cotter
= 2b × t
and shearing strength of the cotter
=2b × t × τ
Equating this to load (P), we have:
P =2b × t × τ
From this equation, width of cotter (b) is determined
7. Failure of socket end in shearing
Since the socket end is in double shear, therefore area that resists
shearing of socket collar:
=2(d4 – d2)c
and shearing strength of socket collar
=2(d4 – d2)c × τ
Equating this to load (P), we have:
P =2(d4 – d2)c × τ
From this equation, the thickness of socket collar (c) may be
obtained
8. Failure of rod end in shear
Since the rod end is in double shear, therefore the area resisting shear of
the rod end
= 2a × d2
and shear strength of the rod end
= 2a × d2 × τ
Equating this to load (P), we have
P = 2a × d2 × τ
From this equation, the distance from the end of the slot to the end of
the rod (a) may be obtained.
Considering the failure of the spigot collar in crushing as shown.
The area that resists crushing of the collar:
= π/4 [d32 – d22]
and crushing strength of the collar:
= π/4 [d32 – d22]σc
Equating this to load (P), we have
P = π/4 [d32 – d22]σc
From this equation, the diameter of the spigot collar (d3) may be
obtained
10. Failure of the spigot collar in shearing
Considering the failure of the spigot collar in shearing as shown. The
area that resists shearing of the collar:
= πd2 × t1
and shearing strength of the collar,
= πd2 × t1 × τ
Equating this to load (P) we have
P = πd2 × t1 × τ
From this equation, the thickness of spigot collar (t1) may be obtained.
11. Failure of cotter in bending
In order to find out the bending stress induced, it is assumed that
the load on the cotter in the rod end is uniformly distributed
while in the socket end it varies from zero at the outer
diameter (d4) and maximum at the inner diameter (d2), as
shown
The maximum bending moment occurs at the centre of the cotter
and is given by:
DESIGN OF SOCKET AND
SPIGOT COTTER JOINT

The section modulus of the cotter:

Z = t × b2/6
∴ Bending stress induced in the cotter:

This bending stress induced in the cotter should be less than the
allowable bending stress of the cotter.
DESIGN OF SOCKET AND SPIGOT COTTER
JOINT
12.The length of cotter (l) is taken as 4d.
13. The taper in cotter should not exceed 1 in 24. In case the
greater taper is required, then a locking device must be
provided.
Notes: 1. When all the parts of the joint are made of steel, the
following proportions in terms of diameter of the rod (d) are
generally adopted:
d1 = 1.75d, d2 = 1.21d, d3 = 1.5d, d4 = 2.4d, a = c = 0.75d, b =
1.3d, l = 4d, t = 0.31d, t1 = 0.45d, e = 1.2d.
Taper of cotter = 1 in 25
2. If the rod and cotter are made of steel or wrought iron, then τ
= 0.8σt and σc = 2σt may be taken
EXAMPLE 12.1
 Design and draw a cotter joint to support a load varying from
30kN in compression to 30kN in tension. The material used is
carbon steel for which the following allowable stresses may
be used. The load is applied statically.
Tensile stress = compressive stress = 50MPa; shear stress =
35MPa and crushing stress = 90MPa.
Given:
P = 30kN = 30 × 103N; σt = 50MPa = 50N/mm2; τ = 35MPa =
35N/mm2; σc = 90MPa = 90N/mm2
Solution:
1. Diameter of the rods
Let d = Diameter of the rods.
 EXAMPLE 12.1

Considering the failure of the rod in tension. We know that load

(P):

d2 = 30 × 103/39.3 = 763 or d = 27.6 say 28mm

2. Diameter of spigot and thickness of cotter
Let d2 = Diameter of spigot or inside diameter of socket,
t = Thickness of cotter. It may be taken as d2/4.
Considering the failure of spigot in tension across the weakest
section. We know that load (P):
EXAMPLE 12.1

(d2)2 = 30 × 103/26.8 = 1119.4 or d2 = 33.4 say 34mm

and thickness of cotter, t = d2/4 = 34/4 = 8.5mm
Now check the induced crushing stress. The load (P):
30 × 103 = d2 × t × σc = 34 × 8.5 × σc = 289σc
∴ σc = 30 × 103/289 = 103.8N/mm2
Since this value of σc is more than the given value of σc =
90N/mm2, therefore the dimensions d2 = 34mm and t =
8.5mm are not safe.
Now find the values of d2 and t by substituting the value of σc =
90N/mm2 in the above expression, i.e.
EXAMPLE 12.1
(d2)2 = 30 × 103/22.5 = 1333 or d2 = 36.5 say 40mm
and t = d2/4 = 40/4 = 10mm
3. Outside diameter of socket
Let d1 = Outside diameter of socket.
Considering the failure of the socket in tension across the slot.
We know that load (P):

30 × 103/50 = 0.7854 (d1)2 – 1256.6 – 10d1 + 400

or (d1)2 – 12.7d1 – 1854.6 = 0
EXAMPLE 12.1

= 49.9 say 50mm

4. Width of cotter
Let b = Width of cotter.
Considering the failure of the cotter in shear. Since the cotter is in
double shear, therefore load (P):
30 × 103 = 2b × t × τ = 2b × 10 × 35 = 700b
∴ b = 30 × 103/700 = 43mm
5. Diameter of socket collar
Let d4 = Diameter of socket collar.
Considering the failure of the socket collar and cotter in crushing.
We know that load (P):
 EXAMPLE 12.1
30 × 103 = (d4 – d2)t × σc = (d4 – 40)10 × 90 = (d4 – 40)900
∴ d4 – 40 = 30 × 103/900 = 33.3 or d4 = 33.3 + 40 = 73.3 say
75mm
6. Thickness of socket collar
Let c = Thickness of socket collar.
Considering the failure of the socket end in shearing. Since the
socket end is in double shear, therefore load (P):
30 × 103 = 2(d4 – d2)c × τ = 2 (75 – 40 )c × 35 = 2450c
∴ c = 30 × 103/2450 = 12mm
7. Distance from the end of the slot to the end of the rod
Let a = Distance from the end of slot to the end of the rod.
EXAMPLE 12.1
Considering the failure of the rod end in shear. Since the rod end
is in double shear, therefore load (P):
30 × 103 = 2a × d2 × τ = 2a × 40 × 35 = 2800a
∴ a = 30 × 103/2800 = 10.7 say 11mm
8. Diameter of spigot collar
Let d3 = Diameter of spigot collar.
Considering the failure of spigot collar in crushing. We know
that load (P):

(d3)2 = 424 + (40)2 = 2024 or d3 = 45mm

EXAMPLE 12.1

9. Thickness of spigot collar

Let t1 = Thickness of spigot collar.
Considering the failure of spigot collar in shearing. We
know that load (P):
30 × 103 = π d2 × t1 × τ = π × 40 × t1 × 35 = 4400t1
∴ t1 = 30 × 103/4400 = 6.8 say 8mm
10. The length of cotter ( l ) is taken as 4d.
∴ l = 4 d = 4 × 28 = 112mm
11. The dimension e is taken as 1.2 d.
∴ e = 1.2 × 28 = 33.6 say 34mm
SLEEVE AND COTTER JOINT

 In this type of joint, a sleeve or muff is used over the two rods
and then two cotters (one on each rod end) are inserted in the
holes provided for them in the sleeve and rods
 The clearance is so adjusted that when the cotters are driven
in, the two rods come closer to each other thus making the
joint tight
SLEEVE AND COTTER JOINT

The various proportions for the sleeve and cotter joint in terms
of the diameter of rod (d ) are as follows:
Outside diameter of sleeve: d1 = 2.5d
Diameter of enlarged end of rod:
d2 = Inside diameter of sleeve = 1.25d
Length of sleeve, L = 8d
SLEEVE AND COTTER JOINT

Thickness of cotter, t = d2/4 or 0.31d

Width of cotter, b = 1.25d
Length of cotter, l = 4d
Distance of the rod end (c) from its end to the cotter hole =
1.25d
DESIGN OF SLEEVE AND COTTER
JOINT

Let P = Load carried by the rods, d = Diameter of the rods, d1 =

Outside diameter of sleeve, d2 = Diameter of the enlarged end
of rod, t = Thickness of cotter, l = Length of cotter, b = Width
of cotter, a = Distance of the rod end from the beginning to the
cotter hole (inside the sleeve end), c = Distance of the rod end
from its end to the cotter hole; σt , τ and σc = Permissible
tensile, shear and crushing stresses, respectively, for the
material of the rods and cotter.
DESIGN OF SLEEVE AND COTTER
JOINT

 The dimensions for a sleeve and cotter joint may be obtained

by considering the various modes of failure as discussed
below:
1. Failure of the rods in tension
The rods may fail in tension due to the tensile load P.
Area resisting tearing = π/4 × d2
∴ Tearing strength of the rods = π/4 × d2 × σt
Equating this to load (P), we have
P = π/4 × d2 × σt
From this equation, diameter of the rods (d) may be obtained
DESIGN OF SLEEVE AND COTTER
JOINT
2. Failure of the rod in tension across the weakest section (i.e.
slot)
Since the weakest section is that section of the rod which has a
slot in it for the cotter, therefore, area resisting tearing of the
rod across the slot:
π/4 (d2)2 – d2 × t
and tearing strength of the rod across the slot:

Equating this to load (P), we have

From this equation, the diameter of enlarged end of the rod (d2)
may be obtained.
Note: The thickness of cotter is usually taken as d2/4
 DESIGN OF SLEEVE AND COTTER
JOINT
3. Failure of the rod or cotter in crushing
We know that the area that resists crushing of a rod or
cotter = d2 × t
∴ Crushing strength = d2 × t × σc
Equating this to load (P), we have P = d2 × t × σc
From this equation, the induced crushing stress may be
checked.
4. Failure of sleeve in tension across the slot
We know that the resisting area of sleeve across the slot

∴ Tearing strength of the sleeve across the slot:

DESIGN OF SLEEVE AND COTTER
JOINT

Equating this to load (P), we have

From this equation, the outside diameter of sleeve (d1) may be

obtained.
5. Failure of cotter in shear
Since the cotter is in double shear, therefore shearing area of the
cotter = 2b × t
and shear strength of the cotter = 2b × t × τ
Equating this to load (P), we have: P = 2b × t × τ
From this equation, width of cotter (b) may be determined.
6. Failure of rod end in shear
Since the rod end is in double shear, therefore area resisting
shear of the rod end
= 2a × d2
and shear strength of the rod end
= 2a × d2 × τ
Equating this to load (P), we have
P = 2a × d2 × τ
From this equation, distance (a) may be determined.
7. Failure of sleeve end in shear
Since the sleeve end is in double shear, therefore the area
resisting shear of the sleeve end
= 2(d1 – d2)c
and shear strength of the sleeve end
= 2(d1 – d2)c × τ
Equating this to load (P), we have
P = 2(d1 – d2)c × τ
From this equation, distance (c) may be determined
EXAMPLE 12.2
-> Do yourself
GIB AND COTTER JOINT

 A gib and cotter joint is usually used in strap end (or big end) of
a connecting rod as shown
 In such cases, when the cotter alone (i.e. without gib) is driven,
the friction between its ends and the inside of the slots in the
strap tends to cause the sides of the strap to spring open (or
spread) outwards as shown
 In order to prevent this, gibs as shown, are used which hold
together the ends of the strap.
GIB AND COTTER JOINT

 Moreover, gibs provide a larger bearing surface for the cotter

to slide on, due to the increased holding power
 Thus, the tendency of cotter to slacken back owing to
friction is considerably decreased
 DESIGN OF A GIB AND COTTER JOINT FOR
STRAP END OF A CONNECTING ROD
 Consider a gib and cotter joint for
strap end (or big end) of a
connecting rod as shown
Let P = Maximum thrust or pull in
the connecting rod,
d = Diameter of the adjacent end of
the round part of the rod,
B1 = Width of the strap,
B = Total width of gib and cotter,
t = Thickness of cotter,
t1 = Thickness of the strap at the
thinnest part,
DESIGN OF A GIB AND COTTER JOINT
FOR STRAP END OF A CONNECTING
ROD
σt = Permissible tensile stress for the material of the strap,
and
τ = Permissible shear stress for the material of the cotter
and gib.
The width of strap (B1) is generally taken equal to the
diameter of the adjacent end of the round part of the rod
(d). The other dimensions may be fixed as follows:
Thickness of cotter,
Thickness of gib = Thickness of cotter (t)
Height (t2) and length of gib head (l3) = Thickness of cotter
(t)
 FAILURE MODES FOR A GIB AND
COTTER JOINT
1. Failure of the strap in tension
Assuming that no hole is provided for
lubrication, the area that resists the
failure of the strap due to tearing = 2
× B1 × t1
∴ Tearing strength of the strap
= 2B1 × t1 × σt
Equating this to the load (P), we get
P = 2B1 × t1 × σt
From this equation, the thickness of the
strap at the thinnest part (t1) may be
obtained.
The thickness of the strap at the
cotter (t3) is increased such that the
area of cross-section of the strap at
the cotter hole is not less than the
area of the strap at the thinnest
part.
In other words:
2t3(B1 – t) = 2t1 × B1
From this expression, the value of t3
may be obtained
2. Failure of the gib and cotter in
shearing
Since the gib and cotter are in
double shear, therefore area
resisting failure
= 2B × t
and resisting strength = 2B × t × τ
Equating this to the load (P), we
get
P = 2B × t × τ
From this equation, the total width
of gib and cotter (B) may be
obtained.
In the joint, as shown, one gib is
used, the proportions of which are:
Width of gib,b1 =0.55B; and width
of cotter, b = 0.45B
The other dimensions may be fixed
as follows:
Thickness of the strap at the crown:
t4 = 1.15t1 to 1.5t1
l1 = 2t1; and l2 = 2.5t1
EXAMPLE 12.3.
 The big end of a connecting rod is subjected to a maximum
load of 50kN. The diameter of the circular part of the rod
adjacent to the strap end is 75mm. Design the joint, assuming
permissible tensile stress for the material of the strap as
25MPa and permissible shear stress for the material of cotter
and gib as 20MPa.
Given: P = 50kN = 50 × 103N; d = 75mm; σt = 25MPa =
25N/mm2; τ = 20MPa = 20N/mm2
Solution:
1. Width of the strap
Let B1 = Width of the strap.
EXAMPLE 12.3.
The width of the strap is generally made equal to the diameter of
the adjacent end of the round part of the rod (d).
∴ B1 = d = 75mm
Other dimensions are fixed as follows:
Thickness of the cotter = t = B1/4 = 75/4 = 18.75 say 20mm
Thickness of gib = Thickness of cotter = 20mm
Height (t2) and length of gib head (l3) = Thickness of cotter =
20mm
2. Thickness of the strap at the thinnest part
Let t1 = Thickness of the strap at the thinnest part.
EXAMPLE 12.3.
Considering the failure of the strap in tension. We know that load
(P):
50 × 103 = 2B1 × t1 × σt = 2 × 75 × t1 × 25 = 3750t1
∴ t1 = 50 × 103/3750 = 13.3 say 15mm
3. Thickness of the strap at the cotter
Let t3 = Thickness of the strap at the cotter.
The thickness of the strap at the cotter is increased such that the
area of the cross-section of the strap at the cotter hole is not
less than the area of the strap at the thinnest part. In other
words:
2t3(B1 – t) = 2t1 × B1
2t3(75 – 20) = 2 × 15 × 75 or 110t3 = 2250
∴ t3 = 2250/110 = 20.45 say 21mm
EXAMPLE 12.3.
4. Total width of gib and cotter
Let B = Total width of gib and cotter.
Considering the failure of gib and cotter in double shear. We
know that load (P):
50 × 103 = 2B × t × τ = 2B × 20 × 20 = 800B
∴ B = 50 × 103/800 = 62.5 say 65mm
Since one gib is used, therefore width of gib:
b1 = 0.55B = 0.55 × 65 = 35.75 say 36mm
and width of cotter, b = 0.45B = 0.45 × 65 = 29.25 say 30mm
The other dimensions are fixed as follows:
t4 = 1.25t1 = 1.25 × 15 = 18.75 say 20mm
l1 = 2t1 = 2 × 15 = 30mm
and l2 = 2.5t1 = 2.5 × 15 = 37.5 say 40mm
HOME WORK
Numerical Problems 1 – 4 (Chapter 12; Khurmi Book)