DESIGN OF COTTER JOINT

Introduction

Cotter joint is used to connect two rods subjected to axial tensile or compressive loads. It is not suitable
to connect rotating shafts which transmit torque. Axes of the rods to be joined should be collinear.
There is no relative angular movement between rods. Cotter joint is widely used to connect the piston
rod and crosshead of a steam engine, as a joint between the piston rod and the tailor pump rod,
foundation bolt etc.

Cotter Joint has mainly three components – spigot, socket and cotter as shown in Figure 1. Spigot is
formed on one of the rods and socket is formed on the other. The socket and the spigot are provided
with a narrow rectangular slot. The cotter is tightly fitted in this slot. Spigot fits inside the socket and
the cotter is passed through both the socket and the spigot. A cotter is a wedge-shaped piece made of
a steel plate. It has uniform thickness and the width dimension is given a slight taper. Taper is usually
1 in 24 and provides mainly two benefits:

i) cotter becomes tight in the slot due to wedge action. This ensures tightness of the joint in
operating conditions and prevents loosening of the parts.
ii) Due to its taper shape, it is easy to remove the cotter and dismantle the joint.
The construction of cotter joint, used to connect two rods subjected to tensile force P is shown in the
figure. When the cotter is inserted into the slot, the central portion of cotter comes in contact with
spigot and the spigot gets pushed into the socket till the collar of the spigot comes in contact with the
collar of socket. As shown in the figure, finally the cotter is in contact with the spigot on one side
having some clearance with the socket slot and is in contact with the socket on the other side having
some clearance with the spigot slot. Clearance provided is generally 1.5 to 3 mm. Cotter gets locked
because of the frictional force of the contacting surfaces.

Advantages of Cotter Joint:

- Simple to design and manufacture.

- Simple to assemble and dismantle.

- Very high tightening force due to wedge action, which prevents loosening of parts in service.

Design of Cotter Joint

Notations Used:

d = diameter of each rod (mm)

d1 = outside diameter of socket (mm)

d2 = diameter of spigot or inside diameter of socket (mm)

d3 = diameter of spigot-collar (mm)

d4 = diameter of socket-collar (mm)

a = distance from end of slot to the end of spigot on rod-B (mm)

b = mean width of cotter (mm)

c = axial distance from slot to end of socket collar (mm)

t = thickness of cotter (mm)

t1 = thickness of spigot collar (mm)

L = length of cotter (mm)

Assumption for stress analysis of Cotter Joint:

- The rods are subjected to axial tensile force.

- The effect of stress concentration due to holes is neglected

- The force is uniformly distributed in different parts.

Free body diagram of forces acting on three components of the cotter joint (socket, cotter and spigot)
are shown in Figure 2.
In order to find out various dimensions of the parts of a cotter joint,
failures in different parts and at different x-sections are considered. The
stresses developed in the components should be less than the
corresponding permissible values of stress. So, for each type of failure,
one strength equation is written and these strength equations are then
used to find various dimensions of the cotter joint. Some empirical
relations are also used to find the dimensions.

Possible Modes of Failure of Cotter Joint

Step:1 Tensile Failure of Rods

Each rod is subjected to a tensile force P.

𝑃
Tensile stress in the rods = 𝜎𝑡 = 𝜋 2 ≤ [𝜎𝑡 ]
𝑑
4

where [σt] = allowable tensile stress for the material selected.

Step:2 Design of Spigot

a) Tensile Failure of Spigot:

𝑃
Tensile Stress in the Spigot 𝜎𝑡 = 𝜋 ≤ [𝜎𝑡 ]
(𝑑 2 )−𝑑2 𝑡
4 2

b) Shear Failure of Spigot:

The spigot end is subjected to double shear

𝑃
Shear Stress in the socket: 𝜏= ≤ [𝜏]
2(𝑎.𝑑2 )

where [] = allowable shear stress for the material selected.

c) Crushing Failure of Spigot:

𝑃
Crushing stresses 𝜎𝑐 = ≤ [𝜎𝑐 ]
𝑑2 𝑡

where [σc] = allowable compressive stress for the material selected.

Step:3 Design of Socket

a) Tensile Failure of Socket:

Area of the weakest section of socket resisting tensile failure

𝑃
𝜎𝑡 = 𝜋 ≤ [𝜎𝑡 ]
(𝑑 2 −𝑑2 2 )−(𝑑1 −𝑑2 )𝑡
4 1

b) Shear Failure of Socket:

The socket end is subjected to double shear

𝑃
Shear Stress in the socket: 𝜏= ≤ [𝜏]
2(𝑑4 −𝑑2 )𝐶

c) Crushing Failure of Socket:

𝑃
Crushing stresses 𝜎𝑐 = (𝑑4 −𝑑2 )𝑡
≤ [𝜎𝑐 ]

Step:4 Design of Cotter

a) Shear Failure of Cotter:

The cotter is subjected to double shear.

Total area of cotter that resists the shear failure = 2bt

𝑃
Shear Stress in the cotter pin = 𝜏 = ≤ [𝜏]
2𝑏𝑡

b) Bending Failure of Cotter:

When the cotter is tight in the socket and spigot,

failure occurs due to shear, but when it is loose,
it is subjected to bending moment as shown in
figure. It is assumed that: the force between
cotter and spigot end is uniformly distributed
and uniformly varying between the socket end
and cotter
Maximum Bending Moment (at centre)

𝑃 1 𝑑4 − 𝑑2 𝑑 𝑃 𝑑2 𝑃 𝑑4 − 𝑑2 𝑑
𝑀𝑀𝑎𝑥 = (3 × + )− × = ( + )
2 2 2 2 4 2 6 4

𝑃 𝑑4 − 𝑑2 𝑑 𝑏
𝑀𝑦 ( + ) 𝑃 (𝑑4 +0.5𝑑2 )
Maximum Bending Stress in the cotter 𝜎𝑏 = = 2 6
3
4 2
= ≤ [𝜎𝑏 ]
𝐼 𝑡𝑏 2𝑡𝑏2
12

The length of cotter (L) in taken as = 4d

*The taper in cotter should not exceed 1 in 24. In case the greater taper is required, then a locking
device must be provided.

Design Procedure for Cotter Joint

Procedure to determine various dimensions of cotter joint is as follows:

Step: 1

𝑃
• Calculate the Diameter of each rod (d) using 𝜎𝑡 = 𝜋 2 ≤ [𝜎𝑡 ]
𝑑
4

Step: 2

• Calculate thickness of cotter using empirical relation t = 0.31d

𝑃
• Calculate diameter of the spigot (d2) on the basis of tensile stress 𝜎𝑡 = 𝜋 ≤ [𝜎𝑡 ]
(𝑑 2 )−𝑑2 𝑡
4 2
• Dimensions a and c are also determined using empirical relations a = c = 0.75 d. or calculate
𝑃
from shear stress equation: 𝜏= ≤ [𝜏]
2(𝑎.𝑑2 )
𝑃
• Check for crushing stresses using 𝜎𝑐 = ≤ [𝜎𝑐 ]
𝑑2 𝑡

Step: 3

• Calculate outside diameter (d2) of the socket on the basis of tensile stress

𝑃
𝜎𝑡 = 𝜋 ≤ [𝜎𝑡 ]
(𝑑 2 −𝑑2 2 )−(𝑑1 −𝑑2 )𝑡
4 1

• Diameter of spigot collar, d3 and diameter of socket collar, d4 are determined using empirical
𝑃
relations d3 = 1.5 d and d4 = 2.4 d or calculate from shear stress equation: 𝜏= ≤
2(𝑑4 −𝑑2 )𝐶
[𝜏]
𝑃
• Check for crushing stresses using 𝜎𝑐 = (𝑑4 −𝑑2 )𝑡
≤ [𝜎𝑐 ]

Step: 4

• Calculate width of cotter by shear and bending consideration and select the width which is
𝑃 𝑃 (𝑑4 +0.5𝑑2 )
maximum 𝜏 = ≤ [𝜏]; and 𝜎𝑏 = ≤ [𝜎𝑏 ]
2𝑏𝑡 2𝑡𝑏2

*Calculate thickness t1 of spigot collar by the following empirical relationship t1 = 0.45d

Problem:

Design and draw a cotter joint to support a load varying from 30 kN in compression to 30 kN 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 = 50 MPa; shear stress = 35 MPa
and crushing stress = 90 MPa.
Sleeve and Cotter Joint

Sometimes, a sleeve and cotter joint as shown in Fig., is used to connect two round rods
or bars. 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 taper of cotter is usually 1 in 24. It may be noted that the taper sides of the
two cotters should face each other as shown in Fig. 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.

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 = 2.5 d
Diameter of enlarged end of rod,
d2 = Inside diameter of sleeve =1.25 d

Length of sleeve, L=8d

Thickness of cotter, t = d2/4 or 0.31
d Width of cotter, b = 1.25 d
Length of cotter, l=4d
Distance of the rod end (a) from the beginning to the cotter hole (inside the sleeve
end) = Distance of the rod end (c) from its end to the cotter hole = 1.25 d

Design of Sleeve and Cotter Joint

The sleeve and cotter joint is shown in
Fig. 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
th
e material of the rods and cotter.
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. We know that

From this equation, diameter of the rods (d) may be obtained.

2. Failure of the rod in tension across the weakest section (i.e.

slot)

From this equation, the diameter of enlarged end of the rod (d2) may be obtained.
The thickness of cotter is usually taken as d2 / 4.

3. Failure of the rod or cotter in crushing

From this equation, the induced crushing stress may be checked.

4. Failure of sleeve in tension across the slot

From this equation, the outside diameter of sleeve (d1) may be obtained.
5. Failure of cotter in shear

From this equation, width of cotter (b) may be determined.

6. Failure of rod end in shear

From this equation, distance (a) may be determined.

7. Failure of sleeve end in shear

From this equation, distance (c) may be determined.

Problem:
Design a sleeve and cotter joint to resist a tensile load of 60 kN. All parts of the joint
are made of the same material with the following allowable stresses: σt = 60 MPa ; τ =
70 MPa ; and σc = 125 MPa.
Gib and Cotter Joint
This joint is generally used to connect two rods of square or rectangular section.
To make the joint; one end of the rod is formed into a U-fork, into which, the end of the
other rod fits-in. When a cotter is driven-in, the friction between the cotter and straps
of the U-fork, causes the straps open. This is prevented by the use of a gib.
A gib is also a wedge shaped piece of rectangular cross-section with two
rectangular projections, called lugs. One side of the gib is tapered and the other straight.
The tapered side of the gib bears against the tapered side of the cotter such that the
outer edges of the cotter and gib as a unit are parallel. This facilitates making of slots
with parallel edges, unlike the tapered edges in case of ordinary cotter joint. The gib also
provides larger surface for the cotter to slide on. For making the joint, the gib is placed
in position first, and then the cotter is driven-in.

Fig. Gib and cotter Joint

Let F be the maximum tensile or compressive force in the connecting rod, and
b = width of the strap, which may be taken as equal to the diameter of the rod. d
h = height of the rod end
t1 = thickness of the strap at the thinnest part
t2 = thickness of the strap at the curved
portion t3 =thickness of the strap across
the slot
l1 = length of the rod end, beyond the
slot 12 = length of the strap, beyond
the slot B = width of the cotter and
gib
t = thickness of the cotter
Let the rod, strap, cotter, and gib are made of the same material with σc' σt' and τ :as the
permissible stresses. The following are the possible modes of failure, and the
corresponding design equations, which may be considered for the design of the joint:
1. Tension failure of the rod across the section of diameter, d

2. Tension failure of the rod across the slot(Fig.1)

Fig.1

If the rod and strap are made of the same material, and for equality of strength, h=2t3
3. Tension failure of the strap, across the thinnest part (Fig.2)

Fig.2

4. Tension failure of the strap across the slot (Fig.3)

 Fig.3

The thickness, t2 may be taken as (1.15 to 1.5) t], and

Thickness of the cotter, t = b/4.
5. Crushing between the rod and cotter (Fig.1)
F = h t σc ; and h = 2t3
6. Crushing between the strap and gib(Fig.3)
F = 2 t t3 σ c
7. Shear failure of the rod end. It is under double shear (Fig.4).

Fig.4
F = 2l1hτ
8. Shear failure of the strap end. It is under double shear (Fig.5).

Fig.5
F = 4 l2 t3τ
9. Shear failure of the cotter and gib. It is under double shear.
F=2Btτ
The following proportions for the widths of the cotter and gib may be followed:
Width of the cotter =0.45 B
Width of the gib = 0.55 B
The above equations may be
solved, keeping in mind about the various relations and
proportions suggested.

Problem:
Design a cotter joint to connect piston rod to the crosshead of a double acting steam
engine. The diameter of the cylinder is 300 mm and the steam pressure is 1 N/mm2. The
allowable stresses for the material of cotter and piston rod are as follows: σt = 50 MPa ;
τ = 40 MPa ; and σc = 84 MPa
 DESIGN OF KNUCKLE JOINT

Introduction

Knuckle joint is used to connect two rods subjected to axial tensile loads. It may also be used to support the
compressive load if the joint is guided. It is not suitable to connect rotating shafts which transmit torque.
Axes of the shafts to be joined should lie in the same plane and may coincide or intersect. Its construction
permits limited relative angular movement between rods, about the axis of the pin. Knuckle joint is widely
used to connect valve rod and eccentric rod, in the link of a cycle chain, levers, tie rod joint for roof truss
and many other links.

Knuckle Joint has mainly three components – eye, fork and pin as shown in Figure 1. Eye is formed on one
of the rods and fork is formed on the other. Eye fits inside the fork and the pin is passed through both the
fork and the eye. This pin is secured in its place by means of a split-pin. The ends of the rods are made
octagonal to some distance for better grip and are made square for some portion before it is forged to make
the eye and fork shapes.

Advantages of Knuckle Joint are:

- Simple to design and manufacture.

- Fewer parts – less cost more reliability.

- Simple to assemble and dismantle.

Design of Knuckle Joint

Notations Used
D = Diameter of each rod (mm)
D1 = Enlarged diameter of each rod (mm)
d = Diameter of knuckle pin (mm)
d0 = Outside diameter of eye or fork (mm)
d1 = Diameter of pin head (mm)
a = Thickness of each eye of fork (mm)
b = Thickness of eye end of rod B (mm)
x = Distance of the centre of fork radius R from the eye (mm)

Assumption for stress analysis of Knuckle Joint

- The rods are subjected to axial tensile force.
- The effect of stress concentration due to holes is neglected.
- The force is uniformly distributed in different parts.

Figure 2 shows the free body diagrams of the three main components of knuckle joint subjected to a
tensile force P.
In order to find out various dimensions of the parts of a knuckle joint, failures in different parts and at
different x-sections are considered. The stresses developed in the components should be less than the
corresponding permissible values of stress. So, for each type of failure, one strength equation is written and
these strength equations are then used to find various dimensions of the knuckle joint. Some empirical
relations are also used to find the dimensions.

Possible Failure Modes of Knuckle Joint

Step 1: Design of rod

a) Tensile Failure of Rods

Each rod is subjected to a tensile force P

𝑃
Tensile stress in the rods = 𝜎𝑡 = 𝜋 2 ≤ [𝜎𝑡 ]
𝐷
4

where [σt] = allowable tensile stress for the material selected.

Step:2 Design of Pin

a) Shear failure of pin

The pin is subjected to double shear

𝑃
Shear stress in pin = 𝜏 = 𝜋 ≤ [𝜏]
2 𝑑2
4

Where [] allowable shear stress for the material selected.

a) Bending failure of pin

When the pin is tight in the eye and fork, failure occurs due to
shear, but when it is loose, it is subjected to bending moment
as shown in Figure. It is assumed that: Load acting on the pin
is uniformly distributed in the eye and uniformly varying in
the two parts of the fork.

Maximum Bending Moment (at centre)

𝑃 𝑏 𝑎
𝑀𝑀𝑎𝑥 = [ + ]
2 4 3

Maximum Bending Stress in the pin,

𝑃 𝑏 𝑎 𝑑
𝑀𝑦 [ + ]
𝜎𝑏 = = 2 4 43 2 ≤ [𝜎𝑏 ]
𝐼 𝜋𝑑
64
Step:2 Design of Eye

a) Tensile Failure of Eye:

Area of the weakest section of eye resisting tensile failure = (d0 – d) b

𝑃
Maximum Tensile Stress in eye, 𝜎𝑡 = ≤ [𝜎𝑡 ]
𝑏(𝑑0 −𝑑)

b) Shear Failure of Eye:

The eye is subjected to double shear

𝑃
Shear Stress in the eye: 𝜏= ≤ [𝜏]
𝑏(𝑑0 −𝑑)

where [] = allowable shear stress for the material selected.

c) Crushing Failure of Eye:

𝑃
Crushing stresses 𝜎𝑐 = ≤ [𝜎𝑐 ]
𝑏𝑑

where [σc] = allowable compressive stress for the material selected.

Step:3 Design of Fork end

a) Tensile Failure of Fork:

Area of the weakest section of fork resisting tensile failure = (d0 – d) b

𝑃
Maximum Tensile Stress in fork, 𝜎𝑡 = ≤ [𝜎𝑡 ]
2a (𝑑0 −𝑑)

b) Shear Failure of Fork:

The fork is subjected to double shear

𝑃
Shear Stress in the fork: 𝜏= ≤ [𝜏]
2a (𝑑0 −𝑑)

where [] = allowable shear stress for the material selected.

c) Crushing Failure of Fork:

𝑃
Crushing stresses 𝜎𝑐 = ≤ [𝜎𝑐 ]
2𝑎 𝑑

where [σc] = allowable compressive stress for

the material selected.
Design Procedure for Knuckle Joint

Some standard proportions for dimensions of the knuckle joint are taken as:

D1 = 1.1 D, d = D, d0 = 2d, a= 0.75 D, b = 1.25 D, d1 = 1.5 d & X = 10 mm

Dimensions can be determined using these empirical relations and the strength equations can be then used
as a check. By doing so the standard proportions of the joint can be maintained. The other method, of
designing it, can be making the use of above strength equations to find the dimensions mathematically.

Procedure to determine various dimensions of knuckle joint is as follows:

Step: 1

𝑃
• Calculate the Diameter of each rod (d) using 𝜎𝑡 = 𝜋 2 ≤ [𝜎𝑡 ]
𝐷
4

Step: 2

• Calculate D1 for each rod using empirical relation D1 = 1.1D

• Calculate dimensions a and b also using empirical relations a = 0.75 D & b = 1.25 D
• Calculate diameter of the pin by shear and bending consideration and select the diameter which is
𝑃 𝑏 𝑎 𝑑
𝑃 [ + ]
2 4 3 2
maximum; 𝜏= 𝜋 ≤ [𝜏]; and 𝜎𝑏 = 𝜋𝑑4
≤ [𝜎𝑏 ]
2 𝑑2
4 64
• Calculate dimensions d0 and d1 using empirical relations d0 = 2d and d1 = 1.5d.

Step: 3

• Check the tensile, crushing and shear stresses in the eye

a) Tensile Failure of Eye:

𝑃
Maximum Tensile Stress in eye, 𝜎𝑡 = ≤ [𝜎𝑡 ]
𝑏(𝑑0 −𝑑)

b) Shear Failure of Eye:

𝑃
Shear Stress in the eye: 𝜏= ≤ [𝜏]
𝑏(𝑑0 −𝑑)

c) Crushing Failure of Eye:

𝑃
Crushing stresses 𝜎𝑐 = ≤ [𝜎𝑐 ]
𝑏𝑑

Step: 4

• Check the tensile, crushing and shear stresses in the Fork

a) Tensile Failure of Fork:

𝑃
Maximum Tensile Stress in fork, 𝜎𝑡 = ≤ [𝜎𝑡 ]
2a (𝑑0 −𝑑)
 b) Shear Failure of Fork:

𝑃
Shear Stress in the fork: 𝜏= ≤ [𝜏]
2a (𝑑0 −𝑑)

c) Crushing Failure of Fork:

𝑃
Crushing stresses 𝜎𝑐 = ≤ [𝜎𝑐 ]
2𝑎 𝑑

Problem:

Design a knuckle joint to transmit 150 kN. The design stresses may be taken as 75 MPa in tension,
60 MPa in shear and 150 MPa in compression.