7

COTTER AND KNUCKLE JOINTS

Cotter joint is used when the members are subjected to axial tensile or compressive loads, easy
assembly and disassembly is required, no relative motion between the two fastened members (rods) is
desired and the axes of two rods are collinear. The cotter joint differs from the key joint as the later is
used to connect the two members transmitting the torque.

7.1 CONSTRUCTIONAL DETAILS AND APPLICATIONS

A generally used cotter joint is composed of essentially three components, namely, cotter, spigot and
socket as shown in Figure 7.1. The cotter is a flat wedge shaped piece of rectangular cross-section
which is uniform in thickness but tapering in width on one side in general. The one of the rod is forged
to form the socket and the other end of the rod is forged to form the spigot. The spigot end fits into
socket and held together by the cotter. Typical applications of the cotter joint are fastening of piston
rods and cross heads in steam engines, yokes to rods, tool fixture and for services of similar kinds.

t2 t

t1
d2 d1 b d d3 d4

l1 l2

Figure 7.1: Cotter joint

The taper in the cotter is provided to take the advantage of wedging action (friction locking). The
taper also keeps the joint alive even after some wear in the joint has taken place as the gap generated
due to the wear automatically filled up by the self travel of the cotter. This travel is assisted due the
taper given in the cotter. The taper should not be too large causing self removal of the cotter under the
external load but if the large taper is essential as in case when frequent disassembly is required,
locking devices such as set screw, lock pin etc become necessary to secure the cotter in position

1
against the slackening or removal of the cotter from its position. Generally, the taper of 1:24 is given
and is decided on the basis of the angle of friction between cotter and rods material. The taper angle
should not be greater than the angle of friction. The thickness of the cotter is generally kept equal to
one fourth to one fifth of its width at the centre. The width of the slot is made 3 to 5 mm bigger than
the cotter. When the cotter fits into the slot, the central portion of the cotter comes in contact with
spigot and pushes it into the socket till the opposite outer ends of the cotter comes in contact with
socket. These forces on the contacting surfaces prestress the joint and provide the required force for
friction locking of the bearing surfaces. Finally, the edges of the cotter and the ends of the slot are
rounded.
7.1.1 Materials and factor of safety
As the spigot and socket are the ends of shafts hence the material is same as shaft. Also, the cotter
joint is subjected to static loading and employed to normal working environment hence alloy steel is
not used. To facilitate the forging operation for forming the spigot and socket, low carbon and
medium carbon steels are preferred. The materials used for the components of the cotter joint are the
steel used for low stresses components. C15Mn25 C20, C25 and C30 can be used for such
components. In some instances when rods are to subjected to high stresses, material is to be selected
accordingly. A factor of safety of 3 to 4 should be used for steel based on yield strength. However, the
factor of safety for cotter may be taken less than the factor of safeties for other components to make
cotter weaker than spigot and socket. This is because the cotter is free from stress concentrations, easy
to replace and manufacture.
7.1.2 Modes of failure and design equations
The design of the cotter joint is based on the basic direct stress equations as the joint is subjected to
axial tensile or compressive loading producing direct stresses.
The minimum data required for design problem of a cotter joint are

Type of load (tensile of compressive)

Magnitude of the load

Section of rods to be fastened (Circular, square or rectangular; A mm2)
In the design of cotter joints, following steps are followed
Selection of material for each component
Note the required material properties such as S y , S ys , S u , S us for each selected material
It is also important to note here that above steps are necessary only if the material or the material
properties are not given in the problem. Otherwise, we have to use the data whatever is given in the
problem statement.
Choose proper factor of safety n
S y , Su S ys , S us
Calculate design stresses for each component σ d = , τd =
n n
If the shear strengths are not available in the table or not given in the problem, we can use the
following relationship
τ d = 0.5σ d according to maximum shear stress theory
τ d = 0.577σ d according to maximum distortion energy theory
Now, to design the cotter joint, the resistance offered in possible modes of failure is equated with the
external load (required capacity) of the joint and then the desired dimension is obtained. This would
be made clearer with examples to follow. Following are the possible failure modes of a cotter joint.
Tensile mode of failure of the solid rod, tearing resistance

2
This failure mode is used to calculate the diameter of the rod by calculating the tearing resistance of
the rod considering the tearing failure.
Tearing resistance = Failure area × Design stress
π
d 2σ d
4
For design to be safe in this mode, tearing resistance ≥ F (external load or design load)
π
F= d 2σ d 7.1
4
This will give d and modify it to standard size.
The thickness and width of the cotter
t = 0.25d1 or 0.4d and b = 4t to 5t or 1.25d1 7.2
Tearing mode of failure of the spigot across the cotter slot, tearing resistance
The spigot may fail under the action of tensile load of F . The failure occurs through a section which
offers least resistance to the applied load.

d1 d3
d
d1

3 4 3 2 1
4 2 1

4
4 3 3 2 1

Figure 7.2: Tensile failure of socket

π
Failure area = d 12 − d 1t
4
The resistance of the spigot area in tearing must be greater than or equal to the load causing the
possible failure i.e. the external load. Mathematically
π
Resistance of spigot in tearing = failure area × design stress in tension = ( d12 − d1t ) σ d
4
π
F =( d12 − d1t ) σ d 7.3
4
Find d1 and modify to suitable design value.
Shearing mode of failure of spigot end through cotter
The shear takes place through two parallel planes (Figure 7.3); hence, it is the case of the double
shear.
Failure area = 2d1l1
Resistance of spigot in double shear = failure area × design stress in shear = 2d1l1τ d
F = 2d1l1τ d 7.4
Find l1

3
 Shear planes
F

Shear area
(both sides)

Figure 7.3: Double shear failure of socket

Tearing mode of failure of socket through cotter

The failure occurs through the weakest section of the socket. Figure 7.4 shows the areas of cross
section of three different sections through which socket can fracture/tear. The area through section 2 is
least and hence possibility of tensile failure will be maximum through this section. Hence the design
equation is
π
F= (d 22 − d12 ) − (d 2 − d1 )tσ d 7.5
4
We can determine d 2 from the above equation.

d1 d2
d1 d2

t
F

Figure 7.4: Tensile failure of socket

Shearing mode of failure of socket through cotter

Figure 7.5 shows the loading and failure area for this mode. It is the case of double shear as shown.
 d 4 − d1 
The resisting= 4 l 2 , hence,
 2 
F = 2(d 4 − d1 )l2τ d 7.6
Find l 2 using d 4 = 2d 1 and round off to next higher integer.

4
 l2

Shear area (four faces)

 d 4 − d1 
 
 2 
F

Figure 7.5: Shear failure of socket

7.1.3 Checking for other failure modes

The above failure modes are sufficient to give all the dimensions of the cotter joint. As the
components may also fail in other modes hence the resistance of those modes must be calculated to
ensure the safe design.
Crushing mode of failure of the cotter and spigot
The cotter and spigot may crush under the action of the load as shown in Figure 7.6a and illustrate the
crushing area between cotter and spigot. The crushing resistance
Fc spigot = d1tσ dc 7.7
For safe design Fc spigot ≥ F

d1 d4
d1

(a ) (b)

Figure 7.6: Crushing failure of spigot and socket with cotter

If this inequality is not satisfied, we have three options; Increase d1 , increase t , select material with
higher compressive strength. The last one is used only when other options are not feasible. The
increase in t is associated with the reduction in the resistance of spigot in tearing (Equation 7.3).
Hence we will use first option of increasing d1 ,
F
d1 =
tσ dc
Crushing failure mode of the cotter and socket
The cotter and socket may crush under the action of the load as shown in Figure 7.6b. The contact area
between socket and cotter will be the crushing area
The crushing resistance is given by Fc socket = (d 4 − d1 )tσ dc 7.8

5
For safe design Fc socket ≥ F
If this inequality is not satisfied, we have three options and the same reasoning can be used in favor of
going for the option of increasing d 4 .
F
d 4 = d1 +
tσ dc
Shearing mode of failure of the cotter
The cotter may fail in double shear under the loading as shown in Figure 7.7a, hence, the shear stress
induced is
F
τ = 7.9
2bt
For safe design τ ≤ τ d
If fails, we can either increase b or t
Bending of cotter
The force due to spigot and socket on cotter may tend to bend the cotter (Figure 7.7b). Although the
exact distribution of the load shown in the figure through out the contact length is not known, hence
the distribution of the load may be assumed as shown in the Figure 7.7c. The orientation of the cotter
is changed for better understating of the students.
The maximum bending moment acts at the centre of the cotter and the expression of this is given by
F  d 4 − d 1 d 1  d 1  F
M =  +  −  = (2d 4 + d1 ) 7.10
2  6 2  4  24
The maximum stress due to this maximum bending moment is given by
M
σ= 7.11
Z
1 2
where Z = section modulus = b t 7.12
6

F F
2 2 (d 4 − d1 )/ 2
d1
4 t
b

b
F F
F
2 d 4 − d1 d1 2
+
6 2

Figure 7.7: Shear failure of cotter and loading on the cotter

The maximum stress induced due to bending in the cotter must be less than the design stress. Hence
the following must be satisfied for the design to be safe
σ ≤σd 7.13
If this is not satisfied, then to reduce the stress due to bending in the cotter we can increase either b or
t other than the change of material. The effect of b in reducing stress is more as compared to t

6
because it appears as quadratic power in the expression of section modulus (Equation 7.12). Also, it
does not affect any other failure mode; hence it is suggested to increase b .
The cotter is kept slightly weaker than the socket and spigot as replacing a cotter is easier and
economical as compared to spigot and socket. Also, there is no change in the geometry of the cotter;
hence, stress concentration is not present. That is why it is recommended to use slightly lower factor
of safety for cotter than spigot and socket. Example Problem 7.3 illustrates this concept.
7.1.4 Cotter joint under compressive load
The compressive load from the spigot rod is transferred to the socket through the collar. The socket
then pushes the cotter and the balancing reaction is produced at the contacting surface of cotter and
spigot. The socket rod transfers the force from rod to socket. When a cotter joint is to withstand a
compressive load, following additional failure modes have to be considered which are otherwise not
among the possible modes of failure when cotter joint is subjected to axial tensile loading.
Crushing mode of failure of the collar and socket
The collar and socket may crush under the action of compressive load and the crushing area is shown
in the Figure 7.8. The design equation for this mode of failure is developed as
F=
π
4
(d 2
3 )
− d12 σ dc 7.14
Find d 3 and round off to next higher integer.
F

Crushing area
Figure 7.8: Crushing failure of collar due to compressive loading

Shearing mode of failure of collar

The collar may shear through the spigot end and the shearing area is shown in the fig. The design
equation for this mode of failure is
F = πd1t1τ d 7.15
Find t1 and round off to next integer.
F

shear area

Figure 7.9: Crushing failure of collar due to compressive loading

Shearing mode of failure of the socket

In this mode of failure the shearing failure of the socket is assumed which is the case when solid rod
pushes into the socket through circumferential shear plane. The mode of failure and shearing area is
shown in the Figure 7.10. The design equation becomes
P = πdt 2τ d 7.16
Find t 2 and round off to next higher integer

7
 shear area

Figure 7.10: Shearing failure of socket through rod due to compressive loading

7.1.5 Other dimensions and details

Length of cotter l = 4d
Taper 1:30 (for steel and steel)
l
Top width of the cotter b1 = b +
60
l
Bottom width of the cotter b2 = b −
60
The edges of the spigot, socket and cotter are chamfered to avoid sharp corner and fillets are provided
to reduce the stress concentration.
It is important to mention that the thickness of the cotter and diameter should be calculated for equal
strength of spigot in tearing mode of failure (Equation 7.3) and crushing mode of failure (Equation
7.7). Equation 7.7 gives
F
d 1t =
σ dc
substituting in Equation 7.3
π F 
F =  d 12 − σ d
4 σ dc 
We can determine d 1 from the above equation. The width of cotter can now be calculated by
considering shear failure of cotter.
7.1.6 Design using empirical relations
We can also design a cotter joint by deciding all the dimensions of the cotter joints based on the
empirical relations given in Table 7.1 and then the capacity of joint is checked in all possible failure
modes. For safe design the calculated capacity of each possible failure mode should be more than the
capacity (external load) of the joint.

Table 7.1 Proportions of cotter joints

Symbols Proportions Symbols Proportions
Rod diameter d Width of cotter b 4t to 5t
Diameter of spigot end, d1 1.25 d Spigot length from cotter slot l1 d
Outer diameter of socket d 2 1.4 d1 Socket length from cotter slot l2 d
Diameter of collar d 3 1.2 d1 Thickness of collar t1 0.5 d
Largest diameter of socket d 4 2.0 d1 Thickness of socket at rod end t2 0.5 d
Thickness of cotter t 0.25 d1

8
7.2 GIB AND COTTER JOINT
Gib and cotter joint is used for the rods of square or rectangular sections. The end of the one rod is
forged in the form of the strap whereas no change in the end of the other rod is made. So, in this case
one end is called strap end and other is called either rod end or sometimes it is called as eye end.
It is used to fast connecting rod of a steam engine or marine engine. The height of the rod end is
increased for compensating the slot for cotter. The details of a gib and cotter joint are shown in Figure
7.11. The function of the gib is to prevent opening of the jaws of the strap. The gib increases the
bearing area of cotter and prevent and slackening of the joint. When gib is used, the sides of the slot
are made parallel and the taper is provided in the gib as shown in the figure. The design procedure is
illustrated in Example Problem.

Figure 7.11a: Gib and cotter joint

Fork end cotter

gib

eye end

Figure 7.11b: Components of Gib and cotter joint

7.3 COTTER FOUNDATION BOLT

The cotter foundation bolt is used to install a machine to foundation. The eye end of the foundation
bolt is restricted below a plate in the foundation and the machine frame is bolted with a nut as shown
in Figure 7.12. The tightening of nut induces tensile force in the foundation bolt. Following modes of
failure are considered for the design of foundation bolt.

9
 Figure 7.12: Cotter foundation bolt

Tensile failure of bolt

π
F= d 2σ d 7.17
4
Tensile failure of bolt through cotter slot
π 
F =  d12 − d1t (σ d ) 7.18
4 
Crushing failure between cotter and bolt
F = d1tσ dc 7.19
Shearing failure of eye end of foundation bolt
F = 2l1d1τ d 7.20
Shear failure of cotter (double shear)
F = 2btτ d 7.21

7.4 SLEEVE AND COTTER JOINT

Sleeve and cotter joint is used to connect two tie rods or sometimes to connect two pipes/tubes. The
ends of both the members to be connected are similar in shape and dimensional proportions. A sleeve
is passed over both the members and the joint is completed with the help of two cotters passing
through the members (eye ends) as shown in Figure 7.13. Example problem 7.4 illustrates the design
procedure of sleeve and cotter joint.

10
 Figure 7.13: Sleeve and cotter joint

7.5 KNUCKLE JOINT

A knuckle joint is generally used to connect rods subjected to axial tensile load. Sometimes, if it is
required to be used to support compressive loading, we must provide guide to constrain the motion of
rod. It facilitates easy assembly and disassembly and also permits limited relative motion between the
two fastened components (rods).

Figure 7.14: Knuckle joint

7.5.1 Constructional details and applications

Figure 7.14 shows a knuckle joint which consists of mainly three parts and five in all. The end of one
rod is forged to form an eye while the other is made in the form of fork and thus called as eye and fork
ends respectively. These two ends are held together with the help of a cylindrical pin driven through
the holes of eye and fork ends. These three part are secured by means of a small lock pin through a
collar to complete the knuckle joint.
It is recommended that the hole is drilled and pin is machined to get the better fitting and improved
performance of the joint. The other rubbing surfaces of the fork and eye end must be machined. The
end of the rods are made octagonal to some distance for firm grip and then it is square for some
portion before it is forged into eye and fork shapes.
This type of joint is widely used in practice to connect valve rod and eccentric rod, levers, tie bars of
truss, links of suspension chains, elevator chains and many other links. The knuckle joint is also used
for fastening more than two rods intersecting at a single point.

11
 Figure 7.15: Components of Knuckle joint

7.4.2 Materials and factor of safety

The materials used for the components of the knuckle joint are similar to the components of cotter
joint as forging is done to form the rod in eye and fork ends. Hence, C15Mn25, C20, C25, C30 and CI
are the commonly employed materials for parts of knuckle joint. When rods are subjected to high
stresses or any specific conditions, material is to be selected accordingly. A factor of safety of 3 to 4
should be used for steel based on yield strength where as factor of safety of 7 to 8 is recommended for
CI based on ultimate strength.
7.4.3 Design Procedure
The design of the knuckle joint is also based on the basic direct stress equations as it was for the cotter
joint. As the knuckle joint is used for tensile loading only, the minimum data required for design
problem of a knuckle joint is the magnitude of the load. Steps followed are:
Selection of material for each component
Note the required material properties such as S y , S ys , S u , S us for each selected material
Choose proper factor of safety n
S y , Su
Calculate design stresses for each component σ d = , τ d = 0.5σ d
n
Now, to design the joints, the resistance offered in possible modes of failure is equated with the
external load (required capacity) of the joint and then the desired dimension is obtained. Following are
the possible failure modes:
Tensile mode of failure of the solid rod, tearing resistance
This failure mode is used to calculate the diameter of the rod by calculating the tearing resistance of
the rod considering the tearing failure.
Tearing resistance = Failure area × Design stress
π
d 2σ d
4

12
For design to be safe in this mode, tearing resistance ≥ F (external load or design load)
π
F= d 2σ d 7.22
4
Find d and modify it as per R20 series or with standard size table.
The shearing failure mode of the pin; Shearing resistance

Figure 7.15: Cross section of the rod

The pin may fail in double shear and hence the design equation is
π
F = 2 × d 12τ d 7.23
4
Find d1 and standardize it as per R20 series
The tearing failure mode of the square section; tearing resistance
The failure area is shown in the Figure 7.16 under the action of tensile force F .
h1

h1

Figure 7.16: Failure area of the rod

Failure area = h12

F = h12 σ d 7.24
Find h1 and round off to next higher integer.
Tearing failure mode of fork end before pin hole; tearing resistance

13
 t3

h1

Figure 7.17: Failure area of the fork end before pin hole

Failure area = 2t 3 h1
The design equation
F = 2t 3 h1σ d 7.25
Find t 3
The crushing failure mode of fork and pin; crushing resistance
The fork and the pin may crush under the action of external load. The force distribution on the fork
and the pin is shown in the Figure , hence the projected area is to be considered for computing the
crushing resistance.

Figure 7.18: Crushing failure of pin/fork

Projected area = 2t1 d1

Design equation
F = 2t1 d1τ d 7.26
The tearing failure mode of fork through pin hole; tearing resistance

14
 t1

d1

d3

Figure 7.19: Failure area of the fork end before pin hole

Failure area (Figure 7.19) = 2(d 3 − d1 )t1

The design equation
F = 2( d 3 − d 1 )t 1 σ d 7.27
Find d 3 and round off to next inte
Tearing failure mode of eye end through pin; tearing resistance
Refer Figure 7.20 for loading and failure area.

h3
d1

d3

Figure 7.20: Failure area of the fork end before pin hole

The design equation is

F = h3 (d 3 − d 1 )σ d 7.28
Find h3 and round off to next integer
Checks
The above failure modes are sufficient to give all the dimensions of the knuckle joint. But all three
components may fail in some other modes and the resistance of those modes must be calculated to
ensure the safe design.
Crushing failure (crushing failure mode) of eye through pin
The projected area is considered. The crushing resistance is given by
Fc = h3 d1σ cd 7.29
For failure safe design Fc ≥ F

15
If this inequality is not satisfied, we have two options other than change of material; increase h3 or
increase d1 . The increase in d1 is associated with the reduction in the resistance of fork and eye in
tearing as per Equations 7.21 and 7.22. Hence we will use first option of increasing h3 .
Shearing resistance (shearing failure mode) of eye end through pin
The shearing failure of eye end shown in Figure 7.21. The shearing resistance is given by
Fs = 2(d 3 − d 1 )h3τ d 7.30

shear area
(2 faces)

h3
F

(d 3 − d1 ) / 2

Figure 7.21: Shear failure area of the eye end

For failure safe design Fs ≥ F

If not satisfied, we can increase h3 , increase d 3 or reduce d1 . The reduction in d1 reduces the
strength of the pin. Hence any of first two options can be used.
Bending of pin
The pin may bend under the assumed force distribution as shown in the Figure The bending moment
diagram is shown in Figure .
F F
2 2
h3
t1
4

F F
2 t1 h3 2
+
3 2

Figure 7.22: Bending of pin

The maximum bending moment acts at the centre of the pin and the expression of this is given by
P  t1 h3  h3 
M =  +  −  7.31
2  3 2  4 
The maximum stress due to this maximum bending moment is given by

16
 M
σ= 7.32
Z
1 3
where Z = section modulus = d 7.33
32 1
The maximum stress induced due to bending in the pin must be less than the design stress for safe
design. Hence the following must be satisfied
σ ≤σd 7.34
If this is not satisfied, then to reduce the stress due to bending in the cotter we can increase either d1
other than the change of material.
Other dimensions
Diameter of pin head, d 2 = 1.5 d1
Diameter of collar, d 2 = 1.5 d1
Diameter of lock pin hole, d 4 = 0.25d1
Length of eye and fork end, L = 4.0 d
Length of octagon shape, l = 2 d
Second method of design
We can decide all the dimensions of the knuckle joints based on the proportion given in Table 7.2 and
then the capacity of joint is checked in all possible failure modes (mode 2 to 10). For safe design the
calculated capacity of each possible failure mode should be more than the capacity (external load) of
the joint.

Table 7.2 Proportions of knuckle joints

Symbols Proportions Symbols Proportions
d1 d h2 1.1 d
d2 1.5 d h3 1.2 d
d3 2.0 d l 2d
d4 0.25 d1 L 4d
h1 1.2 d t1 0.75 d
t2 0.5 d

17