Design of Cotter Joint

TITLE
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 taper varies from 1 in 48 to 1 in 24 and it may be increased up to 1 in 8, if a locking device is provided. The locking device may be a taper pin or a set screw used on the lower end of the cotter. The cotter is usually made of mild steel or wrought iron. 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. It is usually used in connecting a piston rod to the crosshead of a reciprocating steam engine, a piston rod and its extension as a tailor pump rod, strap end of connecting rod etc.
INTOODUCTION
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
NOTATION USED
P = Load carried by the rods, d = Diameter of the rods, d 1 = Outside diameter of socket, d2 = Diameter of spigot or inside diameter of socket, d3 = Outside diameter of spigot collar, t 1= Thickness of spigot collar, d 4 = Diameter of socket collar, c = Thickness of socket collar, b = Mean width of cotter, t = Thickness of cotter, I = Length of cotter, a = Distance from the end of the slot to the end of rod, t= Permissible tensile stress for the rods material, = Permissible shear stress for the cotter material, and c = Permissible crushing stress for the cotter material.
Design procedure
The dimensions for a socket and spigot cotter joint may be obtained by considering the various modes of failure
1) Failure of the rod in tension

The rod may fail in tension due to the tensile load P . We know that resisting tearing= (/4)*d2 Tearing strength of rods=(/4)*(d2)* (t) Equating this to load (P), we have P=[ (/4)*(d2)2 ]*t
From this equation, diameter of the rod (d) may be calculated
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 , therefore Area resisting tearing of the spigot across the slot
=[ (/4)*(d2)2- (d2)*t ]
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 , therefore Area resisting tearing of the spigot across the slot =[ (/4)*(d2)2- (d2)*t ] Tearing strength of the spigot across the slot =[ (/4)*(d2)2- (d2)*t ]*(t)
Equating this to load (P), we have P=[ (/4)*(d2)2- (d2)*t ]*(t)
From this equation, diameter of spigot or inside diameter of socket (d2)may be determined.
3)Failure of the rod or cotter in crushing

We know that the area that resist crushing of the cotter= (d2)*t Tearing strength of rods= (d2)*t * (t)
Equating this to load (P), we have

P=[(d2)*t ]*t
From this equation, the induced crushing stress may be checked.
4)Failure of socket in tension across the slot

We know that Area resisting to the tearing of the socket across the slot =(/4)*[(d1)2 - (d2)2 ]-(d1-d2)*t
4)Failure of socket in tension across the slot

We know that Area resisting to the tearing of the socket across the slot =(/4)*[(d1)2 - (d2)2 ]-(d2-d1)*t Tearing strength of the socket across the slot = {(/4)*[(d1)2 - (d2)2 ]-(d1-d2)*t}*(t)
Equating this to load (P), we have P= {(/4)*[(d1)2 - (d2)2 ]-(d1-d2)*t}*(t)
From this equation, diameter of the rod (d1) may be calculated
5)Failure of COTTER IN SHEAR

Considering the failure of cotter in shear as shown in figure. Since the cotter is in double shear , therefore shearing area of the cotter=2*b*t And shear strength of the cotter =2*b*t*
Equating this to load (P) we have P=2*b*t* . From this equation width of cotter (b) is determined
6.1)Failure of socket collar in crushing.

Considering the failure of socket collar in crushing as shown in figure
We know that area that resists crushing of socket collar =[(d4) - (d2) ]* t
6.2)Failure of socket collar in crushing.

Crushing strength of socket collar
=[(d4) - (d2) ]* t*t
Equating this to load (P) we have

P=[(d4) - (d2) ]* t*t
. From this equation the diameter of socket collar ( d4) May be determined
7) Failure of socket end in

Since the socket end is in the double shear. Therefore area that resist s shearing of socket collar =2*[(d4) - (d2) ]*c And the shearing strength of socket collar =2*[(d4) - (d2) ]*c* Equating this to load (P) We get P=2*[(d4) - (d2) ]*c* From this above equation the the thickness of socket collar ( c ) may be obtained.
8) Failure of rod end in shear

Since the rod end is in the double shear. Therefore area that resists shearing of rod end. =2*a* (d2) And the shearing strength of rod end =2*a* (d2)* Equating this to load (P) We get P=2*a* (d2)*
From this above equation the the thickness of rod end ( c ) may be obtained.
9)Failure of spigot collar in crushingt

Considering the failure of the spigot collar in crushing as shown in figure. We know that Area resisting to the crushing of the spigot collar Crushing strength of the collar
=(/4)*[(d3)2 - (d2)2
=(/4)*[(d3)2 - (d2)2 *(c)
Equating this to load (P), we have =(/4)*[(d3)2 - (d2)2 *(c)
From this equation, diameter of the rod (d3) may be calculated
10)Failure of spigot collar in shearing

Considering the failure of the spigot collar in shearing as shown in figure. We know that Area that resists shearing of the collar And the shearing strength of the collar
=()*(d2)*(t1) =()*(d2)*(t1) *
Equating this to load (P), we have

=()*(d2)*(t1) *
From this equation, diameter of the rod (t1)may be calculated
Failure of cotter in bending

In all the above relation it is assumed that load is uniformly distributed over the various cross-section of the joint . But in actual practice this does not happen and the cotter is subjected to 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 various from zero at the outer diameter d4 and maximum at the inner diameter d2 as shown in figure.

The maximum bending moment occurs at the centre of the cotter and is given by
MMAX=P/2[1/3*(d4-d2)/2+d2/2]- P/2[d2/4] MMAX=P/2[(d4-d2)/6+d2/2-d2/4] MMAX=P/2[(d4-d2)/6+d2/4]
We know that section modulus of the cotter , Z=t*b2/6 Bending stress induced in the cotter,
b= (MMAX/Z)

Bending stress induced in the cotter,
b= (MMAX/Z)
Bending stress induced in the cotter, b= P/2[(d4-d2)/6+d2/4]/( t*b2/6 ) Bending stress induced in the cotter, b= P[(d4)+0.5 *d2]/(2* t*b2 ) This bending stress induced in the cotter should be less than the allowable bending stress of the cotter.
Other dimensions of the cotter joint

The length of the cotter(l) is taken as l=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. The draw of the cotter is generally taken as 2 to 3 mm
When all the parts of the joint are made of steel, the following proportions in terms of the 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 and draw of cotter= 2 to 3 mm.
If the rod and cotter are made of steel or wrought iron then =0.8t And c= 2t May be taken.
FINISHING
DESIGN PROCEDURE OF COTTER JOINT

Design of Cotter Joint

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TITLE

Types of Cotter Joints

Socket and spigot Cotter joint

1) Failure of the rod in tension

From this equation, diameter of the rod (d) may be calculated

2)Failure of spigot in tension across the weakest section (or slot )

2)Failure of spigot in tension across the weakest section (or slot )

Equating this to load (P), we have P=[ (/4)*(d2)2- (d2)*t ]*(t)

3)Failure of the rod or cotter in crushing

Equating this to load (P), we have

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

4)Failure of socket in tension across the slot

4)Failure of socket in tension across the slot

Equating this to load (P), we have P= {(/4)*[(d1)2 - (d2)2 ]-(d1-d2)*t}*(t)

From this equation, diameter of the rod (d1) may be calculated

5)Failure of COTTER IN SHEAR

6.1)Failure of socket collar in crushing.

6.2)Failure of socket collar in crushing.

Equating this to load (P) we have

7) Failure of socket end in

8) Failure of rod end in shear

9)Failure of spigot collar in crushingt

=(/4)*[(d3)2 - (d2)2 *(c)

Equating this to load (P), we have =(/4)*[(d3)2 - (d2)2 *(c)

From this equation, diameter of the rod (d3) may be calculated

10)Failure of spigot collar in shearing

Equating this to load (P), we have

From this equation, diameter of the rod (t1)may be calculated

Failure of cotter in bending

Failure of cotter in bending

MMAX=P/2[1/3*(d4-d2)/2+d2/2]- P/2[d2/4] MMAX=P/2[(d4-d2)/6+d2/2-d2/4] MMAX=P/2[(d4-d2)/6+d2/4]

Failure of cotter in bending

Other dimensions of the cotter joint

DESIGN PROCEDURE OF COTTER JOINT

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Equating this to load (P), we have P=[ (/4)(d2)2- (d2)t ]*(t)

Equating this to load (P), we have P= {(/4)[(d1)2 - (d2)2 ]-(d1-d2)t}*(t)

=(/4)[(d3)2 - (d2)2 (c)

Equating this to load (P), we have =(/4)[(d3)2 - (d2)2 (c)