DESIGN AND FABRICATION OF BOLT

Loyola

Institute Of Technology And

Science

MECHANICAL ENGINEERING
THIRD YEAR
MINI PROJECT

Group no.14
Group Members
: Subin Mathews
(961212114103)
: Clinson Fernandez
(961212114035)
: Jithu Joseph
(961212114059)
Guided By

Mr. V. Suresh Babu

Abstract
An industrial fastener comprises a wide range of items like nuts &
bolts, studs, nails etc.., among which the nuts and bolts consist a major
link in the family of industrial fasteners and are used in every industry.
Bolt is a piece of metal rod whose one end is unsettled and the other end is
threaded nuts the item which rolls on these threads. They are available in
various shapes, designs and size according to what they are needed for.
Various types of loads can be acting on the bolts according to the
application in which it is used for. Now we are going to design and
fabricate the bolt which is eccentrically loaded. Eccentrically loaded bolted
joints are very common in structural connections. For fabricating the bolt
we are selecting the simple manufacturing process like lathe (turning &
threading) etc... Because this processes is simple and more efficient.
We expect the bolt which is fabricated will be most sufficient even for
the eccentrically application as for the conditions. For the further increase
in the strength we can even do heat treatments like tempering or
hardening on the bolt material.

Introduction
There is no one fastener material that is right for every environment.
Selecting the right fastener material from the vast array of those available can be
a daunting task. Careful consideration must be given to strength, temperature,
corrosion, vibration, fatigue and many other variables while selecting the raw
material because the selection itself includes various types of capabilities for the
bolt including the tensile strength, ductility malleability etc.
The thread is a form obtained by the cutting of a continuous helical
groove on the cylindrical surface. The threaded portion will be the engaging part
which engages with a corresponding threaded hole in the nut or the machine part.
Basically they are most commonly used for supporting or transmitting the
power from one medium to the other and to act as fastening to secure one
member to the other. The connections are normally made either by riveting /
bolting or by welding. Normally the Riveted Connections are of bearing type and
the Bolted connections are of both bearing type as well as friction type. Riveted
Connections are being used in all type of situation. But it is seen that they fail
where repetitive dynamic loads are experienced. In these situation, the Bolts are
better substitute of Rivets. And there are many applications in which none other
can substitute a bolted joint.

Literature review
An industrial fastener comprises a wide range of items like nuts & bolts, studs, nails
etc.., among which the nuts and bolts consist a major link in the family of industrial fasteners
and are used in every industry. Bolt is a piece of metal rod whose one end is unsettled and
the other end is threaded nuts the item which rolls on these threads. They are available in
various shapes, designs and size according to what they are needed for.
Nuts and bolts are used for fastening purposes in industries where the replacement
of pieces and parts is necessary. Most of the fasteners application are designed to support or
transmitted some form of externally applied load. The main raw material used in common for
the manufacturing is the mild steel rod of required diameter. It is one of the most interesting,
complex, useful and frustrating component yet devised and offcorse it is a temporary joint.
The figure given below shows the various parts of the bolts,

There are various types of threads available for the bolt and they vary in
accordance with their usage and purpose. The threads are formed by cutting or
rolling a continuous helical groove on a cylindrical surface. The figure given below
shows the nomenclature of a simple V thread,

TYPES OF BOLT
A bolt of cylindrical structure in which one end is threaded and the other
end is made as head. The cylindrical portion in which the threads are not made is
called shank and a head built along with the shank. Shape of the head is decided
depending upon the purpose of the bolt is to be used. Depending upon the shape
of the head, bolts may be classified as: hexagonal, square, slotted and hook. Bolts
may be classified as: for steel structures and the foundations high tensile friction
grip and machine tools.
The figure 2.4 given below shows the different types of bolts classified
based on the shape of the head,

DESIGN OF BOLTS
While designing a bolt first of all we should consider what all are the loads and
forces acting on the bolt we are going to make when the bolt is applied on certain
applications.
The bolts can be loaded on the basis of the application in which the bolt is used for.
According to the application the loading method also differs, the bolt that we are going to
manufacture should be capable of withstanding that type of loading condition in which the
bolt is applied. Now we are going to consider the eccentrically loaded condition types and
design the bolt applicable for withstanding that condition.
ECCENTRICALLY LOADED BOLTED JOINTS.
Eccentrically loaded bolted joints are very common in the structural connections.
There are mainly two in this kind of eccentric loading, they are as follows,
Loading in a plane different from the plane of the bolts.
Plane of loading is same as the plane of the bolt.
Now we are only considering the loads that may act on different plane, the design
procedure for the design of the bolts that is applicable in the condition that the loads that are
acting eccentrically on different plane is as explained in the coming pages,

LOADING ON DIFFERENT PLANE

A simple example for this kind of loading is that of a bracket as shown in
the figure given below,

Let,
P
O
e
l1
l2
n1
n2
q
f1
f2

- External force.
- Fulcrum about which the bracket may tilt.
- Eccentricity.
- Distance between the first row of the bolt and the fulcrum.
- Distance between the second row of the bolt and the fulcrum.
- Number of bolt in the first row.
- Number of bolt in the second row.
- Stiffness of the bolt (Force /unit distance from O).
- Force induced in the first row of bolts.
- Force induced in the second row of bolts.

Taking the moments about O,

P.e =
=

It can be seen from the above that the bolts in the second row are put in
to higher stress because
<
Shear stress induced in the bolts,
=

By maximum shear stress theory, the maximum shear stress,

For designing,
Substituting the values
,
and n,
can be found and from the
arrived value of, we can easily find the suitable size for the bolt.

When the bolt size is chosen then all the basic dimensions can be easily
founded out from PSG DESIGN DATA BOOK page no. 5.42
From here the pitch, length up to which thread have to be formed,
thickness of the bolt head and dimensions for the bolt head arrangement can be easily
founded out.

Problem statement
A bracket as shown in figure given below is fitted to a wall with five bolts, three at
the top and two at the bottom, with all bolts equally spaced. A load of 20000N is
acting at an eccentricity of 200mm. The vertical distances of the first and second
rows from the hinge point are 50mm and 250mm respectively. Assume the bolt to be
square headed of having 50mm length other than the head thickness. The factor of
safety should be 3. Design the bolt for the above application.

CALCULATION
Given data:
P = 20000 N
e = 200 mm
l1 = 50 mm
l2 = 250 mm
n1 = 2
n2 = 3
Solution:
Force on the first row bolts,
=

= 1038.96 N

Force on the second row bolt,

=

= 5194.8 N

From the above answers we can understand that,F2 > F1

Since the second row bolt is of having greater force we only have to consider the F 2
while designing the bolt,
Tensile strength is given by the formula,
Where, is the stress area of the bolt,
Shear stress, =

The maximum shear stress is given by the formula,

But maximum shear stress is also given by,

Where, n is the factor of safety given as 3.

Let the bolt material be mild steel
Minimum yield stress = 200 for mild steel

= 71.529
mm2

From PSG DESIGN DATA BOOK page no. 5.42

For stress area = 71.529 ( 84.3), we choose the M12 bolt.
From PSG DATA BOOK page no. 5.42 for the M12 bolts we can select the pitch to
be,
P = 1.75 mm. (Here we are selecting the coarse series)
For the M12 bolt from DATA BOOK page no. 5.42
Major diameter, d = 12 mm
Minor diameter = 9.853 mm
Pitch diameter
= 10.863 mm

Depth of thread, h = 1.074 mm

Maximum depth of engagement, H = 0.947 mm
These are the basic dimensions for the threads on the bolts.
The values are made according to the Indian Standard - IS: 4218 -1967
The basic dimensions for an square headed bolt can be taken from the
PSG DESIGN DATA BOOK page no. 5.54
For M12 square headed bolts
Length of thread = 30 mm, since the length of the bolt less than 130 mm.
Corner to corner distance, e = 24 mm.
Thickness of the head, k = 8 mm
From these basic dimensions we can fabricate a bolt for the given
specific connection of the bracket to the wall.
RESULT
Thus for the connection of the bracket to the wall in which a load of 20000N
acting at an eccentricity of 200mm, the square headed bolt is designed.

3D MODELING
Solid works is a 3D modeling software used by most of the engineers all over the
world. In this project, we created our 3D model of our bolt with the help of solid
works.

FARICATION OF BOLTS

RAW MATERIAL
The selection of the raw material from a wide variety is basically
done according to the application in which the bolt is about to use. The bolt
material should be capable of withstand the working conditions and should not fail
on the application of the load. The material should be selected in accordance with
the working atmosphere also. Here for the eccentrically loaded condition we are
selecting the bolt material to be mild steel, which is easily available in the local
market and cheap while considering in regardance with the strength. The figure
given below shows the mild steel rod which is used as the raw material. The
chemical composition of mild steel can be observed as given in the table shown
below,
Chemical
-Percentage
Carbon
- 0.16 - 0.18%
Silicon
- 0.40% max.
Manganese - 0.70 - 0.90%
Sulphur
- 0.04% max
Phosphorus - 0.04% max

FACING
Machining the end of the work piece to
produce the flat surface called facing. The work may be held in
a chuck or between centers. The work is rotated about the lathe
axis. A facing tool is fed perpendicular to the axis of the lathe
.The feeding may be done by the hand or power. The figure
given below shows the facing operation done to the mild steel
rod. We are facing the mild steel to a length of 58 mm

including the length of the bolt 50 mm and including the

thickness of the bolt 8 mm.
TURNING
Straight turning is the operations of producing a
cylindrical surface by removing material from outside
diameter of the work piece. Its done by rotating the work
piece about the lathe axis and feeding the tool parallel to
lathe axis. The job is held between the centers or held in a
chuck. The treatment or centerness of the work piece is
checked by the dial indicator or the scriber against the
rotating work piece. The turning is done to the mild steel

THREAD CUTTING
Thread cutting is the operations of producing
helical grooves on a cylindrical work piece. When the job rotates
the tool is automatically for longitudinally by using lockout and
lead screw feed should be equal to the pitch of the thread to be
cut per revolution of the work. The lead screw has definite pitch.
The figure given below shows the operation done during the
thread cutting. A definite ratio between the rotation of headstock
spindle and longitudinally feed is found out so that the screw of
desired pitch can be obtained. The lead screw is connected to
carriage half nut with lead screw.
GRINDING
Grinding is the operation that are used to
removal of the metal by using abrasive metals wheels. By internal
and external grinding can be done in lathe. The grinding is held on
the tool post grinder which is placed on compound rest. Grinding is
done in a lathe on simple jobs like grinding, turning chuck jaws,
sharpening the lathe centers and milling cutters, sizing of work
piece. for obtaining the square headed shape of the required

HEAT TREATMENT
Heat treating is a process utilized to change certain
characteristics of metals and alloys in order to make them more suitable for a particular
kind of application. In general, heat treatment is the term for any process employed
which changes the physical properties of a metal by either heating or cooling. When
properly performed; heat treating can greatly influence mechanical properties such as
strength, hardness, ductility, toughness, and wear resistance. Most carbon steels and
carbon alloy steels can be heat treated for the purpose of improving mechanical
properties such as tensile and yield strength. This is accomplished due to the heat
treatment fundamentally altering the microstructure of the steels In here we are
heating the mild steel bolt to a temperature of 800 C and rapid cooling or quenching
is done by means of dipping it in to oil or water reservoir, this is done in order increase
the hardness of the bolt. The heat treatment can be done on the muffle furnace
available in our laboratory. The figure represents the muffle furnace available in this
local market.

Advantages
Highly reliable during operation.
Easy assembling and disassembling operation.
It is adaptive to multiple operating conditions.
Relatively cheap the produce as they have been standardised.
Efficient manufacturing methods a can be adapted.

Disadvantages
All threaded fasteners introduce stress concentrations at the threads
their strength and the load carrying capability.
They require some sort of locking device, washer etc

which reduce

Applications
Transportation industries: Railways, Aircrafts, Wagons, Automobiles etc
Electrical industries: manufacturing of transformers, electric motors etc
Building activities: construction of bridges, fabrication or various steel structures
etc
Other heavy and light industries, steel and wooden furniture's, machine tools etc

COST ESTIMATION ANALYSIS

SL No.

PROCESSINGS

COST

Raw material

120

Facing process

40

Turning operation

50

Thread cutting

80

Grinding

50

Filling

20

Total

360

PROPER INSTALLATION
As like the designing, the installation is also an important
process.The proper installation of the bolt in to the preferred hole can be made possible
by the using of spanner or bolt driver arrangement. The bolt should be tightened only
to the maximum preferred torque. Or else failure may occur on the application of the
load to the bolt.

CONCLUSION
Thus the square headed bolt is designed and fabricated for the eccentrically
loaded condition. As our given condition is to withstand an eccentrically applied load of
20 KN, an M12 bolt is designed from the proper design procedures and the bolt is
fabricated on the basis of the basic dimensions taken from the PSG DATA BOOK.
On the successful completion of this project, we know the difficulties and the
problems occurred in design and fabrication project. While fabricating this project we
know,
How to design a bolt.
Various factors involved in the design.
Steps involved in the fabrication of bolts.
Importance of team work and leadership.
Importance of guidance.

FUTURE SCOPE
Replacing the conventional bolts with heat treated bolt increases the tensile strength
and hence power losses while transmission could be reduced and life is increased.
An efficient design and manufacturing process of bolt can reduce the cost and

REFERENCE

1) Design of machine elements by M.F.Spotts, Prentice hall of India,

1991.
2) Machine design-an integrated approach by Robert L. Norton, Pearson
Education Ltd, 2001.
3) A textbook of machine design by P.C.Sharma and D.K.Agarwal,
S.K.Kataria and sons, 1998.
4) Mechanical engineering design by Joseph E. Shigley, McGraw Hill,
1986.
5) Fundamentals of machine component design, 3rd edition, by Robert
C.
Juvinall and Kurt M. Marshek, John Wiley & Sons, 2000.
6) The elements of machine design by S.J.Berard and E.O.Waters, Divan
Nostrand Company, 1927.
7) Design of Steel Structures by Sri A.S. Arya.