Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

31 MECHANICAL ASSEMBLY
Review Questions
31.1 How does mechanical assembly differ from the other methods of assembly discussed in previous
chapters (e.g., welding, brazing, etc.)?
Answer. Mechanical assembly uses a mechanical fastening method for joining two (or more) parts,
whereas welding, brazing, soldering, and adhesive bonding use heat and/or pressure, sometimes
combined with a filler material to permanently join parts. Also, many of the mechanical fastening
methods allow for disassembly - not possible with welding and brazing.
31.2 What are some of the reasons why assemblies must be sometimes disassembled?
Answer. For maintenance and repair service, to replace worn-out components, and to make
adjustments.
31.3 What is the technical difference between a screw and a bolt?
Answer. Both are externally threaded fasteners. A screw is generally assembled into a blind
threaded hole, whereas a bolt is assembled using a nut.
31.4 What is a stud (in the context of threaded fasteners)?
Answer. A stud is an externally threaded fastener that does not have the usual head possessed by a
bolt.
31.5 What is torque-turn tightening?
Answer. Torque-turn tightening involves the tightening of the threaded fastener to a certain low
torque level, and then advancing the fastener by a specified additional amount of turn (e.g., a
quarter turn).
31.6 Define proof strength as the term applies in threaded fasteners.
Answer. Proof strength can be defined as the maximum tensile stress that an externally threaded
fastener can sustain without permanent deformation.
31.7 What are the three ways in which a threaded fastener can fail during tightening?
Answer. (1) Stripping of the bolt or screw threads, (2) stripping of the internal fastener threads, and
(3) excessive tensile load on the cross-sectional area of the bolt or screw.
31.8 What is a rivet?
Answer. A rivet is an unthreaded headed pin used to join two parts by inserting the pin through
holes in the parts and deforming the unheaded portion over the opposite side.
31.9 What is the difference between a shrink fit and expansion fit in assembly?
Answer. In a shrink fit, the outside part is expanded by heating to fit over the mating component.
Then cooling causes an interference fit with the component. In an expansion fit, the internal part is
cooled so that it can be readily inserted into the mating component. Then, upon warming to room
temperature, it expands to cause an interference fit with its mating part.
31.10 What are the advantages of snap fitting?
Answer. Advantages of snap fitting include (1) the method is fast, (2) no tooling is required, and (3)
the parts can be designed with self-aligning features for ease of mating.
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

31.11 What is the difference between industrial stitching and stapling?

Answer. In stitching the U-shaped fasteners are formed during the assembly process. In stapling,
the fasteners are preformed.
31.12 What are integral fasteners?
Answer. Integral fasteners make use of a forming operation on one of the parts to be joined to
interlock the components and create a mechanically fastened joint.
31.13 Identify some of the general principles and guidelines for design for assembly.
Answer. Some of the general principles and guidelines in design for assembly include the
following: (1) Use the fewest number of parts possible to reduce assembly required. (2) Reduce
the number of threaded fasteners; instead use snap fits, retaining rings, integral fasteners, and
similar fastening mechanisms that can be accomplished more rapidly. Use threaded fasteners only
where justified, e.g., where disassembly or adjustment is required. (3) Standardize fasteners in
order to reduce the number of sizes and styles in the product. (4) Design parts to be symmetrical
and minimize asymmetric features. (5) Avoid parts that tangle.
31.14 Identify some of the general principles and guidelines that apply specifically to automated
assembly.
Answer. Some of the principles and guidelines that apply specifically to automated assembly
include the following: (1) Use modularity in product design. Each module to be produced on a
single assembly system should have a maximum of 12 or 13 parts and should be designed around
a base part to which other components are added. (2) Reduce the need for multiple components to
be handled at once. (3) Limit the required directions of access. The ideal is for all components to be
added vertically from above. (4) Use only high quality components. Poor quality components cause
jams in feeding and assembly mechanisms. (5) Use snap fit assembly to eliminate the need for
threaded fasteners.

Problems
Answers to problems labeled (A) are listed in an Appendix at the back of the book.
Threaded Fasteners
31.1 (A) (SI units) A metric 6x1.0 bolt is tightened to produce a preload = 200 N. The torque coefficient
= 0.20. Determine (a) the torque that is applied and (b) the resulting stress on the bolt.
Solution: (a) T = CtDF = 0.23(6.0)(200) = 240 N-mm = 0.24 N-m
(b) As = 0.25(D 0.9382p)2 = 0.25 (6.0 0.9382(1.0))2 = 20.12 mm2
= F/As = 200/20.12 = 9.94 N/mm2 = 9.94 MPa
31.2 (USCS units) A 3/8-16 UNC nut and bolt are used to assemble steel plates. The clearance holes in
the plates are 7/16 in. The plates are clamped together by the nut and bolt with a force of 800 lb. If
the torque coefficient is 0.20, determine (a) the torque that is applied and (b) the resulting stress on
the bolt.
Solution (a) T = CtDF = 0.20(3/8)(800) = 60 in-lb
(b) As= 0.25(D 0.9743/n)2 = 0.25(3/8 0.9743/16)2 = 0.0775 in2
= F/As = 800/0.0775 = 10,324 lb/in2
31.3 (SI units) An alloy steel metric 10x1.25 screw is used in a threaded hole and tightened to 40% of its
proof strength (see Table 31.2). Determine the maximum torque that should be used if the torque
coefficient = 0.18.
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

Solution: As = 0.25(10 - 0.9382 x 1.25)2 = 61.2 mm2

= 0.4 of 830 MPa = 332 MPa = 332 N/mm2
F = As = 332(61.2) = 20,318 N
T = CtDF = 0.18(10)(20,318) = 36,573 N-mm = 36.6 N-m
31.4 (SI units) A metric 12x1.75 bolt is subjected to a torque of 20 N-m during tightening. If the torque
coefficient is 0.24, determine the tensile stress on the bolt.
Solution: T = 20 N-m = 20,000 N-mm
F = T/ CtD = 20,000/(0.24 x 12) = 8333 N
As = 0.25(12 - 0.9382 x 1.75)2 = 84.27 mm2
= 8333/84.27 = 98.9 N/mm2 = 98.9 MPa
31.5 (USCS units) A 1/2-20 UNF screw is preloaded to a tension force = 750 lb. The torque coefficient =
0.22. Determine (a) the torque that should be applied and (b) the resulting stress on the bolt.
Solution: (a) T = CtDF = 0.22(0.50)(750) = 82.5 in-lb
(b) As= 0.25(D 0.9743/n)2 = 0.25(1/2 0.9743/20)2 = 0.160 in2
= F/As = 750/0.16 = 4,689 lb/in2
31.6 (SI units) Threaded metric fasteners are available in several systems, two of which are given in
Table 31.1: coarse and fine. Fine threads are not cut as deep and as a result have a larger tensile
stress area for the same nominal diameter. Determine (a) the maximum preload that can be safely
achieved for coarse pitch and fine pitch threads for a 12 mm bolt and (b) the percent increase in
preload of fine threads compared to course threads. Use a proof strength for both bolts = 600 MPa.
Solution: (a) For standard thread,
As = 0.25(D 0.9382p)2 = 0.25(12 0.9382 x 1.75)2 = 84.3 mm2
F = As = 84.3(600) = 50,560 N
For fine thread,
As = 0.25(D 0.9382p)2 = 0.25(12 0.9382 x 1.25)2 = 92.1 mm2
F = As = 92.1(600) = 55,243 N
(b) Percent increase = (55,243 50,560)/50,560 = 0.0926 = 9.26 % increase
31.7 (USCS units) A pneumatic torque wrench is used to tighten 3/4-10 UNC bolts in an automobile
final assembly plant. A torque of 50 ft-lb is generated by the wrench. If the torque coefficient =
0.20, determine the tensile stress in the bolt.
Solution: T = 50 ft-lb = 600 in-lb
F = T/CtD = 600/(0.20 x 0.75) = 4000 lb.
As = 0.25(0.75 - 0.9743/10)2 = 0.334 in2
= 4000/0.334 = 11,976 lb/in2
31.8 (A) (USCS units) The designer has specified that a 3/8-16 UNC low-carbon steel bolt in a certain
application should be stressed to 50% of its proof stress (see Table 31.2). Determine the maximum
torque that should be used if the torque coefficient = 0.25.
Solution: As = 0.25(0.375 - 0.9743/16)2 = 0.0775 in2
From Table 31.2, proof stress for low-carbon steel bolt = 33,000 lb/in2
F = As = 0.50(33,000)(0.0775) = 1279 lb
T = CtDF = 0.25(0.375)(1279) = 120 in-lb
31.9 (SI units) A 300-mm-long wrench is used to tighten a metric 20x2.5 bolt. The proof strength of the
bolt for the particular alloy is 380 MPa. The torque coefficient = 0.21. Determine the maximum
force that can be applied to the end of the wrench so that the bolt does not permanently deform.
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

Solution: As = 0.25(D 0.9382p)2 = 0.25(20 0.9382*2.50)2 = 244.8 mm2

Preload force, F = As = 244.8(380) = 93,022 N
T = CtDF = 0.21(20)(93,022) = 390,690 N-mm
T = FwrenchLwrench ; Fwrench = T/Lwrench = 390,690/300 = 1302 N
31.10 (USCS units) It is desired to determine the value of the torque coefficient for a group of nut and bolt
applications involving the fastening of steel sheet metal parts. Experiments have been carried out on
several sizes of nuts and bolts that will be used in the applications. For 10-24 UNC bolts, a torque of
17 in-lb produced an average tension force = 408 lb; for -20 UNC bolts, a torque of 28 in-lb
produced an average tension force = 498 lb; and for -13 bolts, a torque of 67 in-lb produced an
average tension force = 602 lb. What value of torque coefficient is indicated by this data?
Solution: Given the data, probably the simplest way to determine the torque coefficient is to
calculate the value for each of the data sets and then average them.
Rearranging the torque equation (T = CtDF), Ct = T/DF
For the 10-24 UNC bolts (nominal diameter = 0.190 in), Ct = (17)/(0.190)(408) = 0.219
For the 1/4-20 UNC bolts (nominal diameter = 0.25 in), Ct = (28)/(0.25)(498) = 0.225
For the 1/2-13 UNC bolts (nominal diameter = 0.50 in), Ct = (68)/(0.5)(602) = 0.226
The average value of Ct = 0.223
31.11 (USCS units) A 1-8 UNC low carbon steel bolt (diameter = 1.0 in, 8 threads/in) is currently used for
a certain application. It is preloaded to 75% of its proof strength (see Table 31.2). However, this bolt
is too large for the size of the components involved, and a higher-strength smaller bolt would be
preferable. Determine (a) the smallest nominal size of an alloy steel bolt that could be used to
achieve the same preload from the following standard UNC sizes used by the company: 1/4-20,
5/16-18, 3/8-16, 1/2-13, 5/8-11, or 3/4-10. (b) Compare the torque required to obtain the preload for
the original 1-in bolt and the alloy steel bolt selected in part (a) if the torque coefficient in both
cases = 0.20.
Solution: (a) As = 0.25(1.0 - 0.9743/8)2 = 0.6057 in2
F = As = 0.75(33,000)(0.6057) = 14,992 lb.
For the alloy bolt, = 120,000 lb/in2.
As = F/ = 14992/(0.75 x 120,000) = 0.1665 in2
As = 0.1665 in2 = 0.25(D - 0.9743/n)2
(D - 0.9743/n)2 = 0.1665 in2/0.25 = 0.212 in2
(D - 0.9743/n) = 0.4605 in
Possible bolt sizes are: (1) 1/4-20, (2) 5/16-18, (3) 3/8-16, (4) 1/2-13, (5) 5/8-11, (6) 3/4-10
Try (1): (D - 0.9743/n) = (0.25 - 0.9743/20) = 0.2013 in. Obviously, none of the D values below
0.4605 will be sufficient.
Try (4): (D - 0.9743/n) = (0.500 - 0.9743/13) = 0.425 in < 0.4605 in. Cannot use -13 bolt
Try (5): (D - 0.9743/n) = (0.625 - 0.9743/11) = 0.5364 in > 0.4605 in. Use 5/8-11 bolt
(b) For the original 1-8 bolt, T = CtDF = 0.2(1.0)(14,992) = 2,998 in-lb
For the 5/8-11 bolt, T = CtDF = 0.2(0.625)(14,992) = 1,874 in-lb
Interference Fits
31.12 (SI units) A dowel pin made of steel (elastic modulus = 209,000 MPa) is to be press fitted into a
steel collar. The pin has a nominal diameter of 15.0 mm, and the collar has an outside diameter of
20.0 mm. (a) Compute the radial pressure and the maximum effective stress if the interference
between the shaft OD and the collar ID is 0.02 mm. (b) Determine the effect of increasing the
outside diameter of the collar to 30.0 mm on the radial pressure and the maximum effective stress.
Solution: (a) pf = Ei(Dc2 - Dp2)/DpDc2 = 209,000(0.02)(202 - 152)/(15 x 202) = 122 MPa
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

Max e = 2pfDc2/(Dc2 - Dp2) = 2(122)(202)/(202 - 152) = 557 MPa

(b) When Dc = 30 mm, pf = 209,000(0.02)(302 - 152)/(15 x 302) = 209 MPa
Max e = 2(209)(302)/(302 - 152) = 557 MPa
31.13 (USCS units) A pin made of alloy steel is press-fitted into a hole machined in the base of a large
machine. The hole has a diameter of 1.498 in. The pin has a diameter of 1.500 in. The base of the
machine is 4 ft x 8 ft and is the same steel as the pin: modulus of elasticity = 30 x 106 lb/in2, yield
strength = 85,000 lb/in2, and a tensile strength = 120,000 lb/in2. Determine (a) the radial pressure
between the pin and the base and (b) the maximum effective stress in the interface.
Solution: (a) i = 2.500 2.498 = 0.002 in
pf = Ei/Dp = 30x106 (0.002)/1.5 = 40,000 lb/in2
(b) Max e = 2pf = 2(40,000) = 80,000 lb/in2
31.14 (A) (SI units) A gear made of an aluminum alloy (modulus of elasticity = 69,000 MPa) is press
fitted onto an aluminum shaft. The gear has a diameter of 50 mm at the base of its teeth. The
nominal internal diameter of the gear = 30 mm, and the interference = 0.03 mm. Compute (a) the
radial pressure between the shaft and the gear, and (b) the maximum effective stress in the gear at its
inside diameter.
Solution: (a) pf = Ei(Dc2 - Dp2)/DpDc2 = 69,000(0.03)(502 - 302)/(30 x 502) = 44.16 MPa
(b) Max e = 2pfDc2/(Dc2 - Dp2) = 2(44.16)(502)/ (502 - 302) = 138 MPa
31.15 (USCS units) A steel collar is press fitted onto a steel shaft. The modulus of elasticity of steel = 30 x
106 lb/in2. The collar has an internal diameter = 2.498 in, and the shaft has an outside diameter =
2.500 in. The outside diameter of the collar = 4.000 in. Determine the radial (interference) pressure
on the assembly, and (b) the maximum effective stress in the collar at its inside diameter.
Solution: (a) i = 2.500 2.498 = 0.002 in
pf = Ei(Dc2 - Dp2)/DpDc2 = 30 x 106(0.002)(4.0002 -2.5002)/(2.500 x 4.0002) = 14,625 lb/in2
(b) Max e = 2pfDc2/(Dc2 - Dp2) = 2(14,625)(4.0002)/ (4.0002 2.5002) = 48,000 lb/in2
31.16 (USCS units) The yield strength of a magnesium alloy = 25,000 lb/in2, and its modulus of elasticity
= 7 x 106 lb/in2. It is to be used for the outer ring of a press-fit assembly with a mating shaft made of
the same metal. The nominal inside diameter of the ring is 1.000 in and its outside diameter = 2.500
in. Using a safety factor = 2.0, determine the maximum interference that should be used with this
assembly.
Solution: Max e Y/SF , use Max e = Y/SF = 25,000/2.0 = 12,500 lb/in2 Eq. (31.9)
Max e = 2pfDc2/(Dc2 - Dp2) = 12,500 lb/in2 Eq. (31.6)
Rearranging, pf = e(Dc2 - Dp2)/2Dc2 = 12,500(2.52 - 1.02)/(2 x 2.52) = 5,250 lb/in2
pf = Ei(Dc2 -Dp2)/DpDc2 Eq. (31.5)
Rearranging, i = pf DpDc2/E(Dc2 - Dp2)
i = 5,250(1.0)(2.52)/(7 x 106 (2.52 - 1.02)) = 0.00089 in
31.17 (USCS units) A steel collar is to be heated from room temperature (70F) to 700F. Its inside
diameter = 1.000 in, and its outside diameter = 1.625 in. The coefficient of thermal expansion for
steel is given in Table 4.1. Determine the increase in the inside diameter of the collar.
Solution: From Table 4.1, the coefficient of thermal expansion for steel = 6.7(10-6) F-1
(D2 - D1) = D1(T2 - T1) = 6.7 x 10-6(1.0)(700 - 70) = 4221 x 10-6 = 0.0042 in
31.18 (SI units) A shaft made of aluminum is 25.0 mm in diameter at room temperature (21C). The
coefficient of thermal expansion for aluminum is given in Table 4.1. If it must be reduced in size by
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

0.12 mm in order to be expansion fitted into a hole, determine the temperature to which the shaft
must be cooled.
Solution: From Table 4.1, the coefficient of thermal expansion for aluminum = 24(10-6) C-1
(D2 - D1) = D1(T2 - T1) = -0.12 = 24 x 10-6(25)(T2 - 21)
T2 - 21 = -0.12/(24.8 x 10-6 x 25) = -200
T2 = -200 + 21 = -179C
31.19 (SI units) A steel ring has an inside diameter = 30 mm and an outside diameter = 50 mm at room
temperature (21C). The coefficient of thermal expansion for steel is given in Table 4.1. Determine
the inside diameter of the ring when heated to 400C.
Solution: From Table 4.1, the coefficient of thermal expansion for steel = 12(10-6) C-1
(D2 - D1) = D1(T2 - T1) = D2 - 30 = 12 x 10-6(30)(400 - 21) = 0.136 mm
D2 = 30 + 0.136 = 30.136 mm
31.20 (A) (USCS units) A steel bearing for the output shaft of a 200 hp motor is to be heated to expand it
enough to press on a steel shaft. At 70F the bearing has an inside diameter of 4.000 in and an
outside diameter of 7.000 in. The shaft has an outside diameter of 4.004 in. The modulus of
elasticity and coefficient of thermal expansion for steel are given in Tables 3.1 and 4.1, respectively.
(a) At what temperature will the bearing have 0.005 of clearance to fit over the shaft? (b) After it is
assembled and cooled, what is the radial pressure between the bearing and shaft? (c) Determine the
maximum effective stress in the bearing.
Solution: (a) Interference i = 0.004 in, additional required clearance = 0.005 in
Total expansion = 0.004+0.005 = 0.009 in = (D2 D1)
From Table 3.1, E = 30 x 106 lb/in2; and from Table 4.1, = 6.7x10-6 F-1
T2 = (D2 D1)/D1 + T1 = 0.009/(6.7x10-6 x 4.000) + 70 = 336 + 70 = 406F
(b) pf = Ei (Dc2 Dp2)/DpDc2 = 30x106(0.004)(72 42)/(4 x 72) = 20,204 lb/in2
(c) Max e = 2pfDc2/(Dc2 - Dp2) = 2(20,204)(72)/(72 42) = 60,000 lb/in2
31.21 (USCS units) A steel collar whose outside diameter = 3.000 in at room temperature is to be shrink
fitted onto a steel shaft by heating it to an elevated temperature while the shaft remains at room
temperature. The shaft diameter = 1.500 in. For ease of assembly when the collar is heated to a
temperature = 1000F, the clearance between the shaft and the collar is to be 0.007 in. Determine (a)
the initial inside diameter of the collar at room temperature so that this clearance is satisfied, (b) the
radial pressure, and (c) maximum effective stress on the resulting interference fit at room
temperature (70F). The modulus of elasticity and coefficient of thermal expansion for steel are
given in Tables 3.1 and 4.1, respectively.
Solution: (a) From Table 3.1, E = 30 x 106 lb/in2; and from Table 4.1, = 6.7x10-6 F-1
If the clearance = 0.007 in, then the inside diameter of the collar must be
D2 = Dp + 0.007 = 1.500 + 0.007.
1.507 - D1 = 6.7 x 10-6 D1(1000 - 70)
1.507 - D1 = 0.00623 D1
1.507 = D1 + 0.00623 D1 = 1.00623 D1
D1 = 1.507/1.00623 = 1.4977 in
(b) Interference i = 1.500 - 1.4977 = 0.00233 in
pf = 30 x 106 (0.00233)(3.02 - 1.52)/(1.5 x 3.02) = 34,950 lb/in2
(c) Max e = 2(34,950)(3.02)/ (3.02 - 1.52) = 93,200 lb/in2

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31.22 (SI units) A pin is to be inserted into a collar of the same metal using an expansion fit. The
coefficient of thermal expansion of the metal = 12.3 x 10-6 m/m/C, its yield strength = 400 MPa,
and its modulus of elasticity = 209 GPa. At room temperature (20C), the outer and inner diameters
of the collar = 95.00 mm and 60.00 mm, respectively, and the pin has a diameter = 60.03 mm. The
pin is to be reduced in size for assembly into the collar by cooling to a sufficiently low temperature
that there is a clearance of 0.06 mm. Determine (a) the temperature to which the pin must be cooled
for assembly, and (b) the radial pressure at room temperature after assembly. (c) What is the safety
factor in the resulting assembly?
Solution: (a) D2 D1 = D1(T2 T1) =
T2 = (D2-D1)/(D1) + T1 = ((60.00-0.06) 60.03)/(12.3x10-6*60.03) + 20 = -101.9C
(b) pf = Ei(Dc2 - Dp2)/DpDc2
pf = 209x109(0.03)(952 602)/(60(952) = 0.0628(109) N/m2 = 62.8 MPa
(c) Max e = 2pfDc2/(Dc2 Dp2) = 2(62.8)(952)/(952 602) = 209 MPa
If Y = 400 MPa and Max e = Y/SF, then SF = Y/( Max e ) = 400/209 = 1.91

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