Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) © MPGroover 2007

33 MECHANICAL ASSEMBLY
Review Questions
33.1 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.
33.2 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.
33.3 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.
33.4 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.
33.5 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).
33.6 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.
33.7 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, or
(3) excessive tensile load on the cross-sectional area of the bolt or screw.
33.8 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.
33.9 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.
33.10 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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33.11 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.
33.12 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.
33.13 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: (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.
33.14 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: (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.

Multiple Choice Quiz

There is a total of 18 correct answers in the following multiple-choice questions (some questions have
multiple answers that are correct). To attain a perfect score on the quiz, all correct answers must be given.
Each correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point,
and each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage
score on the quiz is based on the total number of correct answers.
33.1 Most externally threaded fasteners are produced by which of the following processes (one best
answer): (a) cutting the threads, (b) milling the threads, (c) tapping, (d) thread rolling, or (e) turning
the threads?
Answer. (d).
33.2 Which of the following methods and tools are used for applying the required torque to achieve a
desired preload of a threaded fastener (three best answers): (a) arbor press, (b) preload method, (c)
sense of feel by a human operator, (d) snap fit, (e) stall-motor wrenches, (f) torque wrench, and (g)
use of lockwashers?
Answer. (c), (e), and (f).
33.3 Which of the following are reasons for using mechanical assembly (three best answers): (a) ease of
assembly, (b) ease of disassembly, (c) economies of scale, (d) involves melting of the base parts, (e)
no heat affected zone in the base parts, and (f) specialization of labor?
Answer. (a), (b), and (e).

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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) © MPGroover 2007

33.4 Which of the following are the common ways in which threaded fasteners fail during tightening (two
best answers): (a) excessive compressive stresses on the head of the fastener due to force applied by
the tightening tool, (b) excessive compressive stresses on the shank of the fastener, (c) excessive
shear stresses on the shank of the fastener, (d) excessive tensile stresses on the head of the fastener
due to force applied by the tightening tool, (e) excessive tensile stresses on the shank of the fastener,
and (f) stripping of the internal or external threads?
Answer. (e) and (f).
33.5 The difference between a shrink fit and an expansion fit is that in a shrink fit the internal part is
cooled to a sufficiently low temperature to reduce its size for assembly, whereas in an expansion fit,
the external part is heated sufficiently to increase its size for assembly: (a) true, or (b) false?
Answer. (b). In a shrink fit the external part is heated and then cooled to shrink it onto the internal
part. In an expansion fit, the internal part is cooled to contract it for assembly; it then expands to form
the interference fit.
33.6 Advantages of snap fit assembly include which of the following (three best answers): (a) components
can be designed with features to facilitate part mating, (b) ease of disassembly, (c) no heat affected
zone, (d) no special tools are required, (e) parts can be assembled quickly, and (f) stronger joint than
with most other assembly methods?
Answer. (a), (d), and (e).
33.7 The difference between industrial stitching and stapling is that the U-shaped fasteners are formed
during the stitching process while in stapling the fasteners are preformed: (a) true, or (b) false?
Answer. (a).
33.8 From the standpoint of assembly cost, it is more desirable to use many small threaded fasteners rather
than few large ones in order to distribute the stresses more uniformly: (a) true, or (b) false?
Answer. (b). From the standpoint of assembly cost, it is more desirable to use few large threaded
fasteners rather than many small ones because the large fasteners are easier to handle and since there
are fewer of them, they require less assembly time.
33.9 Which of the following are considered good product design rules for automated assembly (two best
answers): (a) design the assembly with the fewest number of components possible; (b) design the
product using bolts and nuts to allow for disassembly; (c) design with many different fastener types to
maximize design flexibility; (d) design parts with asymmetric features to mate with other parts having
corresponding (but reverse) features; and (e) limit the required directions of access when adding
components to a base part?
Answer. (a) and (e). All of the other answers go against design-for-assembly principles.

Problems
Threaded Fasteners
33.1 A 5-mm diameter bolt is to be tightened to produce a preload = 250 N. If the torque coefficient =
0.23, determine the torque that should be applied.
Solution: T = CtDF = 0.23(5.0)(250) = 287.5 N-mm = 0.2875 N-m.
33.2 A 3/8-24 UNF nut and bolt (3/8 in nominal diameter, 24 threads/in) are inserted through a hole in
two stacked steel plates. They are tightened so the plates are clamped together with a force of 1000
lb. The torque coefficient is 0.20. (a) What is the torque required to tighten them? (b) What is the
resulting stress in the bolt?

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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) © MPGroover 2007

Solution (a) T = CtDF = 0.20(3/8)(1000) = 75 in/lb

(b) As= 0.25π(D – 0.9743/n)2 = 0.25π(3/8 – 0.9743/24)2 = 0.0878 in2
σ = F/As = 1000/0.0878 = 11,386 lb/in2
33.3 An alloy steel Metric 10 x 1.5 screw (10 mm diameter, pitch p = 1.5 mm) is to be turned into a
threaded hole and tightened to one/half of its proof strength. According to Table 33.2, the proof
strength = 830 MPa. Determine the maximum torque that should be used if the torque coefficient =
0.18.
Solution: As = 0.25π(10 - 0.9382 x 1.5)2 = 57.99 mm2
σ = 0.5 of 830 MPa = 415 MPa = 415 N/mm2
F = σAs = 415(57.99) = 24,066 N.
T = CtDF = 0.18(10)(24,066) = 43,319 N-mm = 43.32 N-m.
33.4 A M16x2 bolt (16 mm diameter, 2 mm pitch) is subjected to a torque of 15 N-m during tightening.
If the torque coefficient is 0.24, determine the tensile stress on the bolt.
Solution: T = 15 N-m = 15,000 N-mm
F = T/ CtD = 15,000/(0.24 x 16) = 3906 N.
As = 0.25π(16 - 0.9382 x 2)2 = 156.7 mm2
σ = 3906/156.7 = 24.9 N/mm2 = 24.9 MPa.
33.5 A 1/2-in diameter screw is to be preloaded to a tension force = 1000 lb. Torque coefficient = 0.22.
Determine the torque that should be used to tighten the bolt.
Solution: T = CtDF = 0.22(0.50)(1000) = 110 in-lb.
33.6 Threaded metric fasteners are available in several systems, two of which are coarse and fine (Table
33.1). Finer threads are not cut as deep and as a result have a larger tensile stress area for the same
nominal diameter. (a) Determine the maximum preload that can be safely achieved for coarse pitch
and fine pitch threads for a 12 mm bolt. (b) Determine the percent increase in preload of fine
threads compared to course threads. Coarse threads are 12-2.0 and fine threads are 12-1.5. Assume
the proof strength for both bolts is 600 MPa.
Solution: (a) For standard thread:
As = 0.25π(D – 0.9382p)2 = 0.25π(12 – 0.9382 x 2.0)2 = 80.5 mm2
F = Asσ = 80.5(600) = 48,296 N
For fine thread:
As = 0.25π(D – 0.9382p)2 = 0.25π(12 – 0.9382 x 1.50)2 = 88.1 mm2
F = Asσ = 88.13(600) = 52,880 N
(b) Percent increase = (52,880 – 48,296)/48,296 = 0.0949 = 9.5 % increase
33.7 A torque wrench is used on a 7/8-9 UNC bolt (7/8 in nominal diameter, 9 threads/in) in an
automobile final assembly plant. A torque of 70 ft-lb is generated by the wrench. If the torque
coefficient = 0.17, determine the tensile stress in the bolt.
Solution: T = 70 ft-lb = 840 in-lb
F = T/CtD = 840/(0.17 x 0.875) = 5647 lb.
As = 0.25π(0.875 - 0.9743/9)2 = 0.4617 in2
σ = 5647/0.4617 = 12,231 lb/in2
33.8 The designer has specified that a 3/8-16 UNC low-carbon bolt (3/8 in nominal diameter, 16
threads/in) in a certain application should be stressed to its proof stress of 33,000 lb/in2 (see Table
33.1). Determine the maximum torque that should be used if C = 0.25.
Solution: As = 0.25π(0.375 - 0.9743/16)2 = 0.0775 in2
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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) © MPGroover 2007

F = σAs = 33,000(0.0775) = 2557.5 lb

T = CtDF = 0.25(0.375)(2557.5) = 240 in-lb
33.9 A 300 mm long wrench is used to tighten an M20-2.5 bolt. The proof strength of the bolt for the
particular alloy is 380 MPa. The torque coefficient is 0.21. Determine the maximum force that can
be applied to the end of the wrench so that the bolt does not permanently deform.
Solution: As = 0.25π(D – 0.9382p)2 = 0.25π(20 – 0.9382*2.50)2 = 244.8 mm2
Preload force, F = Asσ = 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
33.10 A 1-8 UNC low carbon steel bolt (diameter = 1.0 in, 8 threads/in) is currently planned for a certain
application. It is to be preloaded to 75% of its proof strength, which is 33,000 lb/in2 (Table 33.1).
However, this bolt is too large for the size of the components involved, and a higher strength but
smaller bolt would be preferable. Determine (a) the smallest nominal size of an alloy steel bolt
(proof strength = 120,000 lb/in2) 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; and
(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 = 0.25π(1.0 - 0.9743/8)2 = 0.6057 in2
F = σAs = 0.75(33,000)(0.6057) = 14,992 lb.
For the alloy bolt, σ = 120,000 lb/in2.
As = F/σ = 14992/(0.75 x 120,000) = 0.1665 in2
As = 0.1665 in2 = 0.25π(D - 0.9743/n)2
(D - 0.9743/n)2 = 0.1665 in2/0.25π = 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 (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
33.11 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 16.0 mm, and the collar has an outside diameter of 27.0 mm. (a)
Compute the radial pressure and the maximum effective stress if the interference between the shaft
OD and the collar ID is 0.03 mm. (b) Determine the effect of increasing the outside diameter of the
collar to 39.0 mm on the radial pressure and the maximum effective stress.
Solution: (a) pf = Ei(Dc2 - Dp2)/DpDc2 = 209,000(0.03)(272 - 162)/(16 x 272) = 254 MPa
Max σe = 2pfDc2/(Dc2 - Dp2) = 2(254.3)(272)/(272 - 162) = 784 MPa
(b) When Dc = 39 mm, pf = 209,000(0.03)(392 - 162)/(16 x 392) = 326 MPa
Max σe = 2(325.9)(392)/(392 - 162) = 784 MPa
33.12 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 2.497 in. The pin has a diameter of 2.500 in. The base of the machine is 4 ft x
8 ft. The base and pin have a modulus of elasticity of 30x106 lb/in2, a yield strength of 85,000 lb/in2,
and a tensile strength of 120,000 lb/in2. Determine (a) the radial pressure between the pin and the
base and (b) the maximum effective stress in the interface.

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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) © MPGroover 2007

Solution: (a) pf = Ei/Dp = 30x106 (0.003)/2.5 = 36,000 lb/in2

(b) Max σe = 2pf = 2(36,000) = 72,000 lb/in2
33.13 A gear made of aluminum (modulus of elasticity = 69,000 MPa) is press-fitted onto an aluminum
shaft. The gear has a diameter of 55 mm at the base of its teeth. The nominal internal diameter of
the gear = 30 mm and the interference = 0.10 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(0.10)(552 - 302)/(30 x 552) = 161.5 MPa
(b) Max σe = 2pfDc2/(Dc2 - Dp2) = 2(161.5)(552)/ (552 - 302) = 460 MPa
33.14 A steel collar is press fitted onto a steel shaft. The modulus of elasticity of steel is 30 x 106 lb/in2.
The collar has an internal diameter of 2.498 in and the shaft has an outside diameter = 2.500 in. The
outside diameter of the collar is 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) 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 σe = 2pfDc2/(Dc2 - Dp2) = 2(14,625)(4.0002)/ (4.0002 – 2.5002) = 48,000 lb/in2
33.15 The yield strength of a certain metal = 50,000 lb/in2 and its modulus of elasticity = 22 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 σe ≤ Y/SF , use Max σe = Y/SF = 50,000/2.0 = 25,000 lb/in2 Eq. (33.9)
Max σe = 2pfDc2/(Dc2 - Dp2) = 25,000 lb/in2 Eq. (33.6)
Rearranging, pf = σe(Dc2 - Dp2)/2Dc2 = 25,000(2.52 - 1.02)/(2 x 2.52) = 10,500 lb/in2
pf = Ei(Dc2 -Dp2)/DpDc2 Eq. (33.5)
Rearranging, i = pf DpDc2/E(Dc2 - Dp2)
i = 10,500(1.0)(2.52)/(22 x 106 (2.52 - 1.02)) = 0.00057 in
33.16 A shaft made of aluminum is 40.0 mm in diameter at room temperature (21°C). Its coefficient of
thermal expansion = 24.8 x 10-6 mm/mm per °C. If it must be reduced in size by 0.20 mm in order
to be expansion fitted into a hole, determine the temperature to which the shaft must be cooled.
Solution: (D2 - D1) = -0.20 = 24.8 x 10-6(40)(T2 - 21)
T2 - 21 = -0.20/(24.8 x 10-6 x 40) = -201.6
T2 = -201.6 + 21 = -180.6°C
33.17 A steel ring has an inside diameter = 30 mm and an outside diameter = 50 mm at room temperature
(21°C). If the coefficient of thermal expansion of steel = 12.1 x 10-6 mm/mm per °C, determine the
inside diameter of the ring when heated to 500°C.
Solution: D2 - D1 = D2 - 30 = 12.1 x 10-6(30)(500 - 21)
D2 = 30 + 0.174 = 30.174 mm.
33.18 A steel collar is to be heated from room temperature (70°F) to 700°F. Its inside diameter = 1.000 in,
and its outside diameter = 1.625 in. If the coefficient of thermal expansion of the steel is = 6.7 x 10-6
in/in per °F, determine the increase in the inside diameter of the collar.
Solution: (D2 - D1) = αD1(T2 - T1) = 6.7 x 10-6(1.0)(700 - 70) = 4221 x 10-6 = 0.0042 in
33.19 A bearing for the output shaft of a 200 hp motor is to be heated to expand it enough to press on the
shaft. At 70°F 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 for the shaft and bearing is
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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) © MPGroover 2007

30x106 lb/in2 and the coefficient of thermal expansion is 6.7x10-6 in/in per °F. (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)
T2 = (D2 – D1)/αD1 + T1 = 0.009/(6.7x10-6 x 4.000) + 70 = 336°F
(b) pf = Ei (Dc2 – Dp2)/DpDc2 = 30x106(0.004)(72 – 42)/(4 x 72) = 20,204 lb/in2
(c) Max σe = 2pfDc2/(Dc2 - Dp2) = 2(20,204)(72)/(72 – 42) = 60,000 lb/in2
33.20 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 an elevated temperature
of 1000°F, 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
(70°F). For steel, the elastic modulus = 30,000,000 lb/in2 and coefficient of thermal expansion = 6.7
x 10-6 in/in per °F.
Solution: (a) 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 σe = 2(34,950)(3.02)/ (3.02 - 1.52) = 93,200 lb/in2
33.21 A pin is to be inserted into a collar using an expansion fit. Properties of the pin and collar metal are:
coefficient of thermal expansion is 12.3 x 10-6 m/m/°C, yield strength is 400 MPa, and modulus of
elasticity is 209 GPa. At room temperature (20°C), 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. (a) What is the temperature to which the pin must be cooled for assembly?
(b) What is the radial pressure at room temperature after assembly? (c) What is the safety factor in
the resulting assembly?
Solution: (a) D2 – D1 = αD1(T2 – T1) =
T2 = (D2-D1)/(αD1) + T1 = ((60.00-0.06) – 60.03)/(12.3x10-6*60.03) + 20 = 101.9°C
(b) pf = Ei(Dc2 - Dp2)/DpDc2
pf = 209x109(0.03)(952 – 602)/(60(952) = 0.0628(109) N/m2 = 62.8 MPa
(c) Max σe = 2pfDc2/(Dc2 – Dp2) = 2(62.8)(952)/(952 – 602) = 209 MPa
If Y = 400 MPa and Max σe = Y/SF, then SF = Y/( Max σe ) = 400/209 = 1.91

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