Shear strength is an easy one, but not the only one you'll be needing.
To calculate shear failure, you need shear strength of the material and the area of the material.
For shear strength, use 60% of yield strength...ie if yield strength of the material is 100 000 psi then shear strength is 60 000 psi.
Although I build very much the same as Walter, I prefer to use the screws minor diameter for calculation. A common screw for me to use is either an 8-32 or 10-32 low head socket head cap screw with a yield strength of 160 000psi. These have larger head diameters that help with bearing stress on the tube...which we'll cover in another post.
For calculation, the shear yield strength of these screws is 96 000psi.
Minor diameter of an 8-32 is .140" for an area (pi*r*r) of .0154in2
Multiply area by shear yield strength.... .0154in2 * 96 000psi to get 1478.4 lbs which is the force required to cause a yield failure in shear.
The load on the fasteners holding the "plug" into your tube is calculated by multiplying the pressure in the reservoir by the surface area exposed to pressure. I use a safety factor of 3...so I'll use enough screws to ensure that the screws will yield at a minimum of 3x my maximum working pressure.
Making sense?
Bearing stress is next.
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