Assignment #4 Solution - Spring 2014

MAE 311: Machines and Mechanisms I Spring 2014
Assignment #4 Solution Due Date: 4/7/2014

Copyright 2014 Jobaidur Rahman Khan

Problem 1 (30 Points)
Plot the following sets of stress states on a set of principal axes (an example is provided in Figure 1A of
the Appendix). Calculate the factor of safety for each stress state using both the maximum shear stress
and distortion energy failure theories. Assume steel is used that has a yield strength of 200 kpsi.

Set 1 Set 2
o
1
o
2
o
3
o
1
o
2
o
3

50 kpsi 50 kpsi 0 kpsi 50 kpsi 0 kpsi 0 kpsi

Set 3 Set 4
o
1
o
2
o
3
o
1
o
2
o
3


Solution:

All the problems are done in same way. First MSST,
1. Find principal shear stresses, like

2 1 2
1
12
o o = t ,
3 2 2
1
23
o o = t ,
3 1 2
1
13
o o = t
2. Find the maximum shear stress, | |
13 23 12 max
, , MAX t t t = t
3. Find shear yield stress, kpsi 100 S S
yp 2
1
sy
= =
4. Find factor of safety,
max sy
S n t =

Then DE,
1. Find von-Mises stresses, like
( ) ( ) ( )
2
1
2
3 1
2
3 2
2
2 1
2 2 2
'
(
o o
+
o o
+
o o
= o
2. Find factor of safety, ' S n
yp
o =

The results are shown in following table


Set o
1
o
2
o
3
t
12
t
23
t
13
t
max
S
y
n (MSST) n (DE)
50.0 50.0 0.0 0.0 25.0 25.0 25.0 50.0 4.000 4.000
100.0 100.0 0.0 0.0 50.0 50.0 50.0 100.0 2.000 2.000
150.0 150.0 0.0 0.0 75.0 75.0 75.0 150.0 1.333 1.333
200.0 200.0 0.0 0.0 100.0 100.0 100.0 200.0 1.000 1.000
250.0 250.0 0.0 0.0 125.0 125.0 125.0 250.0 0.800 0.800
50.0 0.0 0.0 25.0 0.0 25.0 25.0 50.0 4.000 4.000
100.0 0.0 0.0 50.0 0.0 50.0 50.0 100.0 2.000 2.000
150.0 0.0 0.0 75.0 0.0 75.0 75.0 150.0 1.333 1.333
200.0 0.0 0.0 100.0 0.0 100.0 100.0 200.0 1.000 1.000
250.0 0.0 0.0 125.0 0.0 125.0 125.0 250.0 0.800 0.800
50.0 0.0 -50.0 25.0 25.0 50.0 50.0 86.6 2.000 2.309
100.0 0.0 -100.0 50.0 50.0 100.0 100.0 173.2 1.000 1.155
110.0 0.0 -110.0 55.0 55.0 110.0 110.0 190.5 0.909 1.050
150.0 0.0 -150.0 75.0 75.0 150.0 150.0 259.8 0.667 0.770
200.0 0.0 -200.0 100.0 100.0 200.0 200.0 346.4 0.500 0.577
50.0 0.0 -25.0 25.0 12.5 37.5 37.5 66.1 2.667 3.024
100.0 0.0 -50.0 50.0 25.0 75.0 75.0 132.3 1.333 1.512
110.0 0.0 -55.0 55.0 27.5 82.5 82.5 145.5 1.212 1.374
150.0 0.0 -75.0 75.0 37.5 112.5 112.5 198.4 0.889 1.008
200.0 0.0 -100.0 100.0 50.0 150.0 150.0 264.6 0.667 0.756
Set 1
Set 2
Set 3
Set 4


Problem 2 (40 Points)
Plot the following sets of stress states on a set of principal axes (an example is provided in Figure 2A of
the Appendix). Calculate the factor of safety for each stress state using both the Brittle Coulomb Mohr
and Modified Mohr failure theories. Assume cast iron is used that has an ultimate tensile strength of 150
kpsi and an ultimate compressive strength of 400 kpsi.

Set 1 Set 2
o
1
o
2
o
3
o
1
o
2
o
3


Set 3 Set 4
o
1
o
2
o
3
o
1
o
2
o
3


Set 6
o
1
o
2
o
3

25 kpsi 0 kpsi 50 kpsi



Solution:
All the problems are done in same way. First Brittle Coulomb-Mohr Theory,
1. Find Cases and factor of safety:
Case 1: 0
B A
> o > o , Design equation,
n
S
ut
A
= o
Case 2:
B A
0 o > > o , Design equation,
n
1
S S
uc
B
ut
A
=
o
o

Case 3:
B A
0 o > o > , Design equation,
n
S
uc
B
= o
Then Modified BCM,
Case 1: 0
B A
> o > o or 0
B A
> o > o and 1
A
B
s
o
o
Design equation,
n
S
ut
A
= o
Case 2:
B A
0 o > > o and 1
A
B
>
o
o
Design equation,
( )
n
1
S S S
S S
uc
B
ut uc
A ut uc
=
o
o

Case 3:
B A
0 o > o > , Design equation,
n
S
uc
B
= o


Set o
1
o
2
o
3
o
A
o
B
Case
(BCM)
Case
(BCM)
n (BCM) n (MM)
50.0 50.0 0.0 50.0 50.0 Case 1 Case 1 3.000 3.000
100.0 100.0 0.0 100.0 100.0 Case 1 Case 1 1.500 1.500
150.0 150.0 0.0 150.0 150.0 Case 1 Case 1 1.000 1.000
200.0 200.0 0.0 200.0 200.0 Case 1 Case 1 0.750 0.750
50.0 0.0 0.0 50.0 0.0 Case 1 Case 1 3.000 3.000
100.0 0.0 0.0 100.0 0.0 Case 1 Case 1 1.500 1.500
150.0 0.0 0.0 150.0 0.0 Case 1 Case 1 1.000 1.000
200.0 0.0 0.0 200.0 0.0 Case 1 Case 1 0.750 0.750
50.0 0.0 -50.0 50.0 -50.0 Case 2 Case 1 2.182 3.000
100.0 0.0 -100.0 100.0 -100.0 Case 2 Case 1 1.091 1.500
110.0 0.0 -110.0 110.0 -110.0 Case 2 Case 1 0.992 1.364
150.0 0.0 -150.0 150.0 -150.0 Case 2 Case 1 0.727 1.000
200.0 0.0 -200.0 200.0 -200.0 Case 2 Case 1 0.545 0.750
50.0 0.0 -25.0 50.0 -25.0 Case 2 Case 1 2.526 3.000
100.0 0.0 -50.0 100.0 -50.0 Case 2 Case 1 1.263 1.500
130.0 0.0 -65.0 130.0 -65.0 Case 2 Case 1 0.972 1.154
150.0 0.0 -75.0 150.0 -75.0 Case 2 Case 1 0.842 1.000
200.0 0.0 -100.0 200.0 -100.0 Case 2 Case 1 0.632 0.750
25.0 0.0 -50.0 25.0 -50.0 Case 2 Case 2 3.429 4.364
50.0 0.0 -100.0 50.0 -100.0 Case 2 Case 2 1.714 2.182
65.0 0.0 -130.0 65.0 -130.0 Case 2 Case 2 1.319 1.678
75.0 0.0 -150.0 75.0 -150.0 Case 2 Case 2 1.143 1.455
100.0 0.0 -200.0 100.0 -200.0 Case 2 Case 2 0.857 1.091
Set 1
Set 2
Set 3
Set 6
Set 4


Problem 3 (30 Points Total)
Compute the factor of safety for points A and B using both the distortion energy theory and max shear
stress theory. The bar is made from AISI 1006 cold-drawn steel, and is loaded with the following load
scenarios:

Load
Scenario
P (N) T (N-m) F (N)
1 2000 12.5 225
2 4000 25 550
3 6000 37.5 775
4 8000 50 1100

Plot your results on a set of principal axes.


Figure 3: Problem 3 Diagram

Sol. Using Table A-20, o
yp
= 280 MPa
Lets analyze the point B,

For point B the bending stress from F will cause a normal stress in the x direction,

o
x from bending

x z
y
t
T

o
x from P



( )
F 805 , 301
m 015 . 0
m 1 . 0 F 32
d
M 32
I
c M
3 3
F F
bend x
=
t

=
t
= = o

For point B the axial stress (tension) from P will cause a normal stress in the x direction,

( )
P 659 , 5
m 015 . 0
P 4
d
P 4
A
P
2 2
axial
=
t

=
t
= = o

So, total axial stress at B, o
x
= o
x,bend
+ o
axial
= 301,805 F + 5,695 P

Shear stress for torsion,
( )
T 025 , 509 , 1
m 015 . 0
T 16
d
T 16
J
Tr
3 3
T
=
t

=
t
= = t

So, total shear stress, T 025 , 509 , 1
T xy
= t = t

So, according to DE, ( ) ( )
2 2
6
2
xy
2
x
T 025 , 509 , 1 3 P 695 , 5 F 805 , 301
n
10 280
3
n
'
+ + =
t + o =
o

So, according to MSST, ( ) ( )
2 2
6
2
xy
2
x
yp
T 025 , 509 , 1 4 P 695 , 5 F 805 , 301
n
10 280
4
n
+ + =
t + o =
o

So, the stress tensor, | |
(
(
(
t
t o
= o
0 0 0
0 0
0
xy
xy x

To find the principal stresses, | | 0
0 0
0
0
Det I Det
P
P xy
xy P x
P
=
(
(
(
o
o t
t o o
= o o

( ) ( ) ( )
( )
2
4
0 , 0
0
0 0 0
2
xy
2
x x
P
2
xy P x
2
P P
2
xy P x
2
P P
P
2
xy
2
P x P xy P xy
2
P P x
t + o o
= o = t o o o = o
= t o o o o
= o t o o o = t o + t + o o o



2 1 2
1
12
o o = t ,
3 2 2
1
23
o o = t ,
3 1 2
1
13
o o = t


13 23 12 max
, , MAX t t t = t

yp 2
1
sy
= =

max sy
S n t =

Then DE,
( ) ( ) ( )
2
1
2
3 1
2
3 2
2
2 1
2 2 2
'
(
o o
+
o o
+
o o
= o

yp
o =

Lets analyze the point A,

For point A the axial stress (tension) from P will cause a normal stress in the x direction,

( )
x
2 2
axial
P 5659
m 015 . 0
P 4
d
P 4
A
P
o = =
t

=
t
= = o

Shear stress for torsion,
( )
T 025 , 509 , 1
m 015 . 0
T 16
d
T 16
J
Tr
3 3
T
=
t

=
t
= = t
Shear stress for bending,
( )
F 545 , 7
m 015 . 0 3
F 4
A 3
F 4
Ib
VQ
2
4
shear
=

= = = t
t

o
x from P

x z
y
t
T

t
shear



So, total shear stress, F 545 , 7 T 025 , 509 , 1
shear T xz
= t t = t

So, according to DE, ( ) ( )
2 2
6
2
xz
2
x
F 545 , 7 T 025 , 509 , 1 3 P 659 , 5
n
10 280
3
n
'
+ =
t + o =
o

So, according to MSST, ( ) ( )
2 2
6
2
xz
2
x
yp
F 545 , 7 T 025 , 509 , 1 4 P 659 , 5
n
10 280
4
n
+ =
t + o =
o

So, the stress tensor, | |
(
(
(
t
t o
= o
0 0
0 0 0
0
xz
xz x

To find the principal stresses, | | 0
0
0 0
0
Det I Det
P xz
P
xz P x
P
=
(
(
(
o t
o
t o o
= o o

( ) ( ) ( ) 0 0 0
P
2
xz
2
P x P xz P xz
2
P P x
= o t o o o = t o + t + o o o

( ) 0
2
xz P x
2
P P
= t o o o o
2
4
0 , 0
2
xz
2
x x
P
2
xz P x
2
P P
t + o o
= o = t o o o = o



2 1 2
1
12
o o = t ,
3 2 2
1
23
o o = t ,
3 1 2
1
13
o o = t

13 23 12 max
, , MAX t t t = t

yp 2
1
sy
= =

max sy
S n t =

Then DE,
( ) ( ) ( )
2
1
2
3 1
2
3 2
2
2 1
2 2 2
'
(
o o
+
o o
+
o o
= o

yp
o =




The stresses are shown in next two tables:

The principal stresses are shown following table:

n (DE) n (MSST) n (DE) n (MSST)
1 2000 12.5 225 8.80 7.75 3.26 3.19
2 4000 25.0 550 4.49 3.95 1.40 1.38
3 6000 37.5 775 2.97 2.62 0.98 0.96
4 8000 50.0 1100 2.24 1.98 0.70 0.69
Point B
F (N) T (N-m) P (N)
Load
Scenario
Point A
1 2000 12.5 225 11.39 0.00 0.00 0.00 0.00 17.17
2 4000 25.0 550 22.78 0.00 0.00 0.00 0.00 33.58
3 6000 37.5 775 34.17 0.00 0.00 0.00 0.00 50.74
4 8000 50.0 1100 45.56 0.00 0.00 0.00 0.00 67.15
Point A (Stresses)
o
y
(MPa) o
z
(MPa) t
xy
(MPa) t
yz
(MPa) t
xz
(MPa)
Load
Scenario
P (N) T (N-m) F (N) o
x
(MPa)
1 2000 12.5 225 79.22 0.00 0.00 -18.86 0.00 0.00
2 4000 25.0 550 188.63 0.00 0.00 -37.73 0.00 0.00
3 6000 37.5 775 267.85 0.00 0.00 -56.59 0.00 0.00
4 8000 50.0 1100 377.26 0.00 0.00 -75.45 0.00 0.00
Point B (Stresses)
Load
Scenario
P (N) T (N-m) F (N) o
x
(MPa) o
y
(MPa) o
z
(MPa) t
xy
(MPa) t
yz
(MPa) t
xz
(MPa)
o
1
o
2
o
3
o
1
o
2
o
3
1 23.8 0.0 -12.4 83.5 0.0 -4.3
2 46.8 0.0 -24.1 195.9 0.0 -7.3
3 70.6 0.0 -36.5 279.3 0.0 -11.5
4 93.7 0.0 -48.1 391.8 0.0 -14.5
Point A Point B Load
Scenario


The stresses are drawn in principal planes in next figure.

Assignment #4 Solution - Spring 2014

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MAE 311: Machines and Mechanisms I Spring 2014

Assignment #4 Solution Due Date: 4/7/2014

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