7.

297

Stress and Deflection Caused by Linear and Bending Impact

SAMPLE PROBLEM 7.3

298

Chapter 7

Impact

3. Hence, the total impact deflection is 0.57 * 7.6 = 4.3 in., but the deflection of
the beam itself is only 0.07 * 7.6 = 0.53 in.
4. The extreme-fiber beam stress is estimated from Fe = 100 * 7.6 = 760 lb:

Bending ImpactEffect of Compound Springs

Figure 7.6 shows a wood beam supported on two springs and loaded in bending
impact. Estimate the maximum stress and deflection in the beam, based on the
assumption that the masses of the beam and spring can be neglected.

s =

SOLUTION

Fe L
760(60)
M
=
=
= 3200 psi
Z
4Z
4(3.56)

Comments:

Known: A 100-lb weight falls from a specified height onto a wood beam of known
material and specified geometry that is supported by two springs.

1. The estimated stress is well within the given modulus of rupture of 6000 psi.
(The modulus of rupture is the computed value of M/Z at failure in a standard
static test.)

Find: Determine the maximum beam stress and deflection.

2. If the supporting springs are removed, the total static deflection is reduced to
0.07 in., and the impact factor increases to 19.6. This would give a computed
maximum beam stress of 8250 psi, which is greater than the modulus of rupture.
If the inertial effect of the beam mass does not cause the actual stress to be very
much higher than 8250 psi, it is possible that the dynamic-strengthening
effect shown in Figure 7.2 would be sufficient to prevent failure. Because this
effect is usually appreciable for woods, the results of standard beam impact tests
are often included in references giving properties of woods.

Schematic and Given Data:

30 in.
100 lb

2 4 white pine
E = 106 psi

12 in.

Mod. of rupture = 6 ksi

100 lb/in.

7.3

1 8 in. 3 8 in., I = bh3/12 = 6.46 in.4

Z = I/c = 3.56 in.3

Stress and Deflection Caused by Torsional Impact

The analysis of the preceding section could be repeated for the case of torsional systems, and a corresponding set of equations developed. Instead, advantage will be
taken of the direct analogy between linear and torsional systems to write the final
equations directly. The analogous quantities involved are

100 lb/in.

60 in.

FIGURE 7.6
Bending impact, with compound spring.

Linear

Torsional

d, deflection (m or in.)

Assumptions:
1. As stated in the problem, the masses of the beam and spring can be neglected.
2. The beam and springs respond elastically.
3. The impact load is applied uniformly at the center of the beam.

Analysis:
1. The static deflection for the beam only, supporting springs only, and total system are
100(60)3
PL3
=
= 0.070 in.
48EI
48(106)(6.46)
100
P
dst(springs) =
=
= 0.50 in.
2k
2(100)
dst(total) = 0.070 + 0.50 = 0.57 in.
dst(beam) =

u, deflection (rad)

Fe , equivalent static force (N or lb)

Te , equivalent static torque (N # m or lb # in.)

m, mass (kg or lb # s2/in.)

I, moment of inertia (N # s2 m or lb # s2 # in.)

k, spring rate (N/m or lb/in.)

K, spring rate (N # m/rad or lb # in./rad)

v, impact velocity (m/s or in./s)

v, impact velocity (rad/s)

U, kinetic energy (N # m or in. # lb)

U, kinetic energy (N # m or in. # lb)

The two following equations have the letter t added to the equation number to
designate torsion:
u =

8.11

1 +

(7.4bt)

For the important special case of torsional impact of a solid round bar of diameter d:

2h
24
= 1 + 1 +
= 7.6
dst
0.57
A

Effect of Stress Concentration with Mean Plus Alternating Loads

(7.3bt)

Te = 22UK

2. From Eq. 7.1 or 7.2 the impact factor is

1 +

2U

AK

339

would lie on the vertical axis (i.e., smin = 0), and points b, c, and d would lie on
the horizontal line, smax = Sy .
At first, we may be inclined to become a little alarmed with the appearance of
points like b, c, and d on the smsa plot. Even point clet alone point dshows a
peak stress in excess of the ultimate strength! We must remember that these are fictitious calculated stresses, and that the extent of yielding they represent is usually
very small. With the tensile bar in this example, there is no way that very much yielding can occur at the notch root without yielding the entire cross sectionand this is
only on the verge of happening at point d.
In summary, the procedure recommended here for fatigue life prediction of
notched parts subjected to combinations of mean and alternating stress is

340

Chapter 8

Fatigue

Schematic and Given Data:

r

T = 1000 250 N m

d
T = 1000 250 N m
D/d = 1.2
r/d = 0.05
SF = 2.0

FIGURE 8.26
Shaft subjected to
mean and alternating
torsion.

Commercial ground finish

Heat-treated alloy steel,
Su = 1.2 GPa, Sy = 1.0 GPa

Assumptions/Decisions:
All stresses (both mean and alternating) are multiplied by the fatigue stress
concentration factor Kf , and correction is made for yielding and resultant residual stresses if the calculated peak stress exceeds the material yield strength.
This procedure is sometimes called the residual stress method because of the recognition it gives to the development of residual stresses.
An alternative procedure sometimes used is to apply the stress concentration
factor to the alternating stress only, and not take residual stresses into account. We
can see that in some cases this reduction in mean stress from not multiplying it by
Kf might be about the same as the reduction in mean stress achieved with the residual stress method by taking yielding and residual stress into account. Because the
mean stress is not multiplied by a stress concentration factor, this alternative procedure is sometimes called the nominal mean stress method. Only the residual stress
method is recommended here for fatigue life prediction.

SAMPLE PROBLEM 8.3

1. The shaft is manufactured as specified with regard to the critical fillet and the
shaft surface finish.
2. The shaft diameter will be between 10 and 50 mm.

Analysis:
1. Construct the fatigue strength diagram shown in Figure 8.27. (Since infinite life
is required, there is no need for an SN curve.) In computing an estimated value
for Sn , we assumed that the diameter will be between 10 and 50 mm. If it is not,
the solution will have to be repeated with a more appropriate value of CG .
2. The calculated notch root stresses (i.e., not yet taking any possible yielding into
account) are
tm = (16Tm/pd 3)Kf
ta = (16Ta/pd 3)Kf
In order to find Kf from Eq. 8.2, we must first determine Kt and q. We find Kt from
Figure 4.35c as 1.57, but the determination of q from Figure 8.24 again requires an
assumption of the final diameter. This presents little difficulty, however, as the
curve for torsional loading of steel of this strength (Su = 1.2 GPa = 174 ksi, or

Determine the Required Diameter of a Shaft

Subjected to Mean and Alternating Torsion

A shaft must transmit a torque of 1000 N # m, with superimposed torsional vibration

causing an alternating torque of 250 N # m. A safety factor of 2 is to be applied to
both loads. A heat-treated alloy steel is to be used, having Su = 1.2 GPa, and
Sy = 1.0 GPa (unfortunately, test data are not available for Sus or Sys). It is required
that the shaft have a shoulder, with D/d = 1.2 and r/d = 0.05 (as shown in Figure
4.35). A good-quality commercial ground finish is to be specified. What diameter is
required for infinite fatigue life?

Alternating torsional stress

a (MPa)

Assuming 10 mm < d < 50 mm

SOLUTION
Known: A commercial ground shaft made from steel with known yield and ultimate
strengths and having a shoulder with known D/d and r/d ratios transmits a given
steady and superimposed alternating torque with a safety factor of 2 applied to both
torques (see Figure 8.26).

Find: Estimate the shaft diameter d required for infinite life.

Sn = Sn' CLCGCSCT CR =
10 6

200

~=

B'
B
A
NA

100

Load line

Yield line

life

150
116
N'B

100

100

(0.58)(0.9)(0.87)(1.0)(1.0) = 272 MPa

max = Ssy

300

0'
200

1200
2

200

NB
300
400
500
600
Ssy 0.58(1000) = 580

Mean torsional stress m (MPa)

FIGURE 8.27
Fatigue strength diagram for Sample Problem 8.3.

700
800
900
Sus 0.8(1200) = 960

8.11

Effect of Stress Concentration with Mean Plus Alternating Loads

341

very close to the top curve of the figure) gives q L 0.95 for r 1.5 mm, which in
this case corresponds to d 30 mm. With the given loading, intuition (or subsequent calculation) tells us that the shaft will have to be at least this large.
Substitution of these values, together with the given values for design overload
(nominal load times safety factor), gives
Kf = 1 + (Kt - 1)q = 1 + (1.57 - 1)0.95 = 1.54

tm = [(16 * 2 * 1000 N # m)/pd 3]1.54 = 15,685/d3

ta = [(16 * 2 * 250 N # m)/pd 3]1.54 = 3922/d3

and ta/tm = 0.25.

3. Starting at the origin of Figure 8.27 (which corresponds to making the diameter
infinite) and moving to the right along the line of slope = 0.25, we tentatively
stop at point A. If no yielding is to be permitted, the stresses can go no higher than
this. At A, ta = 116 MPa or 0.116 GPa. Thus, 3922/d3 = 0.116 or d = 32.2 mm.
4. In most situations, perhaps a little yielding in the localized zone of the fillet
under design overload conditions could be permitted. If so, the diameter can
be further reduced until the calculated stresses reach point B on Figure 8.27, because yielding and residual stresses bring the actual stresses back to point B,
which is right on the infinite life line. Yielding did not affect the alternating
stress magnitude, so the equation for alternating stress can be equated to
150 MPa, giving d = 29.7 mm.
5. Before accepting either the d = 32.3 mm or the d = 29.7 mm answer, it is important to go back and see whether the values for CG and q are consistent with
the diameter finally chosen. In this case they are.

342

Chapter 8

Fatigue

SAMPLE PROBLEM 8.4

Estimate the Safety Factor of a Disk Sander Shaft

Figure 8.28 pertains to the shaft of a disk sander that is made of steel having
Su = 900 MPa, and Sy = 750 MPa. The most severe loading occurs when an object
is held near the periphery of the disk (100-mm radius) with sufficient force to develop
a friction torque of 12 N # m (which approaches the stall torque of the motor).
Assume a coefficient of friction of 0.6 between the object and the disk. What is the
safety factor with respect to eventual fatigue failure of the shaft?

SOLUTION
Known: A shaft with given geometry and loading is made of steel having known
ultimate and yield strengths.

Find: Determine the safety factor for eventual failure by fatigue.

Schematic and Given Data:
50 mm
Ft

Fn
r = 5 mm rad., machined surface

100 mm

Comments:

8.11

Effect of Stress Concentration with Mean Plus Alternating Loads

343

Assumption: The 50-mm disk shaft overhang is necessary.

Analysis:

1. The 12 N # m torque specification requires that the tangential force Ft be 120 N.

With a coefficient of friction of 0.6, this requires a normal force Fn of 200 N.
2. These two force components produce the following loading at the shaft fillet:
Torque: T = 12 N # m = 12,000 N # mm
Axial load: P = 200 N

Bending: In the horizontal plane, Mh = 120 N * 50 mm

In the vertical plane, Mv = 200 N * 100 mm
The resultant is M = 2M 2h + M 2v = 20,900 N # mm
3. From Figure 4.35, geometric stress concentration factors for torsion, axial, and
bending loads are about
Kt(t) = 1.10,

Kt(a) = 1.28,

Kt(b) = 1.28

From Figure 8.24, estimated notch sensitivities q are 0.93 for torsion and 0.91
for bending and axial loads. From Eq. 8.2, values of Kf are estimated as 1.09,
1.25, and 1.25 for torsional, axial, and bending loads, respectively.
4. The three stress components at the fillet are
16(12,000)
16T
Kf(t) =
(1.09) = 16.3 MPa
pd 3
p(16)3
- 200(4)
P
= Kf(a) =
(1.25) = - 1.24 MPa
A
p(16)2
32(20,900)
32M
=
K
=
(1.25) = 65.0 MPa
f(b)
pd 3
p(16)3

t =
s(a)
s(b)

5. Applying the procedure specified for general biaxial loads in Table 8.2, we
construct in Figure 8.28 an estimated infinite-life Goodman line for bending
loads. Next, an operating point that corresponds to the equivalent mean and
equivalent alternating bending stresses is placed on the diagram. Of the three
stress components determined, torsional and axial stresses are constant for
steady-state operating conditions; the bending stress is completely reversed (the
bending stress at any point on the fillet goes from tension-to-compression-totension during each shaft revolution). Using the recommended procedure to determine the equivalent mean and alternating stresses, we have
sem =

sm
sm 2
+
t2 +
2
2
C

2
- 1.24
+ (16.3)2 + a - 1.24 b = 15.7 MPa
2
2
B
2
2
2
= 2sa + 3ta + 2(65.0) + 0 = 65.0 MPa

sea

6. By drawing a line through the origin and the operating point, we see that all
stresses would have to be increased by a factor of about 4 to reach the estimated
failure point where conditions would be on the verge of causing eventual
fatigue failure. Hence, the estimated safety factor is 4.

D = 18 mm (bearing bore)
d = 16 mm (shaft dia.)

Su = 900 MPa

f = 0.6 (between the object

and the disk)
T = 12 N m (friction torque)

Alternating bending stress

ea (MPa)

1. Before even beginning to solve a problem like this, an engineer should carefully
review the design with regard to the critical fillet. Is it really necessary that the
radius be so small? If so, is the quality control in the production and inspection
departments such that the part will not be made with merely a sharp corner?
And what about the control of surface finish? As far as shaft fatigue strength is
concerned, a high-quality finish in the fillet is very important. Will the production and inspection departments be aware of this? The other 99.9 percent of the
shaft surface is of little consequence unless a high-quality finish is needed for
other reasons (as to provide a good bearing surface or close-tolerance fit). If the
quality finish is not needed on these other portions of the shaft, cost might be
lowered by changing to an ordinary machined surface.
2. Before we leave this example, it is interesting to note in Figure 8.27 the operating stresses for normal operation (i.e., Tm = 1000 N # m, Ta = 250 N # m). If
point A is selected as the required overload point, then normal operation involves operating at point NA (midpoint between 0 and A). If B is the selected
overload point, normal operation would be at NB , the midpoint between 0 and B.
But if the machine is operated at the design overload and subsequently operated
normally, a residual stress, represented by 0, is involved. With this residual
stress present, stresses are at 0 when the load is off, at N B when the load is normal, and at B with the design overload.

Sy = 750 MPa

Sn = Sn' CLCGCSCT CR =

10 6

200

100

900

(1)(0.9)(0.72)(1.0)(1.0) = 291 MPa

"Failure point"

300

~=

max = Sy
life

Sy = 750
Su = 900

(15.7, 65.0)
"Operating point"
0

100

200

300
400
500
600
700
Mean bending stress em (MPa)

FIGURE 8.28
Sample Problem 8.4disk sander.

800

900