Stress Analysis Production Materials Session 3

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1
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Course Content
1. Fluid Mechanics (Statics / Dynamics).
2. Pumps/ HVAC / Refrigeration.
3. Stress Analysis / Production / Materials.
4. NFPA codes / other General question.
5. Thermodynamics-1.
6. Thermodynamics-2.
7. Heat Transfer.
8. Compressors/Gas Turbine/Jet Engine.
9. Project Management Fundamentals-1.
10.Project Management Fundamentals-2.
3
Introduction
When a force is transmitted through a body, the body

tends to change its shape or deform. The body is said to
be strained.
Direct Stress = Applied Force (F)

Cross Sectional Area (A)
Units: Usually N/m2 (Pa), N/mm2, MN/m2, GN/m2 or

N/cm2
Note: 1 N/mm2 = 1 MN/m2 = 1 MPa
4
Axial Loading: Normal Stress
• The resultant of the internal forces for an axially

loaded member is normal to a section cut
perpendicular to the member axis.
• The force intensity on that section is defined as

the normal stress.
F P
  lim  ave 
A0 A A
• The normal stress at a particular point may not be

equal to the average stress but the resultant of the
stress distribution must satisfy
P   ave A   dF    dA
A
5

   F 
F A F F  F Tensile stress (+)
F
 
F F Compressive stress (-)
Normal stress =  
Force
A

N / m2  pascal (Pa)
Hydrostatic stress refers to tensile or compressive stress

in all dimensions within or external to a body.
Hydrostatic stress results in change in volume of the
material.
6
Centric & Eccentric Loading
• A uniform distribution of stress in a section
infers that the line of action for the resultant of
the internal forces passes through the centroid
of the section.
• A uniform distribution of stress is only
possible if the concentrated loads on the end
sections of two-force members are applied at
the section centroids. This is referred to as
centric loading.
• If a two-force member is eccentrically loaded,
then the resultant of the stress distribution in a
section must yield an axial force and a
moment.
• The stress distributions in eccentrically loaded
members cannot be uniform or symmetric.
7
• Forces P and P’ are applied transversely to the
Shearing Stress member AB.
• Corresponding internal forces act in the plane
of section C and are called shearing forces.
• The resultant of the internal shear force
distribution is defined as the shear of the section
and is equal to the load P.
• The corresponding average shear stress is,
P
 ave 
A
• Shear stress distribution varies from zero at the

member surfaces to maximum values that may be
much larger than the average value.
• The shear stress distribution cannot be assumed to
be uniform.
8
Shear stress =  = F tangential to the area / A
A 
F

F
9
Shearing Stress Examples
Single Shear Double Shear
P F P F
 ave    ave  
A A A 2A
10
Bearing Stress in Connections
• Bolts, rivets, and pins create
stresses on the points of contact
or bearing surfaces of the
members they connect.
• The resultant of the force

distribution on the surface is
equal and opposite to the force
exerted on the pin.
• Corresponding average force

intensity is called the bearing
stress,
P P
b  
A td
11
Example for Pin Bearing Stresses
• To determine the bearing stress at A in the boom AB,

we have t = 30 mm and d = 25 mm,
P 40 kN
b    53.3 MPa
td 30 mm 25 mm 
• To determine the bearing stress at A in the bracket,

we have t = 2(25 mm) = 50 mm and d = 25 mm,
P 40 kN
b    32.0 MPa
td 50 mm 25 mm 
12
Factor of Safety
Factor of safety considerations:
• uncertainty in material properties
Structural members or machines
must be designed such that the • uncertainty of loadings
working stresses are less than the • uncertainty of analyses
ultimate strength of the material. • number of loading cycles
• types of failure
• maintenance requirements and
FS  Factor of safety deterioration effects
u ultimate stress • importance of member to structures
FS   integrity
 all allowable stress
• risk to life and property
• influence on machine function
13
Normal Strain
P 2P P P
   stress   
A 2A A A
  2 
  normal strain   
L L 2L L
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Normal strain  = fractional change of length= x/l
 
F F x
l
Shear strain = deformation under shear stress = x / l

x
F

l
fixed F
15
Stress-Strain Diagram: Ductile Materials
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Stress-Strain Diagram: Brittle Materials
17
 Q2: The dimension of strain is?
a) LT-2
b) N/m2
c) N
d) Dimensionless
Answer is d:
Strain is the ratio of change in dimension to original dimension.
So it is dimensionless.
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Q3: What is tensile stress?
a) The ratio of change in length to the original length

b) The ratio of original length to the change in length
c) The ratio of tensile force to the change in length
d) The ratio of change in length to the tensile force applied
Answer is a:
The tensile stress is the ratio of change in length to the original
length. It is the stress induced in a body, when subjected to two
equal and opposite pulls. The ratio of increase in length to the
original length is the tensile strain.
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Q4: Find the strain of a brass rod of length 250mm which is
subjected to a tensile load of 50kN when the extension of
rod is equal to 0.3mm?
a) 0.025
b) 0.0012
c) 0.0046
d) 0.0014
Answer is b:
Explanation: Strain = dL/L = 0.3/250 = 0.0012.
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Q5: Find the elongation of an steel rod of 100mm length when
it is subjected to a tensile strain of 0.005?
a) 0.2mm
b) 0.3mm
c) 0.5mm
d) 0.1mm
Answer is c:
Explanation: dL = strain x L = 0.005 x 100 = 0.5mm.
21
Q6: A tensile test was conducted on a mild steel bar. The
diameter and the gauge length of bat was 3cm and 20cm
respectively. The extension was 0.21mm. What is the
value to strain?
a) 0.0010
b) 0.00105
c) 0.0105
d) 0.005
Answer is d:
Explanation: Strain = dL/L = 0.21/200 = 0.00105.
22
Q7: x. Strain is a fundamental behavior of material.
y. Strain does not have a unit.
a) Both x. and y. are true and y. is the correct explanation

of x
b) Both x. and y. ate true but y. is not the correct explanatio
of x
c) x. is true but y. is false
d) y. is true but x. is false
Answer is b:
Explanation: Strain is measured in laboratory that is why it is called
a fundamental quantity. Also since it is the ratio of dimension of
length to the dimension of length, it is dimensionless.
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 Q8: The lateral strain is ?
a) The ratio of axial deformation to the original length

b) The ratio of deformation in area to the original area
c) The strain at right angles to the direction of applied load
d) The ratio of length of body to the tensile force applied on it
Answer is :
24
 Q9: The unit of force in S.I. units is ?
a) Kilogram
b) Newton
c) Watt
d) Dyne
Answer is b:Explanation: Force = mass x acceleration = kg x

m/s2 = N.
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Q10: Which of the following is not the unit of distance?
a) Angstrom
b) Light year
c) Micron
d) Milestone
Answer is d:
Explanation: Milestone means achievement . it is not and unit of distance.
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Hooke’s Law: Modulus of Elasticity
• Below the yield stress

  E
E  Youngs Modulus or
Modulus of Elasticity
• Strength is affected by alloying,

heat treating, and manufacturing
process but stiffness (Modulus of
Elasticity) is not.
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Work
 hardening
Elastic Yield pt. break
deformation
o 
Hooke's law: In elastic region,   , or /  = E

E is a constant, named as Young’s modulus or modulus of elasticity
Similarly, in elastic region, / = G, where G is a constant, named as shear

modulus or modulus of rigidity.
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Direct stress 
Modulus of Elasticity, E = 
Direct strain 
Shear stress 
Also: For Shear stress: Modulus of rigidity or shear modulus, G = 
Shear strain 
Also: Volumetric strain,  v is proportional to hydrostatic

stress,  within the elastic range
i.e. :  / v  K called bulk modulus.
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Elastic vs. Plastic Behavior
• If the strain disappears when the

stress is removed, the material is
said to behave elastically.
• The largest stress for which this

occurs is called the elastic limit.
• When the strain does not return

to zero after the stress is
removed, the material is said to
behave plastically.
30
Fatigue
• Fatigue properties are shown on

S-N diagrams.
• A member may fail due to fatigue

at stress levels significantly below
the ultimate strength if subjected
to many loading cycles.
• When the stress is reduced below

the endurance limit, fatigue
failures do not occur for any
number of cycles.
31
Impact Testing
The toughness of a material is defined as its ability

to withstand a shock loading without fracture. Two
principal impact tests are the:
• Izod and the
• Charpy tests.
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Hardness Test
 The hardness of a material is determined by its ability to
withstand indentation. There are four major hardness tests.
 (i) Rockwell Hardness Test: This uses an indentor with a
120o conical diamond with a rounded apex for hard materials,
or steel ball for softer materials.
 A minor load, F is applied to cause a small indentation as
indicated in Fig. (a) below.
 The major load, Fm is then applied and removed after a
specified time to leave load F still acting. The two stages are
shown as (b) and (c).
33
Poisson’s Ratio • For a homogeneous isotropic material
d d  d
F F
x

x
 normal strain : 

d
 lateral strain : L 
d • Poisson’s ratio is defined as
 Poisson's ratio :    L /  y
lateral strain 
   z
axial strain x x
 value of  : 0.2 - 0.5
34
Residual Stresses
• Residual stresses will remain in a structure after
loading and unloading if
- only part of the structure undergoes plastic
deformation
- different parts of the structure undergo different
plastic deformations
• Residual stresses also result from the uneven heating or

cooling of structures or structural elements
35
Support Types and Reactions (2D):
36
Support Types and Reactions (2D):
37
EXAMPLE
Given: Loads as shown on the truss

Find: The forces in each member
of the truss.
Plan:
1. Check if there are any zero-force members.

2. First analyze pin D and then pin A
3. Note that member BD is zero-force member. FBD = 0
4. Why, for this problem, do you not have to find the external
reactions before solving the problem?
EXAMPLE (continued)
D 450 lb
45 º
45 º
FAD FCD
FBD of pin D
+   FX = – 450 + FCD cos 45° – FAD cos 45° = 0

+   FY = – FCD sin 45° – FAD sin 45° = 0
FCD = 318 lb (Tension) or (T)
and FAD = – 318 lb (Compression) or (C)
EXAMPLE (continued)
Analyzing pin A:
FAD
45 º
A
FAB
AY
FBD of pin A
+   FX = FAB + (– 318) cos 45° = 0; FAB = 225 lb (T)
Could you have analyzed Joint C instead of A?
Q1: Find the vertical reaction at B for the shaft shown.
a. 325.50 N
b. 225.25 N
c. 363.75 N
d. 415.20 N
Answer is c:
41
(800 N/m)(0.150 m) = 120 N
225 N
A B
Ay By
42
Equilibrium Equations
+ M A  0  .400 m (B y )  120 N (.275 m)  225 N (.500 m)

 120 N (.275 m)  225 N (.500 m)
By 
 .400 m
B y  363.75N 
+ Fy  0  Ay  120 N  363 .75 N  225 N
A y  18.75 N
A y  18.75N 
43
Q11:A solid cube is subjected to equal normal forces on all its
faces. The volumetric strain will be x-times the linear strain
in any of the three axes when ?
a) X=1
b) X=2
c) X=3
d) X=4
Answer is c:Explanation: The volumetric strain is the change in

dimension in three directions and the linear strain depends on
change in only one direction so volumetric strain is 1 times the
linear strain in any of the three directions.
44
Q12: A rod 200cm long is subjected to an axial pull due to
which it elongates about 2mm. Calculate the amount of
strain?
a) 0.001
b) 0.01
c) 0.02
d) 0.002
Answer is a: Explanation: The strain is given by = dL / L =

2/2000 = 0.001.
advertisement
45
Q13: Some structural members subjected to long time
sustained loads deform progressively with time especially
at elevated temperatures. What is such a phenomenon
called?
a) Fatigue
b) Creep
c) Creep relaxation
d) Fracture
Answer is b:Explanation: Creep is the deformation

progressively with time. It comes when the body is subjected to
long time load. After the instant deflection due to load the
deformation occurs slowly with time.
46
Q14: Find the strain of a brass rod of length 100mm which is
subjected to a tensile load of 50kN when the extension of
rod is equal to 0.1mm?
a) 0.01
b) 0.001
c) 0.05
d) 0.005
Answer is b:Explanation: Strain = dL/L = 0.1/100 = 0.001.
47
Q15: The property by which a body returns to its original shape
after removal of the force, is called
a) Plasticity
b) Elasticity
c) Ductility
d) Malleability
Answer is b:Explanation: When an external force acts on a

body, the body tends to undergo some deformation. If the
external force is removed and the body comes back to its original
shape and size, the body is known as elastic body and this
property is called elasticity. 48
Q16: The property of a material by which it can be beaten or
rolled into thin plates, is called
a) Malleability
b) Plasticity
c) Ductility
d) Elasticity
Answer is a:Explanation: A material can be beaten into thin

plates by its property of malleability.
49
Q17: Which law is also called as the elasticity law
a) Bernoulli’s law
b) Stress law
c) Hooke’s law
d) Poisson’s law
Answer is c: Explanation: The hooke”s law is valid under the

elastic limit of a body. It itself states that stress is proportional to
the strain within elastic limit.
50
Q18: The materials which have the same elastic properties in
all directions, are called
a) Isotropic
b) Brittle
c) Homogeneous
d) Hard
Answer is a: Explanation: Same elastic properties in all

direction is called the homogeneity of a material.
51
Q19: A member which does not regain its original shape after
removal of load producing deformation is said
a) Plastic
b) Elastic
c) Rigid
d) None of the mentioned
Answer is a: Explanation: A plastic material does not regain its

original shape after removal of load. An elastic material regain
its original shape after removal of load.
52
Q20: The body will regain it is previous shape and size only
when the deformation caused by the external forces, is
within a certain limit. What is that limit?
a) Plastic limit
b) Elastic limit
c) Deformation limit
d) None of the mentioned
Answer is b: Explanation: The body only regain its previous

shape and size only upto its elastic limit.
53
Q21: The materials which have the same elastic properties in
all directions, are called
a) Isotropic
b) Brittle
c) Homogenous
d) Hard
Answer is a: Explanation: Isotropic materials have the same

elastic properties in all directions.
54
Q22: As the elastic limit reaches, tensile strain
a) Increases more rapidly

b) Decreases more rapidly
c) Increases in proportion to the stress
d) Decreases in proportion to the stress
Answer is a: Explanation: On reaching of the tensile stress to

the elastic limit after the proportionality limit, the stress is no
longer proportional to the strain. Then the value of strain rapidly
increases.
55
Q23: What the number that measures an object’s resistance to
being deformed elastically when stress is applied to it?
a) Elastic modulus
b) Plastic modulus
c) Poisson’s ratio
d) Stress modulus
Answer is a: Explanation: The elastic modulus is the ratio of

stress to strain.
56
Q24: Which of the following welding defect is occurred
normally due to repeated cooling
a) Porosity
b) Blowhole
c) Undercut
d) Crack
Answer is : d
57
Q25: Material under failure due to excessive deformation.
The reason may be?
a) Material.
b) Design and Dimensions.
c) All of the above.
d) None of the above.
Answer is c:
58
Q26: What is Morse test?
a) Conducting the performance test for petrol engine.

b) Conducting the performance test for diesel engine.
c) To test the indicative power of single cylinder diesel
engine.
d) to test the brake force for diesel engine.
Answer is : c
59
Q27: Car chassis are ………
a) Felix
b) Rigid
c) Stiff
d) Rough.
Answer is : c
60
Q28: The function of differential gear
a) Reducing speed
b) Changing speed
c) Jerk-off free
d) To turn the vehicle.
Answer is : d
61
Q29: Stress and Strain
a) Directly Proportional
b) Inversely Proportional
c) Power function
d) Non of the above.
Answer is a:
62
Q31: Car dash board from………..
(a) Polymer
(b) metal
(c) Plastic
(d) ceramic
Answer is : a
63
Q33: Stress hardening
(a) Stronger & Tougher

(b) Stronger & Harder
(c) Stronger & Softer
(d) Non of the above
Answer is : b
64
Q34: Car Brake is
(a) Wear resistant

(b) Heat resistance
(c) All of the above
(d) Non of the above
Answer is : c
65
Q36: What is the point P shown in the stress-strain curve?
a) Lower yield point

b) Elastic limit
c) Proportionality limit
d) Breaking point
Answer is d:
Explanation: The breaking point is the point where the material
breaks. The breaking point will be the last point on the stress
strain curve.
66
Q37: The device to be installed in between fire rated walls
is:
(a) Control damper

(b) Splitter damper
(c) Fire dumper
(d) Volume dumper
Answer is c:
67
Q38: Which membrane can be fixed vertically or
horizontally between fire rated walls which control the
spread of the smoke
(a) Control damper

(b) Splitter damper
(c) Fire dumper
(d) Smoke dumper
(e) c&d
Answer is e:
68
Q39: Prevent the spread of smoke inside the ducts and fire
resistance rating from room to room:
(a) Control damper

(b) Splitter damper
(c) Fire dumper
(d) Volume dumper
Answer is c:
69
THANK YOU
ALL THE BEST
Example
SOLUTION:
• Divide the rod into components at
the load application points.
• Apply a free-body analysis on each

6
E  29 10 psi component to determine the
D  1.07 in. d  0.618 in. internal force
• Evaluate the total of the component

Determine the deformation deflections.
of the steel rod shown
under the given loads.
71
SOLUTION: • Apply free-body analysis to each
• Divide the rod into three component to determine internal forces,
components: P1  60 103 lb
P2  15 103 lb
P3  30 103 lb
• Evaluate total deflection,
Pi Li 1  P1L1 P2 L2 P3 L3 
      
A
i i iE E  1A A 2 A 3 

1     
 60  103 12  15  103 12 30  103 16 
 

6 
29 10  0.9 0.9 0.3 
 75.9  103 in.
L1  L2  12 in. L3  16 in.
A1  A2  0.9 in 2 A3  0.3 in 2   75.9 103 in.

72

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Welcome to

MMUP Engineers Registration

Questions are welcomed

When a force is transmitted through a body, the body

Direct Stress = Applied Force (F)

Units: Usually N/m2 (Pa), N/mm2, MN/m2, GN/m2 or

• The resultant of the internal forces for an axially

• The force intensity on that section is defined as

• The normal stress at a particular point may not be

Hydrostatic stress refers to tensile or compressive stress

• Shear stress distribution varies from zero at the

• The resultant of the force

• Corresponding average force

• To determine the bearing stress at A in the boom AB,

• To determine the bearing stress at A in the bracket,

Shear strain = deformation under shear stress = x / l

a) The ratio of change in length to the original length

a) Both x. and y. are true and y. is the correct explanation

a) The ratio of axial deformation to the original length

Answer is b:Explanation: Force = mass x acceleration = kg x

• Below the yield stress

• Strength is affected by alloying,

Hooke's law: In elastic region,   , or /  = E

Similarly, in elastic region, / = G, where G is a constant, named as shear

Also: Volumetric strain,  v is proportional to hydrostatic

i.e. :  / v  K called bulk modulus.

• If the strain disappears when the

• The largest stress for which this

• When the strain does not return

• Fatigue properties are shown on

• A member may fail due to fatigue

• When the stress is reduced below

The toughness of a material is defined as its ability

• Residual stresses also result from the uneven heating or

Given: Loads as shown on the truss

1. Check if there are any zero-force members.

+   FX = – 450 + FCD cos 45° – FAD cos 45° = 0

+   FX = FAB + (– 318) cos 45° = 0; FAB = 225 lb (T)

Could you have analyzed Joint C instead of A?

+ M A  0  .400 m (B y )  120 N (.275 m)  225 N (.500 m)

Answer is c:Explanation: The volumetric strain is the change in

Answer is a: Explanation: The strain is given by = dL / L =

Answer is b:Explanation: Creep is the deformation

Answer is b:Explanation: Strain = dL/L = 0.1/100 = 0.001.

Answer is b:Explanation: When an external force acts on a

Answer is a:Explanation: A material can be beaten into thin

Answer is c: Explanation: The hooke”s law is valid under the

Answer is a: Explanation: Same elastic properties in all

Answer is a: Explanation: A plastic material does not regain its

Answer is b: Explanation: The body only regain its previous

Answer is a: Explanation: Isotropic materials have the same

a) Increases more rapidly

Answer is a: Explanation: On reaching of the tensile stress to

Answer is a: Explanation: The elastic modulus is the ratio of

a) Conducting the performance test for petrol engine.

(a) Stronger & Tougher

(a) Wear resistant

a) Lower yield point

(a) Control damper

(a) Control damper

(a) Control damper

• Apply a free-body analysis on each

• Evaluate the total of the component

• Evaluate total deflection,