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Mechanical Design

Chapter 3 Load & Stress


Analysis
&
Chapter 5 Failures
Resulting from Static
Loading
En. Wan Anuar bin Wan Hassan

Chapter 3 Load & Stress


Analysis

Normal Stress
(Eq. 3-22, page 88)

Bending Stress
(Eq. 3-26a, page 90)

b
h

c = h/2

c=r

Transverse Shear Stress


(Table 3.2, page 97)

Torsional Stress
(Eq. 3-37, page 101)
c

Circular Cross Section

or

Rectangular Cross
Section

Force, F causes twisting & bending of a 20 mm diameter shaft


fixed to a support at the origin of the reference system. In
actuality, the support may be an inertia that we wish to rotate,
but for the purposes of a stress analysis we can consider this a
static problem.
a) Calculate the value of all forces, moments and torques that act
on the shaft AB and the arm BC.
b) Calculate the maximum torsional stress and bending stress in
the arm BC and indicate where these act.
c) Calculate the torsional stress and bending stress at the top
surface of the shaft at A.

a) Shaft AB:
at B, F = 1.3 kN
M = 1.3 kN x 0.038 m = 49.4 N.m
T = 1.3 kN x 0.1 m = 130 N.m
at A, F = 1.3 kN
M = 1.3 kN x 0.163 m = 211.9 N.m
T = 1.3 kN x 0.1 m = 130 N.m
Arm BC:
at C, F = 1.3 kN
M = 1.3 kN x 0 m = 0 N.m
T = 1.3 kN x 0.038 m = 49.4 N.m
at B, F = 1.3 kN
M = 1.3 kN x 0.1 m = 130 N.m
T = 1.3 kN x 0.038 m = 49.4 N.m

b) In arm BC, Moment at C = 0 N.m while Moment at B =


130 N.m. Therefore, maximum bending stress occurs at B
in member BC.

= 130 N.m (0.015 m)


0.006 m (0.030 m)3
12
= 144.44 MPa
The maximum torsional stress occurs in the middle of the
30 mm side. (page 102, second paragraph, last
sentence.)

49.4 N.m x ( 3 +
0.030 m (0.006 m)2

= 153.69 MPa

1.8

0.030 m / 0.006 m

c)

In shaft AB at A, Moment = 211.9 N.m while Torque =


130 N.m. Maximum bending stress at the top at A,

= 211.9 N.m (0.010 m)

(0.010 m)4
4
= 269.80 MPa
Maximum torsional stress at the top A.

= 130 N.m (0.010 m)

(0.010 m)4
2
= 82.76 MPa

x / y / z = Bending Stress + Normal Stress


= Mc + F
I

xy / yz / zx = Torsional Stress + Transverse Stress


= Tr + Transverse Stress
J

Refer to Table 3.2, page 97

Principle Stress

(Eq. 3-13, page 81)

The bar is loaded by the forces F = 0.55 kN, P


= 8.0 kN and T = 30 N.m. Calculate the
stresses (x and xy) at point A and B.

Given F = 0.55 kN, therefore, M = 0.55kN x 0.1 m = 55


N.m.
P = 8000 N, V = 550 N, T = 30 N.m and M = 55 N.m.
For stresses at MC
A,

P 32 M 4 P

2
3
I
A d
d
32 55
4 8000
x

95.49 MPa
3
2
0.020 0.020

x b nor

xy

Tr 16T
16 30

3
19.10 MPa
3
J d
0.020

For stresses at B,

P 4P
2
A d
4 8000
x
25.46 MPa
2
0.020

x nor

xy

16T 4 V
16 30
4
550
3


21.43 MPa

3
d
3 A 0.020
3 0.020 2
4

Chapter 5 Failures
Resulting from Static
Loading

Ductile Materials (yield criteria)


Maximum

Shear Stress (MSS)


Distortion Energy (DE)
Ductile Coulomb- Mohr (DCM)
Brittle Materials (fracture criteria)
Maximum

Normal Stress (MNS)


Brittle Coulomb-Mohr (BCM)
Modified Mohr (MM)

Failures Theories
Structural

metal behaviour is typically


ductile or brittle.
Ductile Material:
f 0.05;
Identifiable Yield Strength (Syt=Syc=Sy).
Brittle

Material:

f < 0.05
Do not exhibit an Identifiable Yield Strength;
Typically classified by ultimate tensile
strength, Sut and ultimate compressive
strength, Suc (in +ve value).

Selection of Failure
Criteria

18

Ductile Materials

Maximum Shear Stress (MSS)


Theory

The

principal stresses given by Eq. (3-13) are


assumed as A and B. Then they are ordered with the
zero principal stress according to the convention 123.

Assume
For

that AB.

design purposes,
(Eq. 5-3, page 220)

Distortion Energy (DE) Theory


Von

Mises Stress, .
(Eq. 5-12, page 223)
(Eq. 5-13, page 223)

(Eq. 5-14, page 223)


(Eq. 5-15, page 223)
(Eq. 5-19, page 223)

Ductile Coulomb-Mohr (DCM)


Theory
Not

all materials have compressive strengths


equal to their tensile strengths.

(Eq. 5-26, page 229)

St = Syt and Sc = Syc

Brittle Materials

Maximum Normal Stress (MSS)


Theory

(Eq. 5-30, page 235)

Brittle Coulomb-Mohr (BCM)


Theory

(Eq. 5-31, page 236)

Modified Mohr (MM) Theory

(Eq. 5-32, page 236)

Introduction to Fracture
Mechanics
Crack Modes & Stress Intensity Factor
Three

distinct modes of crack


propagation exist.
Mode I: the opening crack
propagation mode,
Mode II: the sliding mode,
Mode III: the tearing mode.

Stress

Intensity Factor, KI

where is the Stress Intensity Modification


Factor
From Figures 5-25 to 5-30.
Critical

Stress Intensity Factor, KIc

also called as Fracture Toughness of the


material.

Figure

5.25: Off-center crack in a plate in


longitudinal tension.

Figure

5.26: Plate loaded in longitudinal


tension with a crack at the edge.

The

strength-to-stress ratio KIc / KI can be


used as a factor of safety as;

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