MECH 6441:

Stress Analysis in Mechanical Design

Project A
Presented on: December 23rd, 2016

Project by:
Marco Antonitti 24890477
Ghazaale Zeinaly Fashtali 40028844
Md Tanvir Ibny Gias(Liton) 40025304
Bogdan Opris 40042487
Rohit Kumar Upadhyay 40012770
Agenda
A. Introduction to Problem (i.e. Reported Condition).
B. Displacement, Strain and Stress equations w.r.t. X, Y & Z coordinates.
C. Calculated Values from Reported Condition at each Point.
i. Calculated Displacements
ii. Principal Strains/Stresses & Directions, Max. Shear Stress & Octahedral Stresses
D. Failures ?
E. % Change in Length of a Diagonal.
F. Summary
G. Questions ?
A. Introduction to Problem (i.e. Reported Condition)

Block: 30mm x 20mm x 10 mm (Length x Width x Height).

Block consists of 2 materials.
Bottom Half:

Aluminum 6061-T6 [1]

E (MPa) 70000
0.33
Yield Strength Tension/Comp (Mpa) 260.00
Yield Strength Shear (Mpa) 140.00

Top Half:
Steel High Strength ASTM-A242 [1]
E (MPa) 200000
0.3
Yield Strength Tension/Comp (Mpa) 345.00
Yield Strength Shear (Mpa) 210.00

* Reference:
[1] Ansel C. Ugural, Saul K. Fenster, Advanced Mechanics of Materials and Applied Elasticity, 5th ed., Page 660.
A. Introduction to Problem (i.e. Reported Condition), contd

Block experiences loads which generate the following displacements at each

point:

ACTUAL DISPLACEMENTS

Final State
Initial State "After Loading" Displacement
Point X Y Z X Y Z X Y Z
A 0.000 0.000 20.000 0.001 0.002 20.000 0.001 0.002 0.000
B 30.000 0.000 20.000 30.001 0.000 20.004 0.001 0.000 0.004
C 30.000 10.000 20.000 29.997 10.003 19.996 -0.003 0.003 -0.004
D 0.000 10.000 20.000 0.004 10.009 19.995 0.004 0.009 -0.005
E 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
F 30.000 0.000 0.000 30.009 0.001 0.003 0.009 0.001 0.003
G 30.000 10.000 0.000 29.996 10.003 0.000 -0.004 0.003 0.000
H 0.000 10.000 0.000 0.001 9.996 0.002 0.001 -0.004 0.002
I 30.000 10.000 10.000 29.987 10.005 9.986 -0.013 0.005 -0.014
A. Introduction to Problem (i.e. Reported Condition), contd

Visual analysis of deformations:

Parabolic deformation along CIG?
B) Displacement, Strain and Stress equations w.r.t. X, Y & Z

9 Data Points = 9 coefficients.

3 Directions = 3 Equations derived using Pascals triangle.
Note: Coefficients j, k, m, n, p, and r represent the 6 possible cases to be used to
represent the reported displacements:

, , =
1 + 1 + 1 + 1 + 1 + 1 + 1 + 1 + 12 + 12 + 12 + 12 + 12 + 12

, , =
2 + 2 + 2 + 2 + 2 + 2 + 2 + 2 + 22 + 22 + 22 + 22 + 22 + 22

, , =
3 + 3 + 3 + 3 + 3 + 3 + 3 + 3 + 32 + 32 + 32 + 32 + 32 + 32
B) Displacement, Strain and Stress equations w.r.t. X, Y & Z, contd

Strains were developed based on displacement equations:

, , = =

1 + 1 + 1 + 1 + 12 + 21 + 21 + 12

, , = =

2 + 2 + 2 + 2 + 2 + 22 + 22 + 22 + 22

, , =

3 + 3 + 3 + 3 + 23 + 23 + 32 + 32
B) Displacement, Strain and Stress equations w.r.t. X, Y & Z, contd

Strains were developed based on displacement equations:

, , = + =

1 + 1 + 1 + 1 + 12 + 12 + 21 + 21 +
(2 + 2 + 2 + 2 + 22 + 22 + 22 + 22)

, , = + =

2 + 2 + 2 + 2 + 22 + 22 + 22 + 22 +
(3 + 3 + 3 + 3 + 32 + 32 + 23 + 23)

, , = + =

3 + 3 + 3 + 3 + 32 + 23 + 23 + 32 +
(1 + 1 + 1 + 1 + 21 + 21 + 12 + 12)
B) Displacement, Strain and Stress equations w.r.t. X, Y & Z, contd

Stresses were developed based on strain equations:

=
1 + 1 2

=
2 1+

= {}

_x +2 0 0 0 _x
_y +2 0 0 0 _y
_z +2 0 0 0 _z
_xy 0 0 0 0 0 _xy
_yz 0 0 0 0 0 _yz
_zx 0 0 0 0 0 _zx
C) Calculated Values from Reported Condition.

6 cases were analysed.

Case 1 (x2y): Coefficients j = k = n = p = r = 0, solve for m.
Case 2 (y2z): Coefficients j = k = m = n = r = 0, solve for p.
Case 3 (z2y): Coefficients j = m = n = p = r = 0, solve for k.
Case 4 (y2z): Coefficients j = k = m = n = p = 0, solve for r.
Case 5 (z2x): Coefficients k = m = n = p = r = 0, solve for j.
Case 6 (x2z): Coefficients j = k = m = p = r = 0, solve for n.

Calculate
Obtain expected Compare to
Coefficients for displacements at reported
each case each point using displacements.
equations
C.i) Calculated Displacements Contd

Calculated
Delta
CASE 1: XXY Displacement
CONSTANTS U V W X Y Z X Y Z
A 0.000E+00 0.000E+00 0.000E+00 0.001 0.002 0.000 0.000 0.000 0.000
B 3.000E-04 3.330E-05 8.670E-05 0.001 0.000 0.004 0.000 0.000 0.000
C 1.100E-04 -4.000E-04 2.100E-04 -0.006 0.004 -0.008 -0.003 0.001 -0.004
D 5.000E-05 1.000E-04 0.000E+00 0.004 0.009 -0.005 0.000 0.000 0.000
E 0.000E+00 0.000E+00 0.000E+00 0.000 0.000 0.000 0.000 0.000 0.000
F 9.500E-06 5.500E-05 -3.550E-05 0.009 0.001 0.003 0.000 0.000 0.000
G -1.500E-05 -5.000E-06 2.300E-06 -0.007 0.004 -0.004 -0.003 0.001 -0.004
H 1.200E-06 -1.700E-06 3.000E-07 0.001 -0.004 0.002 0.000 0.000 0.000
M -1.900E-06 8.000E-07 -1.000E-06 -0.006 0.004 -0.006 0.007 -0.001 0.008

CASE 2: YYX
CONSTANTS U V W X Y Z X Y Z
A 0.000E+00 0.000E+00 0.000E+00 0.001 0.002 0.000 0.000 0.000 0.000
B 3.000E-04 3.330E-05 8.670E-05 0.001 0.000 0.004 0.000 0.000 0.000
C 1.100E-04 -4.000E-04 2.100E-04 -0.006 0.004 -0.008 -0.003 0.001 -0.004
D 5.000E-05 1.000E-04 0.000E+00 0.004 0.009 -0.005 0.000 0.000 0.000
E 0.000E+00 0.000E+00 0.000E+00 0.000 0.000 0.000 0.000 0.000 0.000
F 9.500E-06 5.500E-05 -3.550E-05 0.009 0.001 0.003 0.000 0.000 0.000
G -1.500E-05 -5.000E-06 2.300E-06 -0.007 0.004 -0.004 -0.003 0.001 -0.004
H 1.200E-06 -1.700E-06 3.000E-07 0.001 -0.004 0.002 0.000 0.000 0.000
P -5.800E-06 2.300E-06 -2.900E-06 -0.007 0.004 -0.006 0.006 -0.001 0.008
 No deviation btw reported
and calculated displacements
C.i) Calculated Displacements Contd

Calculated
Delta
CASE 3: ZZY Displacement
CONSTANTS U V W X Y Z X Y Z
A 0.000E+00 0.000E+00 0.000E+00 0.001 0.002 0.000 0.000 0.000 0.000
B 3.000E-04 3.333E-05 8.667E-05 0.001 0.000 0.004 0.000 0.000 0.000
C 1.100E-04 -4.000E-04 2.100E-04 -0.003 0.003 -0.004 0.000 0.000 0.000
D 5.000E-05 1.000E-04 0.000E+00 0.004 0.009 -0.005 0.000 0.000 0.000
E -4.700E-05 2.100E-05 -1.567E-05 0.000 0.000 0.000 0.000 0.000 0.000
F -1.805E-04 9.200E-05 -2.755E-04 0.009 0.001 0.003 0.000 0.000 0.000
G -1.500E-05 -5.000E-06 2.330E-06 -0.004 0.003 0.000 0.000 0.000 0.000
H 1.183E-06 -1.717E-06 2.800E-07 0.001 -0.004 0.002 0.000 0.000 0.000
K 9.500E-06 -1.850E-06 1.200E-05 -0.013 0.005 -0.014 0.000 0.000 0.000

CASE 4: YYZ
CONSTANTS U V W X Y Z X Y Z
A 0.000E+00 0.000E+00 0.000E+00 0.001 0.002 0.000 0.000 0.000 0.000
B 3.000E-04 3.330E-05 8.670E-05 0.001 0.000 0.004 0.000 0.000 0.000
C 1.100E-04 -4.000E-04 2.100E-04 -0.006 0.004 -0.008 -0.003 0.001 -0.004
D 5.000E-05 1.000E-04 0.000E+00 0.004 0.009 -0.005 0.000 0.000 0.000
E -5.760E-05 2.310E-05 -2.900E-05 0.000 0.000 0.000 0.000 0.000 0.000
F 0.000E+00 0.000E+00 0.000E+00 0.009 0.001 0.003 0.000 0.000 0.000
G -1.500E-05 -5.000E-06 2.300E-06 -0.007 0.004 -0.004 -0.003 0.001 -0.004
H 1.200E-06 -1.700E-06 3.000E-07 0.001 -0.004 0.002 0.000 0.000 0.000
R 9.000E-07 5.500E-06 -3.500E-06 -0.007 0.004 -0.006 0.006 -0.001 0.008
 No deviation btw reported
and calculated displacements
C.i) Calculated Displacements Contd

Calculated
Delta
CASE 5: ZZX Displacement
CONSTANTS U V W X Y Z X Y Z
A 0.000E+00 0.000E+00 0.000E+00 0.001 0.002 0.000 0.000 0.000 0.000
B 3.000E-04 3.333E-05 8.667E-05 0.001 0.000 0.004 0.000 0.000 0.000
C 1.100E-04 -4.000E-04 2.100E-04 -0.003 0.003 -0.004 0.000 0.000 0.000
D 5.000E-05 1.000E-04 0.000E+00 0.004 0.009 -0.005 0.000 0.000 0.000
E -4.700E-05 2.100E-05 -1.567E-05 0.000 0.000 0.000 0.000 0.000 0.000
F 9.500E-06 5.500E-05 -3.550E-05 0.009 0.001 0.003 0.000 0.000 0.000
G -7.833E-05 7.300E-06 -7.770E-05 -0.004 0.003 0.000 0.000 0.000 0.000
H 1.183E-06 -1.717E-06 2.833E-07 0.001 -0.004 0.002 0.000 0.000 0.000
J 3.167E-06 -6.160E-07 4.000E-06 -0.013 0.005 -0.014 0.000 0.000 0.000

CASE 6: XXZ
CONSTANTS U V W X Y Z X Y Z
A 0.000E+00 0.000E+00 0.000E+00 0.001 0.002 0.000 0.000 0.000 0.000
B 3.000E-04 3.330E-05 8.670E-05 0.001 -0.001 0.004 0.000 -0.001 0.000
C 1.100E-04 -4.000E-04 2.100E-04 -0.006 0.003 -0.007 -0.003 0.000 -0.003
D 5.000E-05 1.000E-04 0.000E+00 0.004 0.009 -0.005 0.000 0.000 0.000
E -5.760E-05 2.310E-05 -2.900E-05 0.000 0.000 0.000 0.000 0.000 0.000
F 9.500E-06 5.500E-05 -3.550E-05 0.009 0.001 0.003 0.000 0.000 0.000
G 0.000E+00 0.000E+00 0.000E+00 -0.007 0.004 -0.004 -0.003 0.001 -0.004
H 1.200E-06 -1.700E-06 3.000E-07 0.001 -0.004 0.002 0.000 0.000 0.000
N -5.000E-07 -2.000E-07 1.000E-07 -0.007 0.004 -0.006 0.006 -0.001 0.008
C.ii) Principal Strains/Stresses & Directions, Max. Shear Stress & Octahedral
Stresses
CASE 3: ZZY
POINT: A B C D E F G H I (Alu.) I (Steel)
MATERIAL
Steel High Strength ASTM-A242 x x x x x
Yield Strength Tension/Comp (MPa) 345.00 345.00 345.00 345.00 345.00
Yield Strength Shear (MPa) 210.00 210.00 210.00 210.00 210.00
Aluminum 6061-T6 x x x x x
Yield Strength Tension/Comp (MPa) 260.00 260.00 260.00 260.00 260.00
Yield Strength Shear (MPa) 140.00 140.00 140.00 140.00 140.00
STRESSES
Principal Stresses
_1 (MPa) 198.27 141.91 681.54 666.94 12.28 77.98 -92.22 -163.56 77.05 223.61
_2 (MPa) 94.28 63.45 281.44 397.78 -3.77 39.14 -146.40 -183.18 -8.99 -27.89
_3 (MPa) 57.45 -20.42 169.77 191.08 -29.10 6.39 -284.55 -337.82 -58.33 -172.12
Max Shear Stress
_max (MPa) 70.41 81.16 255.88 237.93 20.69 35.79 96.17 87.13 67.69 197.86
Octahedral Stresses
_oct (MPa) 116.67 61.65 377.58 418.60 -6.86 41.17 -174.39 -228.19 3.24 7.87
_oct (MPa) 59.63 66.28 219.71 194.83 17.04 29.26 80.98 77.93 55.94 163.52
MARGINS OF SAFETY
Principal Stresses
_1 (MPa) 74% 143% -49% -48% 2017% 233% 182% 59% 237% 54%
_2 (MPa) 266% 444% 23% -13% 6805% 564% 78% 42% 2791% 1137%
_3 (MPa) 501% 1590% 103% 81% 793% 3969% -9% -23% 346% 100%
Max Shear Stress
_max (MPa) 198% 159% -18% -12% 577% 291% 46% 61% 107% 6%
Octahedral Stresses
_oct (MPa) 196% 460% -9% -18% 3689% 532% 49% 14% 7927% 4286%
_oct (MPa) 252% 217% -4% 8% 722% 378% 73% 80% 150% 28%
C.ii) Principal Strains/Stresses & Directions, Max. Shear Stress & Octahedral
Stresses
CASE 5: ZZX
POINT: A B C D E F G H I (Alu.) I (Steel)
MATERIAL
Steel High Strength ASTM-A242 x x x x x
Yield Strength Tension/Comp (MPa) 345.00 345.00 345.00 345.00 345.00
Yield Strength Shear (MPa) 210.00 210.00 210.00 210.00 210.00
Aluminum 6061-T6 x x x x x
Yield Strength Tension/Comp (MPa) 260.00 260.00 260.00 260.00 260.00
Yield Strength Shear (MPa) 140.00 140.00 140.00 140.00 140.00
STRESSES
Principal Stresses
_1 (MPa) 198.57 762.61 681.66 122.21 12.33 -33.05 -92.15 -40.35 1.95 21.07
_2 (MPa) 94.43 341.45 281.75 -16.67 -3.71 -101.01 -146.33 -59.30 -29.77 -71.65
_3 (MPa) 57.70 281.04 169.94 -49.04 -29.01 -236.53 -284.48 -90.58 -65.50 -176.08
Max Shear Stress
_max (MPa) 70.44 240.79 255.86 85.63 20.67 101.74 96.17 25.11 33.72 98.58
Octahedral Stresses
_oct (MPa) 116.90 461.70 377.78 18.83 -6.79 -123.53 -174.32 -63.41 -31.11 -75.55
_oct (MPa) 59.67 214.20 219.67 74.28 17.02 84.58 80.98 20.71 27.55 80.54
MARGINS OF SAFETY
Principal Stresses
_1 (MPa) 74% -55% -49% 182% 2008% 687% 182% 544% 13254% 1537%
_2 (MPa) 265% 1% 22% 1969% 6907% 157% 78% 338% 773% 382%
_3 (MPa) 498% 23% 103% 603% 796% 10% -9% 187% 297% 96%
Max Shear Stress
_max (MPa) 198% -13% -18% 145% 577% 38% 46% 457% 315% 113%
Octahedral Stresses
_oct (MPa) 195% -25% -9% 1732% 3727% 110% 49% 310% 736% 357%
_oct (MPa) 252% -2% -4% 183% 723% 66% 73% 576% 408% 161%
D) Failures ?

Failure Criterion:
A point that is subjected to stresses > material yield allowable.
Plastic deformation = Point has failed.

Case 3:
Qty-4 points have failed, specifically points C & D (Material: Steel) and points G &
H (Material: Aluminum Alloy).
At Points C & D, failure occurred due to excessive Tension and Shear Stress.
At Points G & H, failure occurred due to excessive Compressive Stress.

Case 5:
Qty-3 points have failed, specifically points B & C (Material: Steel) and points G
(Material: Aluminum Alloy).
At Points B & C, failure occurred due to excessive Tension and Shear Stress.
At Points G, failure occurred due to excessive Compressive Stress.
E) % Change in Length of a Diagonal.
F) Summary

2 Cases seemed to best describe our reported displacements, Case 3 & Case
5, so which one is better?
The more conservative approach is to take the one which gives the higher applied
stresses (i.e. Lower Margins of Safety).
According to Case 3, Qty-4 points have failed due to applied Tension, Compression
and/or Shear loads.
According to Case 5, Qty-3 points have failed due to applied Tension, Compression
and/or Shear loads.

We select CASE 3 because according the calculations using this equation, the
overall margin of safety is less than that of Case 5. Therefore, we must design our
part to meet these applied loads PLUS an additional factor of safety.
QUESTIONS?