1.

Stress Analysis
Moment of Inertias
1. Atalet moment of inertia; 2. Polar moment of inertia;

2
I y x dA
2 2 2
I x y dA J z ( x y )dA
Shape Ix Iy J
Rectangle bh3/12 hb3/12

bh 2 2
12
b h
3 3
Triangle bh /36 hb /36 h 2 b 2
bh
18

Circle d4/64 d4/64 d4/32

Stresses
Normal Stresses Shear Stresses
F
Tensile Tr
A
Axial Torsional J
F
Compression 16T / d
3
for solid circular beam
A
VQ
Mc , Q Ay
b Ib
I Transverse max 4V / 3 A for solid circular beam
Bending
32 M (Flexural)
b for solid circular beam max 2V / A for hollow circular section
d
3

max 3V / 2 A for rectangular beam

2
x y x y
1,2 xy
2
Principle stresses
2 2 2 xy
tan 2

2 x y
1,2 xy
x y 2
Max. and min shear stresses
2
' 1 1 2 2 ' x 3 xy (for biaxial)
2 2 2 2
Von-Mises stresses or

Stress States
1 2 3
1
E E
2 1 3
Triaxial stress state 2
E E
3 1 2
2
E E

Stress in Cylinders

Thick-Walled (t/r>1/20) Wessels (internally and externally pressurized cyclinders):

2 2 2 2 2 2 2 2 2 2 2
pi a po b a b ( po pi ) / r pi a po b a b ( po pi ) / r pi a
t 2 2
r 2 2
l 2 2
b a b a b a
 If the external pressure is zero (po=0);

a pi b a pi b
2 2 2 2
t 2 2 1 2 r 2 2 1 2
b a r b a r

2 2 2
b a 2a
r=a r pi t pi 2 2
r=b r 0 t pi 2 2
b a b a

If the internal pressure is zero (pi=0);

b a2
2
b a2
2
t po 2 2
1 2 r po 2 2
1 2
b a r b a r

2 2 2
2b b a
r=a r 0 t po 2 2
r=b r po t po 2 2
b a b a

a=inside radius of the cylinder b=outside radius of the cylinder pi=internal pressure po=external pressure

Thin-Walled Wessels(t/r<1/20):

pd i pd i
t l
2t 4t

Curved Members In Flexure:

A My Mco Mci
r o , i
dA Ae( r y ) Aero Aeri

Press and Shrink Fit:

2 2 2 2
b a c b
it p 2 2
ot p 2 2
b a c b
bp c b
2 2
o 2 2
o
Eo c b

bp b a
2 2
i 2 2
i
Ei b a

bp c b bp b 2 a 2
2 2
o i 2 2
o 2 2
i
Eo c b Ei b a

if Eo Ei E; interface pressure = p =
E c b
2 2

b 2
a
2

b
2b
2
c 2
a
2

 2. Deflection Analysis
F T GJ AE
k , k=spring constant k ,k=Torsional spring rate k for tension or compression loading
y l l

Castiglianos Theorem:

U U Total energy
y
F
F Force on the deflection point
Tl
Angular deflection
GJ

Strain Energy

2 2
F L F L
Axial Load U Direct Shear Force U
2 AE 2 AG

2 2
T L M
Torsional Load U Bending Moment U dx
2GJ 2 EI

2
CF
Flexural Shear U dx , C is constant
2GA

Buckling Consideration:
1/ 2
l I l 2EC
Slenderness ratio= , k
k A k 1 Sy

l l C E
2
C 2 EI
Euler Column ;
Pcr

Critical Unit Load = Pcr
k k 1 A l / k l2
2

2
S y 1 l
2
l l
Johnson's Column
Pcr
Critital Unit Load = = Sy
k k 1 A 2 CE k

1. Both ends are rounded-simply supported C=1

2. Both ends are fixed C=4

3. One end fixed, one end rounded and guided C=2

4. One end fixed, one end free C=1/4

 3.Design For Static Strength
Ductile Materials

1. Max. Normal Stress Theory (MNST): 3. Distortion Energy Theory

If, 1 2 3 If, 1 2 3

Sy ( 1 2 ) ( 2 3 ) ( 3 1 )
2 2 2
n '
1 2

2. Max. Shear Stress Theory (MSST): For baxial stress state;

Yield strength in shear (Ssy)=Sy/2 ' x 3 xy

2 2

max
1 3 , for biaxial stress state; Sy
2 n

1

1 2 2
max x 4 xy
2

S sy
n
max

Brittle Materials

1. Max. Normal Stress Theory (MNST): 3. The Modified Mohr Theory (MMT)

Sut Suc If, 1 2 3

If, 1 2 3 n or n
1 3
Suc
S3
2. The Column Mohr Theory (CMT) or Internal Suc Sut 1
1
Friction Theory (IFT): Sut 3

Suc
S3 S3 n
S3
Suc 1 n
1 3 3
Sut 3
 5. Design for Fatigue Strength

Endurance limit for test specimen (Se);

For ductile materials:

Se=0.5 Sut if Sut<1400 MPa
Se=700 MPa if Sut 1400 MPa
For irons:
Se=0.4 Sut if Sut<400 MPa
Se=160 MPa if Sut 400 MPa
For Aliminiums:
Se=0.4 Sut if Sut<330 MPa
Se=130 MPa if Sut 330 MPa
For copper alloys:
Se 0.4 Sut if Sut<280 MPa
Se 100 MPa if Sut 280 MPa

Se = ka kb kc kd ke Se

Sf=10c Nb

1 0.8Su 0.8Su 2
b log c log
3 Se Se

ka= surface factor, ka=aSutb

Surface Finish Factor a Factor b
Ground 1.58 -0.065
Machined or Cold Drawn 4.51 -0.265
Hot Rolled 57.7 -0.718
As Forged 272 -0.995

kb= size factor;

kb=1 if d 8 mm and kb= 1.189d-0.097 if 8 mm<d 250 mm for bending & torsional loading.
0.097
For non-rotating element, k b 1.189deq deq=0.37d
For pure axial loading, kb=1 and Se=0.45Sut
For combined loading, =1.11 if Sut 1520 MPa and =1 if Sut 1520 MPa for ductile materials.
kc=reliability factor
kd=temperature effects, kd=1 if T 3500 and kd=0.5 if 3500<T 5000
ke=stress concentration factor, ke=1/Kf Kf=1+q(Kt-1)
Kt=geometric stress concentration factor, q=notch sensitivity.

Modified Goodman Soderberg

Infinite Life Finite Life Infinite Life Finite Life
1 1 1 1
n= n= n= n=
a m a m a m a m
+ + + +
Se Su Sf Su Se Sy Sf Sy
Fa=(Fmax-Fmin)/2 Fm=(Fmax+Fmin)/2
 6. Tolerances and Fits

TF=Cmax-Cmin dL=DU-c Cmax=DU-dL Cmin=DL-dU

TF=Imax+Cmax dU=dL+TS Imax=dU-DL Imin=dL-Du
TF=Imax-Imin dU=DL+Imax

TS=dU-dL TH=DU-DL TF=TH+TS

7. Design of Power Screws

Fd m L d m Fd m d m L
TR TL
2 d m L 2 d m L

Or considering tan ;

Fd m Fd m
TR tan TR tan
2 2

If the friction between the stationary member and the collar of the screw is taken into consideration;

Fd m dF Fd m dF
TR tan c c TR tan c c
2 2 2 2

To FL tan
when collar friction is negligible, we obtain as,
TR 2TR tan

L
If tan or then screw is self locking.
d m

Bearing Stresses

4pF Fp p
b b t
h d 2 d r 2 d m th 2

Shear Stresses

For Screw Thread For Nut Thread

2F 2F
s n
d r h dh

Bending Stresses

6F
The maximum bending stress, N=h/p
d m Np
 Tensile or Compressive stresses

F d t 2 dr dm
x At dt
At 4 2

Combined Stresses

16TR
xy
d t 3

Based on distortion energy theory;

16TR Sy
xy ' x 2 3xy 2 n
d t 3 '

Based on maximum shear stres theory;

1 Ssy
max x 2 4xy 2 n
2 max

8. Design of Bolted Joints

kb
Fe=Feb+Fep Feb=CFe Fep=(1-C)Fe C=
kb km

Fb=Fi+CFe Fm=Fi-(1-C)Fe

Ab Eb 1 1 1 1
kb ..........
L k m k1 k 2 kn

Fi Fi
b m
kb km

Shigley and Mishke approach;

For cone angle of 300 ,

1.813Ei d 1 1 1 1
ki ..........
1.15Li 0.5d k m k1 k 2 kn
ln 5
1.15Li 2.5d

1.813Ed
If L1=L2=L/2 and materials are same, k m
2.885L 2.5d
2 ln
0.577L 2.5d
 For cone angle of 450 ,

Ei d
ki
5 2Li 0.5d
ln
2Li 2.5d

Ed
If L1=L2=L/2 and materials are same, k m
L 0.5d
2 ln 5
L 2.5d

Wileman approach;

k m EdAi e(Bid / L)

Where Ai and Bi are constants related to the material. For Steel Ai=0.78715 and Bi=0.62873, for
Aliminium Ai=0.79670 and Bi=0.63816, for Gray cast iron Ai=0.77871 and Bi=0.61616.

Filiz approach;

d 8
L
2
1 B1 EE 0.1d
k m E eq d e 5 L E eq 1 2 B1 B1 1 1
2 1 B2 E1 E 2 L L2

Static loading;

Fb Sy A t or Fb Sp A t S p 0.85Sy Fm 0

1 C nFe Fi Sp At CnFe n=load factor of safety

Fi
Critical load= Fce
1 C

Dynamic Loading:

CnFe Fi 1 A tSu CnFe Su

a m a ns Fi 1
2A t At a m ns 2 Se

Se Su

Fi=the maximum value of preload for there is no fatigue failure.

Limitations:

0.6Fp Fi 0.9Fp where Fp A tSp

cFe n Sut
Fi max A tSut 1
2N Se

Fe cF 180
(1 c) Fi A tSp e 3.5d cb 10d cb
N N N
 9. Design of Riveted Joints

Shearing of Rivets: Secondary Shear Force

F Mri
, F=Force on each rivet Fi ''
A N

r
1
i
2

d 2
A
4

Bearing (compression) Failure: Plate Tension Failure:

F F
, A=td, t=thickness of the plate , A w Nd t
A A

Primary Shear Force w=width of plate

F N=number of rivets on the

F' N

A
1
i
selected cross section

10. Design of Welded Joints

Primary Shear Stress J 0.707hJ u

F
'
A

Secondary Shear Stress I 0.707hIu

Mr
''
J

Bending Stress
Mc

I
Table 9-3 Minimum weld-metal properties
AWS electrode Tensile Strength Yield Strength Percent
Number MPa MPa Elongation
E60xx 420 340 17-25
n
E70xx 480 390 22
E80xx 530 460 19
E90xx 620 530 14-17
E100xx 690 600 13-16
E120xx 830 740 14

Table 9-5 Fatigue-strength reduction factors

Type of Weld Kf
Reinforced butt weld 1.2
Toe of transverse fillet weld 1.5
End of parallel fillet weld 2.7
T-butt joint with sharp corners 2.0
Table 9-1 Torsional Properties of Fillet Welds*
Unit Polar Moment of
Weld Throat Area Location of G
Inertia

*G is centroid of weld group; h is weld size; plane of torque couple is in the plane of the paper; all
welds are of the same size.
Table 9-2 Bending Properties of Fillet Welds*
Weld Throat Area Location of G Unit Moment of Inertia

*Iu, unit moment of inertia, is taken about a horizontal axis through G, the centroid of the weld
group; h is weld size; the plane of the bending couple is normal to the paper; all welds are of the
same size
 Table A3-8 Stress concentration factors for round shaft with

shoulder fillet in tension

D d
.

o= F/A, where A= d2/4

D/d =1,02 D/d =1,05 D/d =1,1 D/d=1,5

r/d Kt Kt Kt Kt

0,025 1,800 - - -

0,028 1,728 - 2,200 -

0,031 1,678 2,000 2,125 -

0,037 1,610 1,868 2,020 -

0,044 1,550 1,778 1,938 2,522

0,050 1,508 1,714 1,866 2,400

0,062 1,452 1,626 1,766 2,235

0,075 1,408 1,550 1,684 2,086

0,088 1,370 1,502 1,624 1,970

0,100 1,336 1,457 1,568 1,893

0,125 1,286 1,400 1,496 1,760

0,150 1,254 1,364 1,452 1,662

0,175 1,230 1,340 1,400 1,600

0,200 1,220 1,314 1,372 1,546

0,250 1,216 1,292 1,342 1,508

0,275 1,200 1,270 1,325 1,480

0,300 1,200 1,250 1,296 1,452

* Adopted from Ref. [12]

Table A3-9 Stress concentration factors for round shaft with shoulder fillet

in torsion

T T
D d

o= Tc/J, where c=d/2 and J=d4/32

D/d =1,09 D/d =1,20 D/d =1,33 D/d =2,0

r/d Kt Kt Kt Kt

0,009 - - - -

0,012 1,800 2,300 - 2,600

0,030 1,566 2,040 2,144 2,288

0,025 1,472 1,894 2,020 2,122

0,033 1,384 1,761 1,878 1,966

0,042 1,322 1,644 1,755 1,828

0,050 1,283 1,576 1,677 1,750

0,062 1,244 1,500 1,600 1,644

0,075 1,206 1,434 1,516 1,572

0,087 1,184 1,378 1,458 1,510

0,100 1,166 1,342 1,412 1,466

0,125 1,144 1,275 1,344 1,400

0,150 1,122 1,220 1,294 1,344

0,200 1,110 1,160 1,220 1,266

0,250 1,100 1,130 1,178 1,222

0,300 1,100 1,120 1,160 1,200

* Adopted from Ref. [12]

 Table A3-10 Stress Concentration factors for round shaft with shoulder

fillet in bending

M D d M

o= Mc/I, where c=d/2 and I=d4/64

D/d =1,02 D/d =1,05 D/d =1,1 D/d =1,5 D/d =3

r/d Kt Kt Kt Kt Kt

0,012 2,290 2,553 2,700 - -

0,017 2,120 2,378 2,500 3,000 -

0,021 2,000 2,240 2,366 2,774 3,000

0,025 1,926 2,134 2,260 2,600 2,862

0,036 1,760 1,936 2,046 2,310 2,600

0,050 1,644 1,782 1,865 2,060 2,310

0,062 1,574 1,700 1,750 1,925 2,140

0,075 1,518 1,628 1,688 1,800 1,986

0,087 1,472 1,563 1,630 1,728 1,880

0,100 1,440 1,534 1,580 1,660 1,804

0,125 1,380 1,468 1,500 1,584 1,684

0,150 1,330 1,412 1,450 1,510 1,584

0,175 1,297 1,358 1,400 1,450 1,510

0,200 1,264 1,336 1,360 1,400 1,457

0,225 1,242 1,308 - - 1,410

0,250 1,225 1,286 - - 1,374

0,275 1,210 1,264 - - 1,340

0,300 1,200 1,242 - - 1,320

* Adopted from Ref. [12]