Lecture 3 - Design For Static Loading

Machine Design & CAD І
(ME-322)
Design for Static Loading

Types of Mechanical Loading
(A)-(i) Axial Load - Tensile (A)-(ii) Axial Load - Compressive
(B) Transverse Load (C) Shear Load

Types of Mechanical Stress
Stress
Simple/Direct Indirect Compound

Stress Stress Stress
Tensile Shear Bending Torsion
mpressive
Thermal Stress
 Thermal Stress: generated when constraints are

imposed to change in size of a body due to ΔT
Thermal Expansion of a Beam Thermal Analysis of Welds

Ductile to Brittle Transition Temperature
 Represents the temperature at which a material’s property

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transits from ductile to brittle behavior
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 Tested via Charpy Test – helps us in determining the min.

temperature at which the material could bear some pre-
defined amount of energy without fracturing
Stress Concentration Factor
 Accounts for the variation in stress from the average/nominal
stress due to geometric/material/load discontinuities
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 To be considered for brittle materials (Ԑ<0.05) under static

loading & ductile/brittle materials for fatigue loading
Value of Kt depend upon the material and geometry of the part.
3D Stress Element
In x-plane in the
direction of y
The above normal stresses and shear stress
are calculated by these equations.
Transformation of Plane Stresses
Principal Planes & Stresses
 Principal Plane: The plane which solely consists of

normal stresses (σn) – no shear stress (Ƭx’y’) exists
 Principal Stresses: The max. & min. value of normal

stresses (σ1,σ2) acting on the principal planes – lie
90° apart from each other
NOTE: Conventionally, θ is taken as +ve in the anti-clockwise direction from x-axis

Maximum Shear Stress
→ →
 Having equal magnitudes but would differ in

direction
 Planes of max. shear stress would occur at 45° to the

principal planes
Mohr’s Circle for Plane Stress
 A graphical tool used to represent the plane stress

transformation equations on a plot
 Helps us understand the relation between σx’/ σy’ and

Ƭx’y’ acting on different planes at a point in a body
under stressed state
 Provides useful insights for failure analysis including

principal stresses and maximum shear stresses
coupled with their respective planes
Mohr’s Circle for Plane Stress (cont.)
Numericals

Question # 1
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Two plates subjected to a tensile force of 50 kN, are fixed together by means of
three rivets. The plates and rivets are made up of plain carbon steel having a tensile
yield strength of 250 N/. Given that the yield strength in shear is 50% of the tensile
yield strength and the factor of safety for these designed plates is 2.5, determine
the (a) diameter of rivets and (b) thickness of plates.
Numericals (cont.)

Question # 2
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A cotter is a pin/wedge used to hold rods firmly together. In this problem we will be
determining the smallest thickness (t) of the cotter and the smallest diameter (d) of
the rods. All parts are made up of steel for which the failure normal stress () is 500
MPa whereas the failure shear stress () is 375 MPa. Use a factor of safety of 2.5 in
tension while 1.75 in shear.
Numericals (cont.)

Question # 3
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For the flat tension bar with a stepped cross section as shown in the figure, the
fillets are quarter circles having the radius consistent with the two widths D and d
i.e. . Given that an axial tensile force of 15 kips is applied to the bar having a larger
width of 4 inches and thickness of 1 inch, find
(a) the max. normal stress in the bar if the smaller width is 3 inch
(b) The min. width of d that can be used for a reduced-width cross section so that
the max. normal stress in the bar doesn’t exceed the value of 8.5 ksi
Numericals (cont.)
Numericals (cont.)
Question # 4
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For the state plane stress consisting of a 90 MPa tensile stress on the x-plane, a 60
MPa compressive stress on the y-plane and a shear stress of +20 MPa, determine
the principal planes, principal stresses, max shear stress plane, max. shear stress
and the corresponding normal stresses by using
(a) the transformation equation for plane stresses

(b) Mohr’s circle
Static Failure Theories

 Applied to applications under constant load
 These theories are characterized on the basis of

material type – generally defined by yielding for
ductile and fracture for brittle materials
 Based upon the comparison of component’s

strength with the material property () obtained
through a simple tensile test
Maximum Normal Stress Theory

 Predicts that failure occurs when the maximum principal stress at any
point in the component surpasses the ultimate tensile strength of the
material
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 Used for brittle materials – limited by their tensile strengths

Maximum Shear Stress Theory

 Predicts that failure occurs when the maximum shear stress at any point
in the component surpasses the shear strength at yield of the material
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 Used for ductile materials – limited by their shear strengths

Maximum Distortion Energy Theory
 Based upon the strain energy produced within the body after
deformation
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 Devised by classifying strain energy density into two components –

hydrostatic volume changing energy and angular distortion energy
 Yielding primarily occurs due to distortion energy

Maximum Distortion Energy Theory (cont.)

 Predicts that failure occurs when the strain energy density due to
distortion at any point of the component surpasses the strain energy
density due to distortion at yield of the material
 Used for ductile materials – limited by their shear strengths
=
Maximum Distortion Energy Theory (cont.)
Numericals (cont.)

Question # 5
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A hot-rolled steel has a yield strength of = 100 kpsi and a true strain at fracture of
= 0.55. Estimate the F.O.S for the following stress state having = -40 kpsi, = -60 kpsi
and = 15 kpsi by using relevant failure theories
Question # 6
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A single horizontal force of 150 lb is applied to end D of lever ABD. Determine (a)
the normal and shearing stresses on an element at point H (b) the principal planes
and stresses at point H.
Numericals (cont.)
Question # 7
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A force F is applied at D near the end of a 15-in lever shown in Figure. This force
results in certain stresses in the cantilevered bar OABC which is made up of AISI
1035 steel, forged and heat-treated so that having a minimum yield strength of 81
kpsi. Find the max force F that can be applied without any failure. Ignore any stress
concentration. The lever DC is strong enough and failure may occur at point A. Use
Max. Distortion / Von Mises Theory

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Machine Design & CAD І

Design for Static Loading

(A)-(i) Axial Load - Tensile (A)-(ii) Axial Load - Compressive

(B) Transverse Load (C) Shear Load

Simple/Direct Indirect Compound

Tensile Shear Bending Torsion

 Thermal Stress: generated when constraints are

Thermal Expansion of a Beam Thermal Analysis of Welds

 Represents the temperature at which a material’s property

 Tested via Charpy Test – helps us in determining the min.

 To be considered for brittle materials (Ԑ<0.05) under static

 Principal Plane: The plane which solely consists of

 Principal Stresses: The max. & min. value of normal

NOTE: Conventionally, θ is taken as +ve in the anti-clockwise direction from x-axis

 Having equal magnitudes but would differ in

 Planes of max. shear stress would occur at 45° to the

 A graphical tool used to represent the plane stress

 Helps us understand the relation between σx’/ σy’ and

 Provides useful insights for failure analysis including

(a) the transformation equation for plane stresses

 Applied to applications under constant load

 These theories are characterized on the basis of

 Based upon the comparison of component’s

 Used for brittle materials – limited by their tensile strengths

 Used for ductile materials – limited by their shear strengths

 Devised by classifying strain energy density into two components –

 Yielding primarily occurs due to distortion energy

 Used for ductile materials – limited by their shear strengths

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