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Chapter 3 Load and stress analysis

Chapter 3-Load and Stress Analysis

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Page 1: Chapter 3-Load and Stress Analysis

Chapter 3

Load and stress analysis

Page 2: Chapter 3-Load and Stress Analysis

Outline

1. Introduction

2. Equilibrium and Free-Body Diagrams

3. Shear Force and Bending Moments in Beams

4. Stress

5. Normal Stresses for Beams in Bending

6. Shear Stresses for Beams in Bending

7. Torsion

8. Stress Concentration

9. Contact stress

Page 3: Chapter 3-Load and Stress Analysis

Machine elements carry different types of loads (concentrated,

distributed, axial, lateral, moments, torsion, etc.) according to the

function and configuration of each element. These loads cause

stresses of different types and magnitudes in different locations

in the element.

When designing machine elements it is important to locate the

critical locations (or sections) and to evaluate the stress at the

critical sections to ensure the safety and functionality of the

machine element.

1. Introduction

Page 4: Chapter 3-Load and Stress Analysis

2. Equilibrium and Free-Body Diagrams (1)

Equilibrium of a body requires both a balance of forces (to prevent

translation) and balance of moments (to prevent rotations):

A free body diagram (FBD) is a sketch of an element or group of

connected elements that shows all the forces acting on it (applied

loads, gravity forces, and reactions)

See Example 3-1

Page 5: Chapter 3-Load and Stress Analysis

Example 3-1

2. Equilibrium and Free-Body Diagrams (2)

Page 6: Chapter 3-Load and Stress Analysis

3. Shear Force and Bending Moments in Beams

Shear and moment diagrams are important in locating the critical sections

in a beam (sections with maximum shear or moment) such that stresses

are evaluated at these sections.

When the loading is not simple, he shear force and moment diagrams can

be obtained by using sections.

Page 7: Chapter 3-Load and Stress Analysis

Shear force V and bending moment M are related by equation

3. Shear Force and Bending Moments in Beams

Page 8: Chapter 3-Load and Stress Analysis

Singularity functions

3. Shear Force and Bending Moments in Beams

Page 9: Chapter 3-Load and Stress Analysis

Singularity functions Load function

3. Shear Force and Bending Moments in Beams

Page 10: Chapter 3-Load and Stress Analysis

Example 3-2: Derive the loading, shear-force, and bending-

moment relations for the beam

Singularity functions

3. Shear Force and Bending Moments in Beams

Page 11: Chapter 3-Load and Stress Analysis

Singularity functions

3. Shear Force and Bending Moments in Beams

Page 12: Chapter 3-Load and Stress Analysis

4. Stress

In general, the stress at a point on a cross-section will have

components normal and tangential to the surface, which hare

named as normal stress and shear stress .

Stress is the term used to define the intensity and direction of

the internal forces acting at a given point on a particular plane.

Page 13: Chapter 3-Load and Stress Analysis

The state of stress at a point is described by three mutually

perpendicular surfaces. Thus, in general, a complete state of stress is

defined by nine stress components

Plane stress with “cross shear” equal

Nine stress components:x , y , z , xy , xz , yx ,yz, zx ,zy

For equilibrium, “cross-shears” are equal:

xy = xz ; yx =yz ; zx =zy

4. Stress (2)

Six stress components:x , y , z , xy yz, zx

Page 14: Chapter 3-Load and Stress Analysis

Mohr’s Circle for plane stress

4. Stress (3)

Concerning with the stresses σ and τ

that act upon this oblique plane.

By summing the forces caused by all

the stress components to zero, the

stresses σ and τ are found to be

Page 15: Chapter 3-Load and Stress Analysis

Principal stresses and principal directions

Max = 1

Min = 2

0

p= 0

- 1, 2 are principal stresses and their corresponding

directions are principal directions.

- zero shear tresses

Mohr’s Circle for plane stress

4. Stress (4)

Page 16: Chapter 3-Load and Stress Analysis

0

Two surfaces containing the maximum shear stresses also

contain equal normal stresses of (x + y )/2

Mohr’s Circle for plane stress

4. Stress (5)

Page 17: Chapter 3-Load and Stress Analysis

The parametric relationship between and is a circle.

This circle is known as Mohr’s circle, where it provides a

convenient method of graphically visualizing the state of

stress and it can be used to find the principal stresses as

well as performing stress transformation

xyyxyx

τ)σσ

(R σσ

cwhere

Rc

22

222

2 and

2

)(

4. Stress (6)

Mohr’s Circle for plane stress

Page 18: Chapter 3-Load and Stress Analysis

Mohr’s Circle for plane stress

4. Stress (7)

Page 19: Chapter 3-Load and Stress Analysis

4. Stress (8)

Mohr’s Circle for plane stress

Page 20: Chapter 3-Load and Stress Analysis

Example

Mohr’s Circle for plane stress

4. Stress (9)

Page 21: Chapter 3-Load and Stress Analysis

Solution

4. Stress (9)

a) Draw the and axes first.

Establish point A on x surface

with coordinates

A (x, cw

xy)= (80, 50cw)MPa

along with axis.

Corresponding to the y

surface, locates point B with

coordinates

B (y, ccw

xy)= (0, 50ccw)MPa.

The line AB form diameter of

the Morh’s circle. The

intersection of the circle with

the axis defined 1 and 2.

The maximum shear stress is equal to the radius of the circle:

𝜏1 = ±𝜎𝑥−𝜎𝑦

2

2+ 𝜏𝑥𝑦

2 = ± 402 + 502 = ±64 MPa.

The principal stresses can be found on the circle to be

𝜍1, 𝜍2 =𝜎𝑥+𝜎𝑦

𝜎𝑥−𝜎𝑦

2

2+ 𝜏𝑥𝑦

2 𝜍1 = 40 + 64 = 104 MPa

𝜍2 = 40 − 64 = 24 MPa

Page 22: Chapter 3-Load and Stress Analysis

Solution

4. Stress

The angle 2∅ from the x axis clockwise

to 𝜍1 is

𝑡𝑎𝑛2∅𝑝 =2𝜏𝑥𝑦

𝜎𝑥−𝜎𝑦

→ 2∅𝑝 = 𝑡𝑎𝑛−1 2𝜏𝑥𝑦

𝜎𝑥−𝜎𝑦= 𝑡𝑎𝑛−1 50

40= 51.30

To draw the principal stress element

(Fig. 3–11c), sketch the x and y axes

parallel to the original axes. The angle

φp on the stress element must be

measured in the same direction as is the angle 2φp on the Mohr circle.

From x measure 25.7° (half of 51.3°)

clockwise to locate the σ1 axis. The σ2 axis is 90° from the σ1 axis and the

stress element can now be completed

and labeled as shown. Note that there

are no shear stresses on this element.

Page 23: Chapter 3-Load and Stress Analysis

Solution

The two maximum shear

stresses occur at points E

and F in Fig. 3–11b.

The two normal stresses

corresponding to these

shear stresses are each 40

MPa, as indicated. Point E

is 38.7° ccw from point A on

Mohr’s circle.

Therefore, in Fig. 3–11d,

draw a stress element

oriented 19.3° (half of

38.7°) ccw from x. The

element should then be

labeled with magnitudes

and directions as shown.

4. Stress

Page 24: Chapter 3-Load and Stress Analysis

Solution

b) The transformation equations are programmable.

From Eq. (3–10),

→ ∅𝑝 =1

2𝑡𝑎𝑛−1 2𝜏𝑥𝑦

𝜎𝑥−𝜎𝑦 =

1

2𝑡𝑎𝑛−1 2(−50)

80= −25.70; 64.30

From Eq. (3–8), for the first angle ∅𝑝 =−25.7◦

𝜍 =𝜎𝑥+𝜎𝑦

2+

𝜎𝑥−𝜎𝑦

2𝑐𝑜𝑠2∅ + 𝜏𝑥𝑦𝑠𝑖𝑛2∅

𝜍 =80+0

2+

80−0

2𝑐𝑜𝑠 2 −25.70 + −50 𝑠𝑖𝑛 2 −25.70 = 104.3 𝑀𝑃𝑎

The shear stress on this surface is obtained from Eq. (3.9) as

𝜏 = −𝜎𝑥−𝜎𝑦

2𝑠𝑖𝑛2∅𝑝 + 𝜏𝑥𝑦𝑐𝑜𝑠2∅𝑝

𝜏 = −80−0

2𝑠𝑖𝑛 2 −25.70 + −50 𝑐𝑜𝑠 2 −25.70 = 0 𝑀𝑃𝑎

For ∅𝑝 = 64.30

𝜍 =80+0

2+

80−0

2𝑐𝑜𝑠 2 64.30 + −50 𝑠𝑖𝑛 2 64.30 = −24.03 𝑀𝑃𝑎

𝜏 = −80−0

2𝑠𝑖𝑛 2 64.30 + −50 𝑐𝑜𝑠 2 64.30 = 0 𝑀𝑃𝑎

→ 𝜍1 = 104.3𝑀𝑃𝑎; ∅𝑝1 = −25.70

𝜍2 = −24.3𝑀𝑃𝑎; ∅𝑝2 = 64.30

4. Stress

Page 25: Chapter 3-Load and Stress Analysis

To determine 1 and 2, we first use Eq. (3.11) to calculate ∅𝑠:

→ 𝑡𝑎𝑛2∅𝑠 = −𝜎𝑥−𝜎𝑦

2𝜏𝑥𝑦

→ ∅𝑠 =1

2𝑡𝑎𝑛−1 −

𝜎𝑥−𝜎𝑦

2𝜏𝑥𝑦

→ ∅𝑠 =1

2𝑡𝑎𝑛−1 −

80−0

2(−50)= 19.30; 109.30

For ∅𝑠 = 19.30, Eq. (3.8) and (3.9) yield

𝜍 =80+0

2+

80−0

2𝑐𝑜𝑠 2 19.30 + −50 𝑠𝑖𝑛 2 19.30 = 40.0 𝑀𝑃𝑎

𝜏 = −80−0

2𝑠𝑖𝑛 2 19.30 + −50 𝑐𝑜𝑠 2 19.30 = −64.0 𝑀𝑃𝑎

For ∅𝑠 = 19.30, Eq. (3.8) and (3.9) yield

𝜍 =80+0

2+

80−0

2𝑐𝑜𝑠 2 109.30 + −50 𝑠𝑖𝑛 2 109.30 = 40.0 𝑀𝑃𝑎

𝜏 = −80−0

2𝑠𝑖𝑛 2 109.30 + −50 𝑐𝑜𝑠 2 109.30 = 64.0 𝑀𝑃𝑎

4. Stress

Page 26: Chapter 3-Load and Stress Analysis

To determine 1 and 2, we first use Eq. (3.11) to calculate ∅𝑠:

→ 𝑡𝑎𝑛2∅𝑠 = −𝜎𝑥−𝜎𝑦

2𝜏𝑥𝑦

→ ∅𝑠 =1

2𝑡𝑎𝑛−1 −

𝜎𝑥−𝜎𝑦

2𝜏𝑥𝑦

→ ∅𝑠 =1

2𝑡𝑎𝑛−1 −

80−0

2(−50)= 19.30; 109.30

For ∅𝑠 = 19.30, Eq. (3.8) and (3.9) yield

𝜍 =80+0

2+

80−0

2𝑐𝑜𝑠 2 19.30 + −50 𝑠𝑖𝑛 2 19.30 = 40.0 𝑀𝑃𝑎

𝜏 = −80−0

2𝑠𝑖𝑛 2 19.30 + −50 𝑐𝑜𝑠 2 19.30 = −64.0 𝑀𝑃𝑎

For ∅𝑝 = 64.30

𝜍 =80+0

2+

80−0

2𝑐𝑜𝑠 2 64.30 + −50 𝑠𝑖𝑛 2 64.30 = −24.03 𝑀𝑃𝑎

𝜏 = −80−0

2𝑠𝑖𝑛 2 64.30 + −50 𝑐𝑜𝑠 2 64.30 = 0 𝑀𝑃𝑎

→ 𝜍1 = 104.3𝑀𝑃𝑎; ∅𝑝1 = −25.70

𝜍2 = −24.3𝑀𝑃𝑎; ∅𝑝2 = 64.30

4. Stress

Page 27: Chapter 3-Load and Stress Analysis

General Three-Dimensional Stress

4. Stress

Page 28: Chapter 3-Load and Stress Analysis

5. Elastic Strain

Normal strain 𝜖 is given as

𝜖 =𝛿

𝑙 (3.16)

where δ is the total elongation of the bar within the length l.

Hooke’s law for the tensile specimen is given as

𝜍 = 𝐸𝜖 (3.17)

where the constant E called Young’s modulus or the modulus of elasticity

When a material is placed in tension, there exists not only an axial strain, but also

negative strain (contraction) perpendicular to the axial strain.

Assuming a linear, homogeneous, isotropic material, this lateral strain is proportional

to the axial strain. If the axial direction is x, then the lateral strains are

𝜖𝑦 = 𝜖𝑧 = 𝜈𝜖𝑥

The constant of proportionality 𝜈 is called Poisson’s ratio, which is about 0.3 for

most structural metals.

See Table A–5 for values of v for common materials.

Page 29: Chapter 3-Load and Stress Analysis

5. Elastic Strain

𝜖𝑥 =1

𝐸𝜍𝑥 − 𝜈 𝜍𝑦 + 𝜍𝑧

𝜖𝑦 =1

𝐸𝜍𝑦 − 𝜈 𝜍𝑥 + 𝜍𝑧 (3.19)

𝜖𝑧 =1

𝐸𝜍𝑧 − 𝜈 𝜍𝑦 + 𝜍𝑥

Shear strain γ is the change in a right angle of a stress element when subjected

to pure shear stress, and Hooke’s law for shear is given by

𝜏 = 𝐺𝛾 (3.20)

where the constant G is the shear modulus of elasticity or modulus of rigidity. It

can be shown for a linear, isotropic, homogeneous material, the three elastic

constants are related to each other by

𝐸 = 2𝐺(1 + 𝜈) (3.21)

If the axial stress is in the x direction, then from Eq. (3–17)

𝜖𝑥 =𝜎𝑥

𝐸; 𝜖𝑦 = 𝜖𝑦 = −𝜈

𝜎𝑥

𝐸 (3.18)

For a stress element undergoing σx , σy , and σz simultaneously, the normal strains

are given by

Page 30: Chapter 3-Load and Stress Analysis

6. Normal stresses for beams in Bending

Page 31: Chapter 3-Load and Stress Analysis

or

where Z= I/c is called the section modulus.

I is the second-area moment

of inertia (second-area

moment) about the z axis

Tables A-6, A-7 and A-8 in the text give the I and Z values for

some standard cross-section beams

6. Normal stresses for beams in Bending

Page 32: Chapter 3-Load and Stress Analysis

For a rectangular cross-section,

𝐼 =𝑏𝑑3

12 (3–25a)

Where,

b is distance parallel to the neutral axis (mm)

d is distance perpendicular to the neutral axis

For a circular cross-section,

𝐼 =𝜋𝑑4

12 (3–25b)

Where, d is the diameter of the cross-section.

When the cross-section is irregular, the moment of inertia about the centroidal axis is

given by equation 3.29.

The parallel axis theorem for this area is given by the expression,

𝐼𝑧 = 𝐼𝑐𝑎 + 𝐴𝑑2 (3.29)

Where,

Ica is the moment of inertia of area about its own centroidal axis.

Iz is moment of inertia of the area about any parallel axis a distance d removed.

A is area of the cross-section.

6. Normal stresses for beams in Bending

Page 33: Chapter 3-Load and Stress Analysis

Two-plane bending

The maximum tensile and compressive bending stresses occur where the

summation gives the greatest positive and negative stresses, respectively

where the first term on the right side of the equation is identical to Eq. (3–

24). My is the bending moment in the xz plane (moment vector in y

direction). z is the distance from the neutral y axis, and Iy is the moment of

inertia of the area about the y axis.

For a beam of diameter d the maximum distance from the neutral axis is d/2, and

from Table A–18, I = πd4 /64.

The maximum bending stress for a solid circular ross section is then

6. Normal stresses for beams in Bending

Page 34: Chapter 3-Load and Stress Analysis

Example 3.6 As

shown in Fig. 3–16a,

beam OC is loaded in

the xy plane by a

uniform load of 50

lbf/in, and in the xz

plane by a

concentrated force of

100 lbf at end C. The

beam is 8 in long.

(a) For the cross section shown determine the maximum tensile

and compressive bending stresses and where they act.

(b) If the cross section was a solid circular rod of diameter,

d=1.25 in, determine the magnitude of the maximum bending

stress

6. Normal stresses for beams in Bending

Page 35: Chapter 3-Load and Stress Analysis

Solution

The reactions at O and the bending-moment

diagrams in the xy and xz planes are shown in

Figs. 3–16b and c, respectively. The maximum

moments in both planes occur at O where

(𝑀𝑧)𝑜= −1

250 82 = −1600𝑙𝑏𝑓. 𝑖𝑛

(𝑀𝑦)𝑜= 100(8) = 800𝑙𝑏𝑓. 𝑖𝑛

The moments of inertia of area in both planes

are

𝐼𝑧 =1

120.75 (1. 5)3 = 0.2109𝑖𝑛4

𝐼𝑧 =1

12(1.5)(0.75)3 = 0.05273𝑖𝑛4

The maximum tensile stress occurs at point A, shown in Fig. 3–16a, where the

maximum tensile stress is due to both moments. At A, yA = 0.75 in and zA = 0.375 in.

Thus, from Eq. (3–27)

The maximum compressive bending stress occurs at point B where, yB =−0.75 in and

zB =−0.375 in. Thus

6. Normal stresses for beams in Bending

Page 36: Chapter 3-Load and Stress Analysis

Figure 3.16 (a) Beam loaded in two

planes; (b) loading and bending-

moment diagrams in xy plane; (c)

loading and bending-moment diagrams

in xz plane.

6. Normal stresses for beams in Bending

Page 37: Chapter 3-Load and Stress Analysis

(b) For a solid circular cross section of diameter, d = 1.25 in, the

maximum bending stress at end O is given by Eq. (3–28) as

6. Normal stresses for beams in Bending

Page 38: Chapter 3-Load and Stress Analysis

6. Normal stresses for beams in Bending

It is rare to encounter beams subjected to pure bending moment only (no

shear). Most beams are subjected to both shear forces and bending

moments.

τ =VQ

Ib (3-31)

For a beam subjected to

shear force V, the shear

stress is found as

Where,

V is the shear force at the

section of interest.

Q the first moment of the area A’

with respect to the neutral axis.

This stress is known as the transverse shear stress. It is always

accompanied with bending stress.

I is the second moment of area of the entire section about the neutral axis.

b is the width at the point where τ is determined

Page 39: Chapter 3-Load and Stress Analysis

6. Shear Stresses for Beams in Bending (2)

Q is the first moment of the area A’ with respect to the neutral axis, Q,

is found as:

where,

A’ is the area of the portion of

the section above or below the

point where τ is determined.

𝑦 ′ is the distance to the

centroid of the area A’

measured from the neutral axis

of the beam.

The shear stress is maximum at the neutral axis (since Q will be max), and it is

zero on the top and bottom surfaces (since Q is zero).

For any common cross section beam, if the beam length to height ratio is greater

than 10, the transverse shear stress is generally considered negligible compared

to the bending stress at any point within the cross section.

A’

'y

Neutral axis

1y

Page 40: Chapter 3-Load and Stress Analysis

6. Shear Stresses for Beams in Bending (3)

Table 3–2 Formulas for Maximum Transverse Shear Stress from VQ/Ib

Figure 3–18

Transverse shear

stresses in a

rectangular beam.

Page 41: Chapter 3-Load and Stress Analysis

3–5 Shear Stresses for Beams in Bending

A beam 12 in long is to support a load of 488 lbf acting 3 in from the left

support. The beam is an I beam with the cross-sectional dimensions shown.

To simplify the calculations, assume a cross section with quare corners.

Points of interest are labeled (a, b, c, and d) at distances y from the neutral

axis of 0 in, 1.240- in, 1.240+ in, and 1.5 in (Fig. 3–20c). At the critical axial

location along the beam, find the following information.

(a) Determine the profile of the distribution of the transverse shear stress,

obtaining values at each of the points of interest.

(b) Determine the bending stresses at the points of interest.

(c) Determine the maximum shear stresses at the points of interest, and

compare them.

(a) Example

Page 42: Chapter 3-Load and Stress Analysis

3–5 Shear Stresses for Beams in Bending

Solution The transverse shear stress is not likely to be negligible in this

case since the beam length to height ratio is much less than 10,

and since the thin web and wide flange will allow the transverse

shear to be large.

The loading, shear-force, and bending-moment diagrams are

shown in Fig. 3–20b. The critical axial location is at x=3- where

the shear force and the bending moment are both maximum.

(a) We obtain the area moment of inertia I by evaluating I for a

solid 3.0-in � 2.33-in rectangular area, and then subtracting the

two rectangular areas that are not part of the cross section.

Page 43: Chapter 3-Load and Stress Analysis

3–5 Shear Stresses for Beams in Bending

Solution

Applying Eq. (3–31) at each point of

interest, with V and I constant for each

point, and b equal to the width of the

cross section at each point, shows that

the magnitudes of the transverse shear

stresses are

Page 44: Chapter 3-Load and Stress Analysis

3–5 Shear Stresses for Beams in Bending

Solution

Page 45: Chapter 3-Load and Stress Analysis

3–5 Shear Stresses for Beams in Bending

Solution (c) Now at each point of interest, consider a

stress element that includes the bending

stress and the transverse shear stress. The

maximum shear stress for each stress

element can be determined by Mohr’s circle,

or analytically by Eq. (3–14) with σy = 0,

Page 46: Chapter 3-Load and Stress Analysis

7. Torsion (1) Any moment vector that is collinear with an axis of a mechanical element is called

a torque vector, because the moment causes the element to be twisted about that

axis. A bar subjected to such a moment is also said to be in torsion.

When a circular shaft is subjected to torque, the shaft will be twisted and the angle

of twist is found to be:

𝜃 =𝑇𝑙

𝐺𝐽 (3.35)

where T = torque; l = length

G = modulus of rigidity 𝐺 =𝐸

2(1+𝜈)

J = polar second moment of area.

For a solid round section,

𝐽 =𝜋𝑑4

32 (3.38)

where d is the diameter of the bar.

For the hollow round section,

𝐽 =𝜋(𝑑0

4−𝑑𝑖4)

32 (3.39)

where the subscripts o and i refer to the outside and inside diameters, respectively.

Page 47: Chapter 3-Load and Stress Analysis

7. Torsion (1) Shear stresses develop throughout the cross section. For a round bar in torsion,

these stresses are proportional to the radius ρ and are given by

𝜏 =𝑇𝜌

𝐽 (3.36)

Designating r as the radius to the outer surface, we have

𝜏𝑚𝑎𝑥 =𝑇𝑟

𝐽 (3.37)

The parameter α is a factor that is a function of the ratio b/c as shown in the following

table.

The angle of twist is given by

𝜃 =𝑇𝑙

𝛽𝑏𝑐3𝐺 (3-41)

where β is a function of b/c, as shown in the table.

The maximum shearing stress in a rectangular b × c

section bar occurs in the middle of the longest side b and

is of the magnitude.

𝜏𝑚𝑎𝑥 =𝑇

𝛼𝑏𝑐2=

𝑇

𝑏𝑐23 +

1.8

𝑏/𝑐 (3-40)

Page 48: Chapter 3-Load and Stress Analysis

7. Torsion (2)

max

Page 49: Chapter 3-Load and Stress Analysis

It is often necessary to obtain the torque T from a consideration of the power and

speed of a rotating shaft.

For convenience when U.S. customary units are used, three forms of this relation

are

𝐻 =𝐹𝑉

33000=

2𝜋𝑇𝑛

33000(12)=

𝑇𝑛

63025 (3-42)

Where H = power, hp

T = torque, lbf · in

n = shaft speed, rev/min

F = force, lbf

V = velocity, ft/min

7. Torsion (3)

When SI units are used, the equation is

𝐻 = 𝑇𝜔 (3.43)

Where H = power, W

T = torque, N · m

ω = angular velocity, rad/s

The torque T corresponding to the power in watts is given approximately

by

𝑇 = 9.55𝐻

𝑛 (3-44)

Page 50: Chapter 3-Load and Stress Analysis

3–6 Torsion

Example 3-9:

The 1.5-in-diameter solid steel shaft shown in Figure is simply

supported at the ends. Two pulleys are keyed to the shaft where

pulley B is of diameter 4.0 in and pulley C is of diameter 8.0 in.

Considering bending and torsional stresses only, determine the

locations and magnitudes of the greatest tensile, compressive, and

shear stresses in the shaft.

Page 51: Chapter 3-Load and Stress Analysis

3–6 Torsion

Example:

Page 52: Chapter 3-Load and Stress Analysis

Example:

3–6 Torsion

Page 53: Chapter 3-Load and Stress Analysis

8. Stress Concentration

Stress concentration occurred at any discontinuity in a machine part.

- The discontinuities are called stress raisers.

- The regions in which they alert are called the areas of stress concentration.

- A theoretical, or geometric, stress-concentration factor Kt or Kts is used to

relate the actual maximum stress at the discontinuity to the nominal stress.

The factors are defined by the equations

𝐾𝑡 =𝜍𝑚𝑎𝑥

𝜍𝑜 𝐾𝑡𝑠 =

𝜏𝑚𝑎𝑥

𝜏𝑜 (3-48)

Where:

Kt – for normal stresses

Kts – for shear stresses

The nominal stress σ0 or τ0 is the stress

calculated by using the elementary stress

equations and the net area, or net cross section.

The stress-concentration factor depends for its

value only on the geometry of the part.

Page 54: Chapter 3-Load and Stress Analysis

8. Stress Concentration (2)

Page 55: Chapter 3-Load and Stress Analysis

8. Stress Concentration (3)

Page 56: Chapter 3-Load and Stress Analysis

9. Contact Stresses

When two bodies having curved surfaces are pressed

together, point or line contact changes to area contact, and

the stresses developed in the two bodies are called the

contact stress.

Contact-stress problems arise

in the contact of a wheel and

a rail, in automotive valve

cams and tappets, in mating

gear teeth, and in the action of

rolling bearings.

Typical failures due to contact

stress are seen as cracks,

pits, or flaking in the surface

material.

Page 57: Chapter 3-Load and Stress Analysis

9. Contact Stresses

When two solid spheres of diameters d1 and d2

are pressed together with a force F, a circular

area of contact of radius a is obtained.

Specifying E1, ν1 and E2, ν2 as the elastic

constants of the two spheres, the radius a is

given by the equation

𝒂 =𝟑𝑭

𝟖

𝟏 − 𝒗𝟏𝟐 /𝑬𝟏 + 𝟏 − 𝒗𝟐

𝟐 /𝑬𝟐

𝟏/𝒅𝟏 + 𝟏/𝒅𝟐

𝟑

𝒑𝒎𝒂𝒙 =𝟑𝑭

𝟐𝝅𝒂𝟐

𝝈𝟏 = 𝝈𝟐 = 𝝈𝒙 = 𝝈𝒚 = −𝒑𝒎𝒂𝒙 𝟏 −𝒛

𝒂𝒕𝒂𝒏−𝟏

𝟏

𝒛/𝒂𝟏 + 𝒗 −

𝟏

𝟐 𝟏 +𝒛𝟐

𝒂𝟐

𝝈𝟑 = 𝝈𝒛 =−𝒑𝒎𝒂𝒙

𝟏 +𝒛𝟐

𝒂𝟐

𝝉𝒎𝒂𝒙 = 𝝉𝟏/𝟑 = 𝝉𝟐/𝟑 =

𝝈𝟏 − 𝝈𝟑

𝟐=

𝝈𝟐 − 𝝈𝟑

𝟐

The maximum pressure occurs at the center of

the contact area and is

The maximum stresses occur on the z axis, and these are principal stresses

Page 58: Chapter 3-Load and Stress Analysis

9. Contact Stresses

Magnitude of the stress components below the surface as a function of the maximum

pressure of contacting spheres. Note that the maximum shear stress is slightly below

the surface at z=0.48a and is approximately 0.3pmax. The chart is based on a Poisson

ratio of 0.30. Note that the normal stresses are all compressive stresses.

Page 59: Chapter 3-Load and Stress Analysis

9. Contact Stresses

(a) Two right circular cylinders held in contact by

forces F uniformly distributed along cylinder length

l. (b) Contact stress has an elliptical distribution

across the contact zone width 2b.

𝒃 =𝟐𝑭

𝝅𝒍

𝟏 − 𝒗𝟏𝟐 /𝑬𝟏 + 𝟏 − 𝒗𝟐

𝟐 /𝑬𝟐

𝟏/𝒅𝟏 + 𝟏/𝒅𝟐

𝒑𝒎𝒂𝒙 =𝟐𝑭

𝝅𝒃𝒍

𝝈𝒙 = −𝟐𝒗𝒑𝒎𝒂𝒙 𝟏 +𝒛𝟐

𝒃𝟐 −𝒛

𝒃

𝝈𝒚 = −𝒑𝒎𝒂𝒙

𝟏 + 𝟐𝒛𝟐

𝒃𝟐

𝟏 +𝒛𝟐

𝒃𝟐

− 𝟐𝒛

𝒃

𝝈𝟑 = 𝝈𝒛 =−𝒑𝒎𝒂𝒙

𝟏 + 𝒛𝟐/𝒃𝟐

The maximum pressure is

The stress state along the z axis is given by the equations

Page 60: Chapter 3-Load and Stress Analysis

9. Contact Stresses

Magnitude of the stress components below the surface as a function of the maximum

pressure for contacting cylinders. The largest value of max occurs at z/b = 0.786. Its

maximum value is 0.30pmax. The chart is based on a Poisson ratio of 0.30. Note that all

normal stresses are compressive stresses.