EXAMPLES in STATIC MULTI-AXIAL STRESS

Example 1: A solid circular shaft of 100 mm diameter is subjected to a

bending moment of 15000 N-m, a twisting moment of 25000 N-m and an
axial tensile load of 500000 N. Find the principal stresses and the factor of
safety for each of the five theories of failure, if the yield strength of the
material is 500 MPa and the Poissons ratio is 0.3.
Solution:
Normal stress: 1) from axial load P & 2) from bending moment Mb.
Shear stress:
from twisting moment Mt only.
x1 = P/A = 500000 x 4/( x 0.12) = 63.7 MPa

1)From Axial load:

2)From B.M

x2 = Mb x c/I = 15000x 0.05 x 64/( x 0.14)

= 152.8 MPa

Since x1 is positive, choose + sign for x2.

x = x1 + x2 = 216.5 MPa
3) From Torque:

xy = Mt x c/ Ip
= 25000x 0.05 x 32/( x 0.14) = 127.3 MPa

y, z, yz and zx = 0 and hence I3 = 0 and 3 = 0.

Note: This is bi-axial stress problem.
I1= x and I2 = xy2.
Equation (5) becomes
2 - x - xy2 = 0
1, 2 = x /2 [(x /2) 2 + xy2] = 108.5 [(108.5) 2 +127.32 ]
= 108.25 [(108.25) 2+127.32 ] = 108.25 167.1
= 275.4, - 58.8 MPa
Principal stresses: (in their order of values)
1, 2, 3 = 275.4, 0, - 58.8 MPa
Normal Stress Theory:
1

(5)

|1| is the largest and therefore

F.S = Y/1 = 500 /275.4 = 1.816
Normal Strain Theory:
1 -(2+ 3) Y,
2 -(3+ 1) Y or
3 -(1+ 2) Y
275.4 0.3 (- 58.8) = 293 or - 58.8 0.3 x 275.4 = 141
or 0 - 0.3 (275.4 58.8) = 64.98
The largest of the three is 293 MPa and F.S = 500/ 293 = 1.71
Shear Stress Theory:

- 2 Y , 2 - 3 Y or 3 - 1. Y

275.4 - (-58.8) = 334.2 or - 58.8 = 58.8 or - 275.4 = 275.4

The largest of the three is 334.2 MPa and F.S = 500/334.2 = 1.493
Strain Energy Theory:
I12 - 2(1 + ) I2 Y2
x2 - 2(1.3)( xy2 ) = 216.52 + 2.6(127.3)2 = 89006
F.S = 500/ 89006 = 1.676
Distortion Energy Theory:
I12 - 3 I2 Y2
x2 - 3( xy2 ) =216.52 + 3(127.32 ) = 95488
F.S = 500/ 95488 = 1.618
Inference: The shear stress theory gives the lowest F.S. For a conservative
design this should be taken as valid.
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Example 1 (a): In Example 1, consider hollow shaft of diameters 100

mm & 50 mm and the axial load is a thrust (compressive).
Solution:
Normal stress: 1) from axial load P & 2) from bending moment Mb.
Shear stress:
from twisting moment Mt only.
Note: The already calculated values at Example1 are used with necessary
modifications to advantage for my easy computation.
1) From Axial load:

x1 = P/A

A = (0.12 0.052)/4 = (0.12)(1 (1/2)2/4 = (0.12)(3/4)/4

x1 = P/A = -500000 x (4/3) 4/( 0.12) = - 63.7(4/3) = - 84.933 MPa
2) From B.M

x2 = Mb x c/I

c = do/2 (Carefully note this. With BE mugged up formula you will go

wrong here)
I = (do4 di4)/64 = (0.14 0.054)/64 = (0.14)(1 (1/2)4)/64
= (0.14)(15/16)/64
x2 = Mb x c/I = 15000x 0.05 x(16/15) x 64/( x 0.14)
= 152.8 (16/15) = 162.986 MPa
Since x1 is negative, choose - sign for x2.
x = x1 + x2 = - (84.933 +162.986) = - 247.916 MPa
3) From Torque:

xy = Mt x c/ Ip = 25000 x 0.05 x(16/15) x 32/( x 0.14)

xy = 127.3 x (16/15) = 135.786 MPa

y, z, yz and zx = 0 and hence I3 = 0 and 3 = 0.
Note: This is bi-axial stress problem.
I1= x and I2 = xy2 .
Equation (5) becomes
2 - x - xy2 = 0
1, 2 = x /2 [(x /2) 2 + xy2]
3

(5)

= - (247.916/2) [(247.916/2) 2 +135.7862]

= -123.95 183.857 = 59.9, -307.8 MPa
Principal stresses: (in their order of values)
1, 2, 3 = 59.9, 0, -307.8 MPa
Normal Stress Theory:
|3| is the largest and therefore
F.S = |Y/3| = 500 /307.8 = 1.6244 (for solid shaft 1.826)
Normal Strain Theory:
1 -(2+ 3) Y, 2 -(3+ 1) Y or 3 -(1+ 2) Y
59.9 0.3 (- 307.8) = 152.24 or 0 0.3 (-307.8+59.9) = 74.37
or - 307.8 - 0.3 (59.9 + 0) = 325.77
The largest of the three is 325.77 MPa and therefore
F.S = 500/ 325.77= 1.535(for solid shaft 1.71)
Shear Stress Theory:

- 2 Y , 2 - 3 Y or 3 - 1. Y

59.9 0 = 59.9 or 0 (-307.8) = 307.8

or - 307.8 - 59.9 = 367.72
The largest of the three is 367.72 MPa and
F.S = 500/367.72 = 1.36 (for solid shaft 1.493)
Strain Energy Theory:
I12 - 2(1 + ) I2 Y2
x2 - 2(1.3)( xy2 ) = (- 247.916)2 + 2.6(127.3)2
= 103596 s = 321.86
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F.S = 500/ 321.86 = 1.553 (for solid shaft 1.676)

Distortion Energy Theory:
I12 - 3 I2 Y2
x2 - 3( xy2 ) = (- 247.916)2 + 3(127.3)2
= 110078 os = 331.78
F.S = 500/ 331.78 = 1.51 (for solid shaft 1.618)
Inference: The shear stress theory gives the lowest F.S. For a conservative
design this should be taken as valid.
Example 2: A solid circular shaft of 100 mm diameter is subjected to a
bending moment of 15000 N-m, a twisting moment of Mt N-m and an axial
tensile load of 500000 N. For a factor of safety of 1.25, make the final
choice of the value of the twisting moment that can be safely applied for
each of the five theories of failure, if the yield strength of the material is 500
MPa and the Poissons ratio is 0.3.
Solution:
Normal stress: (1) from axial load P & (2) from bending moment Mb.
Shear stress: from twisting moment Mt only.
1) From Axial load:

x1 = P/A = 500000 x 4/(x 0.12) = 63.7 MPa

2) From B.M

x2 = Mb x c/I = 15000x 0.05 x 64/(x 0.14)

= 152.8 x106 Pa =

152.8 MPa

Total Axial stress

x = x1 + x2 = 216.5 MPa

3) From Torque:

xy = Mt x c/ Ip = Mt x 0.05 x 32/(x0.14)
= 5.1x 103 Mt Pa
xy = 5.1x 10-3 Mt MPa

y, z, yz and zx = 0 and hence I3 = 0 and 3 = 0.

Note: This is bi-axial stress problem
I1= x and I2 = xy2.
5

(A)

Equation (5) becomes

2 - x - xy2 = 0

(5)

1, 2 = x /2 [(x /2) 2 +xy2]

= X [X2 + Y2] = X Z
= 216.5/2 [(216.5/2)2 +(zx) 2]
= 108.25 [(108.25 2 +(zx) 2] MPa
Normal Stress Theory
1 = 108.25 + [(108.25) 2 +(zx)2] MPa
1 = 1Y/F.S =500 / 1.25 = 400 = 108.25 + [(108.25)2 + (zx)2] MPa
Rewriting and squaring (!!!!!)
(400 108.25)2 = (108.25)2 +(zx)2
(zx)2 = [(400 108.25)2 (108.25) 2 ] =73400
(zx) = 270.92434 MPa
From (A)
Mt = 270.92434 / (5.1 x 10-3 )
Mt = 53122 N-m
Normal Strain Theory:
1 -(2+ 3) Y, 2 -(3+ 1) Y or 3 -(1+ 2) Y
Since 3 = 0 and = negative, the first expression is relevant
1 0.3 2 = X + Z 0.3 (X Z)
= 0.7 x 108.25 + 1.3x[(108.25) 2 +(zx) 2] = 400
Rewriting
[(108.25)2 + (zx)2] = [(400 0.7 x 108.25) / 1.3]
Squaring and rewriting
(zx)2 =[(400 0.7 x 108.25) / 1.3] 2 -108.252 = 50484
(zx) = 224.687 MPa
From (A)
Mt = 224.687/(5.1 x 10-3)
Mt = 44056 N-m
Shear Stress Theory:
1 - 2 Y , 2 - 3 Y or 3 - 1. Y
Since 3 = 0 and 2 = X Z, is negative, the first expression is relevant.
1 - 2 = 2 [(108.25)2 +(zx)2] = 400
(zx)2 =(2002 108.252 ) = 28168.282
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(zx) = 168.1 MPa

From(A)
Mt = 168.17 /(5.1 x 10-3)
Mt = 32975 N-m

Strain Energy Theory:

I12 - 2(1 + ) I2 Y2
x2 - 2(1.3)( xy2 ) = 216.52 + 2.6(zx)2 = 4002
(zx)2 = (4002 - 216.52)/2.6 = 43510.7
(zx) = 208.6 MPa
From (A)
Mt = 208.6 /(5.1 x 10-3)
Mt = 40900 N-m
Distortion Energy Theory:
I12 - 3 I2 Y2
x2 - 3( xy2 ) = 216.52 +3 (xy2)2 = 4002
xy2 = [4002 -216.52]/3 =37709
xy = 194.2 MPa
From(A)
Mt = 194.2 /(5.1 x 10-3)
Mt = 38077 N-m
Inference: The choice of maximum Torque that can be applied will be the
minimum among these five values, for a conservative design. The
maximum shear stress theory gives this minimum torque of 32975 N-m.
Note: The minimum F.S. of Example 1 corresponds to the shear stress
theory and therefore is consistent. However, it will not be always like
this. For different combinations of stresses different theory may be
conservative.
(The students may consider either the axial load or the bending moment as
unknown and get familiar with the variations of this problem)
Example 3: A hollow circular shaft of 100 mm and 50 mm diameters is
subjected to a bending moment Mb15000 N-m, a twisting moment of Mt
30000 N-m and an axial tensile load of P N. For a factor of safety of 1.25,
make the final choice of the value of the tensile load that can be safely
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applied for each of the five theories of failure, if the yield strength of the
material is 500 MPa and the Poissons ratio is 0.3.
Solution:
Normal stress: (1) from axial load P & (2) from bending moment Mb.
Shear stress: from twisting moment Mt only.
1) From Axial load:

x1 = P/A = 4 P/((0.12 - 0.052) MPa

2) From B.M

x2 = Mb x c/I = 15000x 0.05 x 64/((0.14 - 0.054))

= 163 x106 Pa =

163 MPa

Since axial stress is tensile choose + sign.

Total Axial stress

x = x1 + x2 = (P/A +163) MPa

Let (P/A +163) be unknown = 2 X

3) From Torque: xy = Mt x c/ Ip = 30000 x 0.05 x 32/((0.14 - 0.054))
= 163 x 106 Pa = 163 MPa
y, z, yz and zx = 0 and hence I3 = 0 and 3 = 0.
Note: This is bi-axial stress problem
I1= x and I2 = xy2.
Equation (5) becomes
2 - x - xy2 = 0
1, 2 = x /2 [(x /2) 2 +xy2]
= X [X2 + Y2],
where Y = zx
1, 2 = X [X2 + Y2]
Normal Stress Theory
1 = 1Y/F.S =500 / 1.25 = 400 = X + [X2 + Y2]
Rewriting and squaring (!!!!!)
(400 X)2 = (X)2 +(zx)2
160000 + X2 800 X = X2 + (163)2
160000 26569 = 800 X
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(5)

X = 166.8 MPa
2 X = 333.6 = (P/A +163) P/A = 170.6 MPa
P = 170.6 (0.12 - 0.052)/4 = 1.005 MN = 1.005 x 106 N
Normal Strain Theory:
1 -(2+ 3) Y, 2 -(3+ 1) Y or 3 -(1+ 2) Y
Since 3 = 0 and 2 = negative, the first expression is relevant
1 0.3 2 = X + [X2 + Y2] - 0.3{X - [X2 + Y2]}
= 0.7 X + 1.3 [X2 + Y2] = 400
Rewriting
[X2 + Y2] = [(400 0.7X) / 1.3]
Squaring
[X2 + Y2] = [(160000 + 0.49X2 - 560X) / 1.69]
Rewriting
(1.69 0.49)X2 + 560 X = 160000 1.69x1632 = 115098
X2 + 466.7 X - 95915 = 0
X = - 233.35 387
Choosing + sign for tension.
X = 153.6 MPa
P/A = 2X 163 = 307.2 163 = 144.2 MPa
P = 0.85 x 106 N
Shear Stress Theory:
1 - 2 Y , 2 - 3 Y or 3 - 1. Y
Since 3 = 0 and 2 = X Z, is negative.
(1) 1 - 2 = 2 [(X)2 +(zx)2] = 400
(X)2 = (2002 1632) = 13431
X = 116 MPa
2X = 232 = P/A + 163 P/A = 69
P = 0.409 x 106 N
(2)
(3)
in

2 - 3| = 2 = X - [X2 + Y2] = 400

(400 X)2 = (X)2 +(zx)2. This is same as for 1.
3 - 1. = 1. This is same as (2) and normal stress theory resulting
P = 1.005 x 106 N

Strain Energy Theory:

I12 - 2(1 + ) I2 Y2
x2 - 2(1.3)( xy2 ) = (2X)2 + 2.6(163)2 = 4002
X= 150.8
2X = 301.4 = P/A + 163 P/A = 138.4
P = 0.818 x 106 N
Distortion Energy Theory:
I12 - 3 I2 Y2
x2 - 3( xy2 ) = (2X)2 +3 (163)2 = 4002
(2X)2 = 4002 - 3 (163)2
X = 141.8MPa
2X = 283.6 = P/A + 163 P/A = 120.6
P = 0.8 x 106 N
Shear stress theory yields the smallest P = 0.409 x 106 N
The choice is the smaller value P = 0.409 x 106 N
Example 4: A solid circular shaft of diameter d is subjected to a bending
moment of Mb, and a twisting moment of Mt. Derive expressions for
equivalent bending moment based on normal stress theory of failure and
equivalent torque based on the shear stress theory.
(This is what most of you used in UG in design perhaps without seriously
knowing there are two different theories involved in it)
Solution:
x = Mb c / I = Mb /Z
xy = Mt c / Ip = Mt c / 2I = Mt / 2Z
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since for a circular shaft Ip = 2I

1/2Z

and Z = Modulus of section c/I; and c/Ip =

1, 2 = x /2 [(x /2) 2 + xy2 ]

1, 2 = Mb /2Z [(Mb /2Z) 2 + (Mt /2Z) 2]
= (1/Z)(1/2){Mb [(Mb) 2 + (Mt) 2]}
Note 2 will be negative. This sign is important to find the maximum shear
stress.
Maximum normal stress theory needs 1.
1 = (1/Z)(1/2){Mb + [(Mb) 2 + (Mt) 2 ]}

= (Mb)equivalent /Z

where,
(Mb)equivalent = (1/2){Mb + [(Mb)2 + (Mt) 2]}

Maximum shear stress theory needs max.

max =

- 2 /2 = (1/2Z)[(Mb)2 + (Mt)2] = (1/2Z) (Mt)equivalent

where,
(Mt)equivalent = [(Mb) 2 + (Mt) 2]
Recall, most of us used these equivalent moments blindly in our BE course.
Example 5: A thin-walled cylindrical vessel of internal diameter 80 mm and
wall thickness of t mm is subjected to an internal pressure of 20 MPa, an
axial tensile load of 40000 N and twisting moment of 400 N-m. If the yield
strength is 700 MPa, Poissons ratio is 0.3 and a factor of safety of 2 is
required, find a safe thickness, using the five theories of failure.
Solution:
Longitudinal stress x: From
1) Axial load, P = 40000 N & 2) Internal pressure, p= 20 MPa.
Circumferential / Hoop stress y: From internal pressure, p = 20 MPa.
Shear stress xy: From twisting moment/Torque, Mt ,= 400N-m.
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Let t be in meter (m)

x1= P/Dt = (1/t) P/D =(1/t) 40000 x 103/80 = (1/t) x 0.1592 MPa
x2 = pD/4t = (1/t) pD/4 = (1/t) 20(MPa) x 80/(103 x 4)
= (1/t) x 0.4 MPa
x = x1 + x2 = (1/t) x 0.5592 MPa
y = pD/2t = (1/t) pD/2 = 20 x 80/(103 x 2) = (1/t) x 0.8 MPa
xy = Mt x c/Ip
Approximation for Ip for thin cylinders in terms of t and D.
(If accurate method is used, Ip = (/64)(Do4 Di4) and Do = Di + t and c =
Do/2. When t is unknown, that is the case here, it will be cumbersome)
The thin ring area = Dt. The tangential stress (causing torque) is xy. The
tangential force causing torque = tangential stress x area of ring = xy x Dt.
The torque or twisting moment Mt = tangential force x radius
= xy x Dt x D/2.
From this,
xy = 2Mt / D2 t
This simple method derived above is a good approximation and is an
intelligent way to do this directly.
Now

xy = 2 Mt / D2 t = (1/t) 2 x 400 x 106 / 802 N/m2 or Pa

= (1/t) 2 x 400 x 106 / 802/106 MPa = (1/t) x 0.0398 MPa
(1, 2) = (x+ y)/2 {[(x - y)/2 ]2 + xy2}
(1, 2) t = (1.3592)/2 {[(0.2408)/2 ] 2 + 0.03982}
(1, 2) = [0.6896 {[0.12042 + 0.03982}] / t
= [0.6896 0.1268]/t = [0.8164, 0.5628]/t MPa
Normal Stress Theory
1 = Y/F.S = Y/ 2 = 700/2 =350 = 0.8164 / t, t in meters.
t = 0.8164 / 350 m = 2.333 mm
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Normal Strain Theory

1 -(2+ 3) = Y/F.S = 350 = (0.8164 0.3 x 0.5628) / t
t = 0.64756 / 0.35 mm = 1.85 mm
Shear Stress Theory
1 - 2 = 0.2536 / t, 2 - 3 = 0.5628 / t or 3 - 1 = 0.8164 / t
The last one is the maximum and therefore,
0.8164 / t = 350
t = 2.333 mm, which is same as due to the Normal Stress Theory.
Note: Maximum shear stress is not 1 - 2| /2. It is 3 - 1 /2
Strain Energy Theory
I12 - 2(1 + ) I2 = (x + y) 2 2(1 + 0.3)( x y - xy2) =Sw2
= [(1.3592) 2 2.6 (0.5592 x 0.8 - 0.03982)] /(t x t) = (350)2
t = 0.68842 /0.35 = 0.8297 / 0.35 = 2.37 mm
Distortion Energy Theory
I12 - 3 I2 = (1.3592) 2 3 (0.5592 x 0.8 - 0.03982)] / t2 =Sw2
t = 0.51 /0.35 = 2.0 mm
Inference: The thicknesses are 2.333, 1.85, 2.333, 2.37 and 2.0 mm. A
conservative design would suggest a choice of 2.37 mm. In general 2.0 mm
given by Distortion Energy Theory will be chosen, because of its soundness.
(The students should familiarize themselves of cases, where any one among
factor of safety, internal pressure, axial tension or twisting moment - is
considered as unknown)
Example 6: A thin-walled cylindrical vessel of internal diameter D mm and
wall thickness of t mm is subjected to an internal pressure of p MPa, an axial
tensile load of F N and twisting moment of T N-m. If the working stress =
Sw, derive a general expression for a safe thickness, using the distortion
energy theory of failure.
Solution:
For easy working, let pD/4t =A, then pD/2t = 2A.
Let F/Dt = B and 2T/D2t = C.
x1= F/Dt = B
x2 = pD/4t = A
13

x = x1 + x2 = A + B
y = pD/2t = 2A
xy = 2T / D2 t = C
I12 - 3 I2 = (x +y)2 3 (xy - xy2) = (x2 +y2) (xy) + 3xy2)
= (A+B)2 + (2A)2 (A+B)(2A) + 3C2
= A2+B2 +2AB+ 4A2 2A2 - 2AB + 3C2
= 3A2 + B2 + 3C2 = Sw2
(A)
Substituting for A, B and C,
3(pD/4t)2 + (F/Dt)2 + 3(2T / D2 t)2 = Sw2

(B)

From this t could be found to be

t = [3 (pD/4)2 + (F/D) 2 + 3 (2T/ D2) 2]0.5/ Sw
The student should derive for other cases such as p or T or F or D as
unknowns, from expression (A) or (B).
For the case of diameter D as unknown, a cubical equation in D2 needs to
be solved and may look complicated. But a designer will face only this kind
of problem in design! So learn it!!
3(p/4t) D6 + (F/t)2 D2 + 3(2T / t)2 = Sw2 D4
D6 - (4tSw2 /3p) D4 + (4F/3p)2 D2 + (8T /)2 = 0
Letting D2 = X
X3 - a X2 +b X + c = 0

(C)
(D)
(E)

Solving (E) diameter D can be found.

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