MecE 360: Engineering Design II

Section 4: Loading & Stress Analysis

Day 2

Class Notifications
Pick up bearing catalogue in machine shop
von Mises next day with failure discussion
Office Hours: Extended 5:00 to 6:00 meeting
times for Feb meetings
May change further depending on sign-up
trends
Project: How to convey information on design
1 page template with key information?
Currently have final report posted for one, in
process of getting reports from Chen

Objectives
1. Stress concentration for fatigue
2. Deflections and slopes for loaded beams
Many long examples

SCF for Cyclic Loading

(p.4-25)

Brittle materials are more susceptible to stress

concentration (SC) than ductile materials
Ductile materials deform if local equivalent stresses
exceed yield strength
Brittle materials fail if stress reaches Sut (no yield)
Components under cyclic loading often fail
in a brittle manner
Ductile materials that plastically deform are work
hardened and become brittle
Cracks propagate with each cycle in a brittle material

SCF for Cyclic Loading

Fatigue SCF (Kf) Static (theoretical) SCF (Kt)
If the material being cycled is rittle
Kf = Kt and Kfs = Kts
(tensile)
(shear)
Brittle materials are more sensitive to
notches and stress concentrations
Need to define a characteristic that relates the
level of sensitivity to change in geometry and SCF for
cyclic loading

SCF for Cyclic Loading

Notch sensitivity q and qs provide relationship between
fatigue SCF and theoretical SCF
unknown
unknown
K f 1
K fs 1
qs
Material
q
Material
Kts 1
K t 1 Property, in
Property, in
charts/graphs
charts/graphs
Known/given
Known/given/from last day
For very brittle materials q = 1 and qs = 1

SCF for Cyclic Loading

Graphically find q or qs based on Sut and notch radius
For qs , add 20 kpsi to Sut, then find q
1

Sut [kpsi/MPa]
240/1656
200/1379
160/1103
140/965
120/827

0.9

0.8

100/689
80/552

0.7

r
0.6

70/483
60/414
50/345

M
d

0.5

0.4

0.3
0

0.05

0.1
notch radius, r (in)

0.15

0.2

SCF for Cyclic Loading

Example: Sut = 120 kpsi, r = 0.1 in
1

Sut [kpsi/MPa]

q 0.86

240/1656
200/1379
160/1103
140/965
120/827

0.9

0.8

100/689
80/552

0.7

70/483
60/414
50/345

0.6

0.5

0.4

0.3
0

0.05

0.1
notch radius, r (in)

0.15

0.2

SCF for Cyclic Loading

Example: Sut = 120 kpsi, r = 0.1 in
1

Sut [kpsi/MPa]

qs 0.89
0.9

0.8

For qs use
Sut+ 20 kpsi
= 140 kpsi

0.7

240/1656
200/1379
160/1103
140/965
120/827
100/689
80/552
70/483
60/414
50/345

0.6

0.5

0.4

0.3
0

0.05

0.1
notch radius, r (in)

0.15

0.2

SCF for Cyclic Loading

For alternating stress

a K f an
q

Nominal stress

K f 1
Kt 1

Shaft with groove in bending

5

Kt

240/1656
200/1379
160/1103
140/965
120/827

0.9

0.8

100/689
80/552

0.7

70/483
60/414
50/345

0.6

0.5

0.4

0.3
0

0.05

0.1
notch radius, r (in)

0.15

0.2

1
0

0.1

0.2

0.3

r/d

D/d=

D/d=2

D/d=1.5

D/d=1.3

D/d=1.15

D/d=1.1

D/d=1.05

D/d=1.01

SCF for Cyclic Loading

For mean stress

m K fm mn

Nominal stress

Approach to solve for Kfm:

If
If
If

K f max n S y then: K fm K f
K f max n S y then: K fm

Most common case

Sy K fan

mn

K f max n min n 2S y then: K fm 0

Ductile to brittle
transition at notch
Compression and tension;
yielding occurs;
mean stress has little effect

Example 4-3

(p.4-30)

The 50 mm diameter shaft shown has fully reversed

bending (100 Nm) and fluctuating torsion (50 25 Nm).
The small diameter is d is 40 mm and the radius of
curvature of the groove is 5 mm. The shaft is made of
AISI 1018 cold-drawn steel with Sut = 440 MPa, Sy = 370
MPa.
Calculate mean and alternating bending and torsional
stresses
Given: The theoretical tensile and shear SCF are 1.75
and 1.5, respectively. r
T

M
d

Solution

from last day.

Solution

Sut [kpsi/MPa]

Solution

Solution Contd

Solution Final

Shaft Deflection

( p.4-32)

Besides strength considerations, it is usually

also important to examine component deflection
We will investigate shaft deflections

Shaft Deflection
Note that a shaft is usually stepped to
accommodate gears and bearing.
It is necessary to account for changes in loading
and geometry along the length of the shaft.

Shaft Deflection
Need to solve deflection equations (see CivE 270)
d2y M 1
radius of curvature : 2

dx
EI
x

dy
d2y
M
slope:
2 dx dx C1
dx 0 dx
EI
0
x

x x

dy
M
deflection: y dx dx C1 x C2
dx
EI
0
0 0
where

shear : V qdx
moment : M V dx

Some functions to
integrate/differentiate

Shaft Deflection
Use of singularity functions, which are on/off
type equations (brackets: < >)
Value of a singularity function
if a x, x a 0
xa
if x a, x a x - a

Integration:

xa
n
xa xa

n 1

n1

if n 0

n1

if n 1

If n < 0, then x - an = 0

Shaft Deflections
Singularity functions are applied to the different
shaft loads when defining shear flow equation
Distributed load (w), shear flow (q), [N/m]
Force (F), shear (V), [N]
Couple/moment (M), [Nm]

xa

xa

xa

a is the position where the loading appears on the shaft

Shaft Deflection
R1=100N
y
25mm
x

M=10Nm

R2

R2=75N
RL

RR

75mm
100mm

Left reaction (RL) @ a = 0m

R1 @ a = 0.025m
M @ a = 0.025m
R2 @ a = 0.075m
Right reaction (RR) @ a = 0.1m

x0
x 0.025
x 0.025
x 0.075
1
x 0.1

2
1

R1

Shaft Deflection
R1=100N
25mm
x
M=10Nm
R2=75N
RL

RR

75mm
100mm

q( x ) RL x

R1 x 0.025

R2 x 0.075

M x 0.025

RR x 0.1

Integrate shear flow q twice with respect to x to find M(x).

Use M(x) to find slope (x) and deflection y(x).

Shaft Deflection
Resultant deflection from all forces at critical
position
y-deflection

total

z-deflection

ABtotal

ABtotal

ABtotal y

ABtotal z

Example 4-4

Find the equations for deflection and slope at any point on the
beam.
Example in notes package

Example Problem- Singularity

Functions

Solution

Solution

Example Problem

Solution

45.469 N

R2y=- R1y +P1y+ q (0.025)

=- 45.469+50 +50 N/m (0.025m)
R2y= 5.78125

Solution

Soln contd- x-y plane

Solution- Slope and Deflection

Solution- Solve Constants with

Boundary Conditions

- 0.014909

Solution- Slopes and

Deflections in x-y plane

C1/EI

x-z plane- Fast Forward

Slope and Deflection-Fast

Forward

Solving Boundary ConditionsFast Forward

Boundary Conditions- Fast

Forward

Slopes and Deflections- Fast

Forward

Total Deflection and Slope

Whats next
Section 5: Material Failure
von Mises equivalent stress
Design criteria
Failure modes
Influential factors