Faculty of Engineering

HK08 Mechanical Engineering

Semester 2 2016/2017

KM42602 CAE

Assignment 3

Stress Concentration, Torsion and Buckling

Analysis

Name: Muhamad Zulhafiz Bin Zaini

Student ID: BK12110218

Submission Date: 19th May 2017

Question 1: Stress Concentration

1. Pre-processing

1.1 Geometry Creation

Model is created based on the dimensions assigned.

1.2 Material Property Assignment

Material applied is Alloy Steel with the following mechanical properties.

1.3 Boundary Condition Specification

Fixed geometry on the left-side surface (Fixed-free end).

2000 N force applied at the right-side surface

1.4 Mesh Generation

Intermediate mesh with total nodes = 10941 and total elements = 6766
2. Solution

For simulation, the study used is static analysis.

3. Post-processing

ii. Maximum and minimum normal stress,

Based on figure above,

Maximum normal stress, = 4.332 x 10^-4 MPa

Minimum normal stress, = -1.974 x 10^-5 MPa

iii. What is the stress concentration K factor,

2
= = 1.61616 104
(300 25)(45)

4.332 104
= = 2.68
1.61616 104
iv. If the hole diameter reduced to 75%, 50% and 25%, respectively, compute the K factor and
compare the factor respect to the hole diameter reduction. Discussed about the hole
diameter effect on stress concentration due to the loading.

Hole diameter reduced to 75% hole diameter = 0.75 x 25 = 18.75 mm

Maximum normal stress, = 4.268 x 10^-4 MPa

2
= = 1.5803 104
(300 18.75)(45)

4.268 104
= = 2.70
1.5803 104

Hole diameter reduced to 50% hole diameter = 0.5 x 25 = 15 mm

 Maximum normal stress, = 4.768 x 10^-4 MPa

2
= = 1.55945 104
(300 15)(45)

4.768 104
= = 3.06
1.55945 104

Hole diameter reduced to 25% hole diameter = 0.25 x 25 = 6.25 mm

Maximum normal stress, = 4.041 x 10^-4 MPa

2
= = 1.51300 104
(300 6.25)(45)

4.041 104
= = 2.67
1.513 104

Theoretically, when the hole diameter is decreased, the stress concentration will be less.
However in simulation, hole diameter with 12.5 mm dimensions, has the highest stress
concentration.
 v. If the plate is without the hole and applied with the same amount of tension load at the plate end
face, what is the consequence behaviour compare to the initial problem.

Maximum normal stress, = 3.288 x 10^-4 MPa

Without the hole, the maximum normal stress is much lower compared to the initial
problem which yielding maximum normal stress of 4.332 x 10^-4 MPa .

vi. If the plate total length increased to 150% and two holes with diameter of d, distance
between center is c and the hole center is distance from the plate center of c/2, determine the
normal stress (maximum and minimum) and K factor. Compare and discuss the prediction result
with the initial problem.

Total length increased to 150%, .5 X 300 =450mm

 Maximum normal stress, = 4.438 x 10^-4 MPa
Minimum normal stress, = -3.683 x 10^-5 MPa

2
= = 1.61616 104
(300 25)(45)

4.438 104
= = 2.74
1.61616 104

By comparing with the initial problem, the maximum normal stress for 2 holes model is
slightly higher. However the minimum normal stress of 2 holes model is a lot lower
compared to the initial problem.

Question 2: Torsion Analysis

a. Determine the shaft diameter.

Given:

= 1200

= 40 = 4 107 2

= 0.75/

To get shaft diameter, the following formula is used:

T is the applied torque or moment of torsion in Nm.

r is the distance between the rotational axis and the farthest point in the section (at the
outer surface).
J is the torsion constant for the section. It is almost equal to the second moment of area Jz = Iz
for twisting about axis z. For more accuracy, finite element analysis (FEA) is the best method.
Other calculation methods include membrane analogy and shear flow approximation.

=
2

4
, =
32
Shaft diameter, d is:

1200 2
7 2
4 10 =
4
32

= 0.5346 = 53.46

b. If replaced with a hollow shaft, determine the shaft outer and inner diameter with the thickness is
equal to 1/10 of outer diameter.

Calculation to obtain shaft outer diameter, D and inner diameter, d:

( 4 4 )
, =
32
4
Given, 4 4 = 10

Max shear stress or allowable shear stress is:

1200 2
7 2
4 10 =
4

10
32

= 0.11518 = 115.18

4
Since, 4 4 = 10
, inner diameter of the shaft, d is :

115.184
115.184 4 =
10

= 112.86

Shaft outer diameter, D = 115.18

Shaft inner diameter, d = 112.86

Proving with SOLIDWORKS

1. Pre-processing

1.1 Geometry creation

The length of the shaft is assumed to be 1000 mm length

Shaft dimensions : diameter = 53.46 mm (as calculated)
Hollow shaft dimensions: outer = 115.18mm, inner = 112.186mm (as calculated)

1.2 Material Property Assignment

1.3 Boundary Condition Specifications

Both models have the same boundary condition, fixed geometry at one end, and applying
1200 Nm Torque at the other end.

1.4 Mesh Generation

Intermediate mesh is applied to both models with the following mesh details.
Shaft Hollow Shaft
2. Solution

To compare the results, simulation study of static analysis is used.

3. Post-processing

The following figure shows the result of shear stress in Y direction on Y-Z plane.
For Shaft:

= 4.17 107

= 4.155 107

For Hollow-shaft:

= 4.125 107

= 4.134 107

4. Conclusion

From the result obtained, the value for max shear stress and min shear stress for shaft and
hollow-shaft is almost the same. Hence, justifying the calculation made.

Question 3: Buckling Analysis

1. Pre-processing

1.1 Geometry creation

With the dimensions of: 2 m height, 12.5 mm web thickness, and H = 120mm.
 1.2 Material Property Assignment
o Alloy steel mechanical properties

1.3 Boundary Condition Specifications

5 tonnes or 5000 kgs distributed mass is applied at one end of the model, and fixed
geometry is applied on the other end. Also, gravity of 9.81 m/s^2 is included as boundary
condition.
1.4 Mesh Generation

Intermediate mesh is applied to the model with the following mesh details

2. Solution

Buckling study is used for the simulation.

3. Post-processing

Pcr = 33.3658
 The larger the area, A the lower the critical buckling pressure will be

2
Pcr =
2