EXAMPLE- DESIGN OF THICK CYLINDERS

DESIGN OBJECTIVE

A Hydraulic cylinder is to be built with an internal diameter of 300 mm. to generate a

pressing load of 20 tonnes, as shown in Drawing No. 1.

The internal pressure required is then determined as shown below.

d 2 * 300 2
F 20 * 1000 * 9.81 Newtons p * p*
4 4
Where F Pr es sin g load , p Internal pressure in cylinder, d Internal diameter of cylinder
20000 * 9.81 * 4
p 2.78 N mm 2 ( Mpa) 3 ( Mpa)
* 300 2
THE HYDRAULIC CYLINDER IS THEREFORE TO BE DESIGNED TO CARRY
AN INTERNAL PRESSURE OF 3 Mpa.

The location of extreme stress is at the inner surface where values of stresses in terms of
internal pressure p , internal radius a , and external radius b , are

p a2 b2
The tangential stress 1 t 2
b a2
a2
The longitudinal stress 2 l p * 2 2
b a
The radial stress 3 r p

Q.1 Determine the wall thickness required when cylinder is made from grey cast iron, to
British standard specification BS 150, whose properties are shown at Appendix A. Apply
Lames equation shown below.
 di d p
t
2 p 1 Lame' s equation for thick cylinder of brittle material
d
Use a factor of safety of 4 to derive the design (allowable) stress.

Apply the design procedure proposed below

1) Select of material for cylinder

2) External load on member to be designed for
3) Design equation to be used for cylinder and its variables
4) Design (allowable) stress for material and equation chosen
5) Solving design equation for cylinder
40 Marks
Q.2 Determine the wall thickness required when cylinder is made from low carbon steel,
to British standard specification BS 070M20, Hot rolled and normalised, whose properties
are shown at Appendix B. Apply Birnies equation shown below

di d 1 p
t 1 Birnie' s equation Open ended Ductile Material
2 d 1 p

Use a factor of safety of 2.5 to derive the design (allowable) stress.

Apply the design procedure proposed for Q.1.

45 marks
Q.3 Determine the wall thickness required when cylinder is made from low carbon steel,
to British standard specification BS 070M20, Hot rolled and normalised, whose properties
are shown at Appendix B. Apply Clavarinos equation shown below

d i d 1 2 p
t 1 Cla var ino' s equation Close ended Ductile Mterial
2 d 1 p

Use a factor of safety of 2.5 to derive the design (allowable) stress.

Apply the design procedure proposed for Q.1.

45 marks
Q.4 Determine the wall thickness required when cylinder is made from low carbon steel,
to British standard specification BS 070M20, Hot rolled and normalised, whose properties
are shown at Appendix B. Apply the equation derived from maximum shear stress theory
shown below.

di

d
t 1 Maximum shear stress theory (ductile material )
2 2 p
d

Page 2 of 12
Use a factor of safety of 2.5 to derive the design (allowable) stress.

Apply the design procedure proposed for Q.1.

45 marks

Page 3 of 12
6) SELECT OF MATERIAL FOR CYLINDER

Select cast iron from Appendix A

Mechanical Properties Grade Designation (British Standard Specification) 150
Tensile strength (Mpa.) 150
Compressive strength (Mpa.) 587
Shear strength (Mpa.) 176
Endurance limit (Mpa.) 71
Young's modulus (Gpa.) 71-96
Modulus of rigidity(Gpa.) 29-40
Hardness (HB) 160

7) EXTERNAL LOAD ON MEMBER TO BE DESIGNED FOR

External load Internal pressure p=3 Mpa

8) DESIGN EQUATION TO BE USED FOR CYLINDER AND ITS VARIABLES

For brittle material subject to internal pressure only, Lames equation is applied
d d pi
t i 1 Lame' s equation for thick cylinder of brittle material
2 d pi
where pi Internal pressure load N mm 2 ( Mpa )
d i Inside diameter of cylinder mm
d Design stress of chosen material N mm 2 ( Mpa)
t Wall thickness required mm

Lames equation is based on the maximum normal stress theory. Failure therefore occurs
when maximum normal stress at point of failure equals or exceeds maximum normal
stress when failure occurs in tension test specimen, of a brittle material.

MAXIMUM NORMAL STRESS-FAILURE IN SIMPLE TENSION SPECIMEN

When failure occurs in the simple tension specimen of a brittle material, the stress is given by

1 S ut , or 3 S uc
Where
S ut Ultimate tensile strength of the material
S uc Ultimate compressiv e strength of the material

9) DESIGN STRESS FOR MATERIAL CHOSEN AND EQUATION APPLIED

For chosen material,

Tensile strength (Mpa.) 150
Compressive strength (Mpa.) 587

Page 4 of 12
Tensile strength S ut compressiv e strength S uc

For thick cylinder subject to internal pressure, made out of the cast iron,
At the location of extreme stress (internal surface)

pi a 2 b 2
Maximum normal stress 1 ti 2
and Minimum normal stress 3 p ,
b a2
Maximum normal stress 1 (Tensile ) Minimum normal stress 3 (compressive)
Tensile strength Sut compressive strength Suc

DEFINING DESIGN (ALLOWABLE) STRESS

Lames equation is therefore predicts failure in tension when 1 S ut , rather than in

compression when 3 S uc

Relevant (significant) stress and equivalent strength are therefore 1 and S ut , tensile
stress and tensile strength
S ut
d Where d Design (allowable) stress and f .s factor of safety
f .s
Applying a factor of safety of f.s.=4 to the tensile strength of chosen cast iron, design stress
d is given by
S ut
d and substituting S ut 150 Mpa ( N mm 2 ), and f .s 4
f .s
150
d 37.5 Mpa ( N mm 2 )
4

10) SOLVING DESIGN EQUATION FOR CYLINDER

Substituting pi 3 Mpa ( N mm 2 ) , d i 300 mm., d 37.5 N mm 2

Lame' s equation becomes

t
300

37.5 3
1 150
40.5

1 150 1.1739 1 1501.08347 - 1 150 * 0.08347 mm
2 37.5 3 34.5
t 12.5205 12.5 mm.

Page 5 of 12
Q.2 Determine the wall thickness required when cylinder is made from low carbon steel,
to British standard specification BS 070M20, Hot rolled and normalised, whose properties
are shown at Appendix B. Apply Birnies equation shown below

Use a factor of safety of 2.5 to derive the design (allowable) stress.

1) SELECT MATERIAL FOR CYLINDER

Material British Production Maximum Yield Tensile Elonga Hardness

Standard1 process section size, Strength Strength, tion % Number, HB
mm. Mpa Mpa
0.20C 070M20 HR2 152 215 430 22 126-179

2) EXTERNAL LOAD ON MEMBER TO BE DESIGNED FOR

External load Internal pressure p=3 Mpa

3) DESIGN EQUATION TO BE USED FOR CYLINDER AND ITS VARIABLES

d i d 1 p i
t 1 Birnie' s equation Open ended Ductile Material
2 d 1 pi
where
pi Internal pressure load N mm2 ( Mpa)
d i Inside diameter of cylinder mm
d Design stress of chosen material N mm 2 ( Mpa)
t Wall thickness required mm
Poisson' s ratio

MAXIMUM NORMAL STRAIN AT POINT OF FAILURE

At inner surface of open ended thick cylinder where stresses are highest, maximum normal
stress are given by
p(b 2 a 2 )
1 t , 2 l 0, 3 r p
(b 2 a 2 )
Maximum normal strain occurs in direction of maximum normal stress and is given by
1
1 1 2 3
E
1 Normal strain in the direction of normal stress 1

MAXIMUM NORMAL STRAIN-FAILURE IN SIMPLE TENSION SPECIMEN

At the point of failure in the simple tension specimen of a ductile material, signified by
yielding, the maximum normal strain is given by

1
British Standards Institution, BS 970: Part 1: 1983
2
HR-Hot rolled and normalised

Page 6 of 12
 Sy
1 , For ductile material
E
S yt Tensile yield strength S yc Compressive yield strength of the material S y
DEFINING DESIGN (ALLOWABLE) STRESS

Birnies equation is based on the maximum normal strain theory. Failure therefore occurs
when maximum normal strain at point of failure equals or exceeds maximum normal
strain when failure occurs in tension test specimen, of a ductile material. This maximum
normal strain coincides with the maximum normal stress
1 2 3 S y
Applying a factor of safety to the indicator of failure, design equation becomes
Sy
1 2 3 d , where d Design stress
f .s

4) DESIGN STRESS FOR MATERIAL CHOSEN AND EQUATION APPLIED

For chosen material,

Tensile yield strength S y 200 Mpa

Applying a factor of safety of f.s.=2.5 to the tensile yield strength of chosen plain, low
carbon steel, design stress d is given by
Sy
d and substituting S y 200 Mpa ( N mm 2 ), and f .s 2.5
f .s
200
d 80 Mpa ( N mm 2 )
2.5

5) SOLVING DESIGN EQUATION FOR CYLINDER

di d 1 p i
t 1 Birnie' s equation Open ended Ductile Material
2 d 1 p i
Substituting
p i 3 N mm 2 ( Mpa ) , d i 300 mm, d 80 N mm 2 ( Mpa)
Substituting Poisson' s ratio 0.27 for steel
300 80 1 0.27 3 300 80 2.19 82.19
t 1 1 150 1
2 80 1 0.273 2 80 3.81 76.19

t 150 1.07875 1 1501.03862 1 150 0.03862 5.793 mm
6 mm

Page 7 of 12
Q.3 Determine the wall thickness required when cylinder is made from low carbon steel,
to British standard specification BS 070M20, Hot rolled and normalised, whose properties
are shown at Appendix B. Apply Clavarinos equation shown below

Use a factor of safety of 2.5 to derive the design (allowable) stress.

1) SELECT MATERIAL FOR CYLINDER

Material British Production Maximum Yield Tensile Elonga Hardness

Standard3 process section size, Strength Strength, tion % Number, HB
mm. Mpa Mpa
0.20C 070M20 HR4 152 215 430 22 126-179

2) EXTERNAL LOAD ON MEMBER TO BE DESIGNED FOR

External load Internal pressure p=3 Mpa

3) DESIGN EQUATION TO BE USED FOR CYLINDER AND ITS VARIABLES

For close ended cylinder of ductile material such as steel, Clavarinos equation is applied
di d 1 2 pi
t 1 Cla var ino' s equation Close ended Ductile Mterial
2 d 1 pi
where
pi Internal pressure load N mm2 ( Mpa)
d i Inside diameter of cylinder mm
d Design stress of chosen material N mm2 ( Mpa)
t Wall thickness required mm
Poisson' s ratio

MAXIMUM NORMAL STRAIN AT POINT OF FAILURE

At inner surface of close ended thick cylinder where stresses are highest, maximum normal
stress are given by
p(b 2 a 2 ) pa 2
1 t , 2 l , 3 r p
(b 2 a 2 ) (b 2 a 2 )
1
1 1 2 3 where 1 Normal strain in the direction of normal stress 1
E

MAXIMUM NORMAL STRAIN-FAILURE IN SIMPLE TENSION SPECIMEN

At the point of failure in the simple tension specimen of a ductile material, signified by
yielding, the maximum normal strain is given by

3
British Standards Institution, BS 970: Part 1: 1983
4
HR-Hot rolled and normalised

Page 8 of 12
 Sy
1 For ductile material
E
S yt Tensile yield strength S yc Compressive yield strength of the material S y
DEFINING DESIGN (ALLOWABLE) STRESS

Clavarinos equation is based on the maximum normal strain theory. Failure therefore
occurs when maximum normal strain at point of failure equals or exceeds maximum
normal strain when failure occurs in tension test specimen. This maximum normal strain
coincides with the maximum normal stress
1 2 3 S y
Applying a factor of safety to the indicator of failure, design equation becomes
Sy
1 2 3 d , where d Design stress
f .s

4) DESIGN STRESS FOR MATERIAL CHOSEN AND EQUATION APPLIED

For chosen material, Tensile yield strength S y 200 Mpa

Applying a factor of safety of f.s.=2.5 to the tensile yield strength of chosen plain, low
carbon steel, design stress d is given by
Sy
d and substituting S y 200 Mpa ( N mm 2 ), and f .s 2.5
f .s
200
d 80 Mpa ( N mm 2 )
2.5

5) SOLVING DESIGN EQUATION FOR CYLINDER

d 1 2 p i
t i d 1 Cla var ino' s equation Close ended Ductile Mterial
2 d 1 p i
Substituting
p i 3 N mm 2 ( Mpa) , d i 300 mm, d 80 N mm 2 ( Mpa) , 0.27
Cla var ino' s equation becomes
300 80 1 2 * 0.27 3 80 1 0.54 3 80 0.46 * 3
t 1 150 1 150 1
2 80 1 0.273 80 1.273 80 1.273
80 1.38
t 150
80 3.81

1 150
81.38
76.19


1 150 1.0681 1 150 * 1.03349 - 1 5.0247 mm

t 5 mm

Page 9 of 12
Q.4 Determine the wall thickness required when cylinder is made from low carbon steel,
to British standard specification BS 070M20, Hot rolled and normalised, whose properties
are shown at Appendix B. Apply the equation derived from maximum shear stress theory
shown below.

1) SELECT MATERIAL FOR CYLINDER

Material British Production Maximum Yield Tensile Elonga Hardness

Standard5 process section size, Strength Strength, tion % Number, HB
mm. Mpa Mpa
0.20C 070M20 HR6 152 215 430 22 126-179

2) EXTERNAL LOAD ON MEMBER TO BE DESIGNED FOR

External load Internal pressure p=3 Mpa

3) DESIGN EQUATION TO BE USED FOR CYLINDER AND ITS VARIABLES

di

d
t 1 Maximum shear stress theory (ductile material )
2 2 p
d i
where
pi Internal pressure load N mm 2 ( Mpa )
d i Inside diameter of cylinder mm
d Design stress of chosen material N mm 2 ( Mpa )
t Wall thickness required mm

MAXIMUM SHEAR STRESS AT POINT OF FAILURE

At inner surface of thick cylinder where stresses are highest

p (b 2 a 2 ) pa 2
1 t , 2 l , 3 r p
(b 2 a 2 ) (b 2 a 2 )
1 3 pb 2
max 2
2 (b a 2 )

MAXIMUM SHEAR STRESS-FAILURE IN TENSION TEST SPECIMEN

Failure in the simple tension specimen of a ductile material, the stress is given by
1 S y , 2 0, 3 0
1 3 1 0 1 S y
Maximum shear stress max S sy
2 2 2 2

Sy
Where S sy Shear yield strength of the material, and therefore S sy
2

5
British Standards Institution, BS 970: Part 1: 1983
6
HR-Hot rolled and normalised

Page 10 of 12
But S yt Tensile yield strength S yc Compressive yield strength of the material S y
DEFINING DESIGN (ALLOWABLE) STRESS

The design equation is based on the maximum shear stress theory of failure. Failure
therefore occurs when the maximum shear stress at point of failure equals or exceeds
maximum shear stress when failure occurs in tension test specimen.
pb 2 Sy 2 * pb 2
max S sy or Sy
(b 2 a 2 ) 2 (b 2 a 2 )
Applying a factor of safety to the yield strength (indicator of failure)
2 * pb 2 Sy
d Where d Design stress
(b a )
2 2
f .s
5) DESIGN STRESS FOR MATERIAL CHOSEN AND EQUATION APPLIED

For chosen material,

Tensile yield strength S y 200 Mpa

Applying a factor of safety of f.s.=2.5 to the tensile yield strength of chosen plain, low
carbon steel, design stress d is given by
Sy
d and substituting S y 200 Mpa ( N mm 2 ), and f .s 2.5
f .s
200
d 80 Mpa ( N mm 2 )
2.5

5) SOLVING DESIGN EQUATION FOR CYLINDER

Design equation is derived by equating maximum shear stress at the point of failure to the
shear strength expressed in terms of tensile yield strength and design stress based on
tensile yield strength.
di

d
t 1 Maximum shear stress theory (ductile material )
2 2 p
d i
Substituting
p i 3 N mm 2 ( Mpa ) , d i 300 mm, d 80 N mm 2 ( Mpa)

Design equation becomes

t
300

80 300
1
80 1 300 80

1 150 1.08108 1
2 80 2 * 3 2 80 6 2
74
t 1501.03975 1 150 * 0.03975 5.9625
t 6 mm.

Page 11 of 12
APPENDIX A: MECHANICAL PROPERTIES OF GREY CAST IRON
(TENSILE STRENGTH CORRESPONDS TO THE BS GRADE)
Mechanical Properties Grade Designation (British Standard Specification)
150 180 220 260 300 350 400
Tensile strength (Mpa.) 150 180 220 260 300 350 400
Compressive strength (Mpa.) 587 663 766 868 970 1097 1225
Shear strength (Mpa.) 176 222 284 346 407 484 562
Endurance limit (Mpa.) 71 82 96 111 125 143 161
Young's modulus (Gpa.) 71-96 79-104 89-114 100-124 110-135 124-147 137-160
Modulus of rigidity(Gpa.) 29-40 32-42 36-45 40-48 43-51 48-55 53-58
Hardness (HB) 160 176 196 216 236 261 286

APPENDIX B7: MECHANICAL PROPERTIES OF SOME STEELS

Material British Production Maximum Yield Tensile Elonga Hardness
Standard8 process section size, Strength Strength, tion % Number, HB
mm. Mpa Mpa
0.20C 070M20 HR9 152 215 430 22 126-179
254 200 400 20 116-170
CD10 13 385 530 12 154
76 340 430 14 125
0.30C 080M30 HR 152 245 490 20 143-192
254 230 460 19 134-183
CD 13 470 600 10 174
63 385 530 12 154
H&T11 63 385 550-700 13 152-207
0.40C 080M40 HR 150 280 550 16 152-207
CD 63 430 570 10 165
H&T 63 385 625-775 16 179-229
0.50C 080M50 HR 150 310 620 14 179-229
CD 63 510 650 10 188
H&T 150 430 625-775 11 179-229
1Cr 530M40 H&T 100 525 700-850 17 202-255
29 680 850-1000 13 248-302
1.5MnMo 605M36 H&T 150 525 700-850 17 202-255
29 755 925-1075 12 269-331
1.25NiCr 640M40 H&T 152 525 700-850 17 202-255
102 585 770-930 15 223-277
64 680 850-1000 13 248-302
29 755 930-1080 12 269-331
3NiCr 653M31 H&T 64 755 930-1080 12 269-331
680 850-1000 12 248-302
1CrMo 708M40 H&T 150 525 700-850 17 201-255
13 940 1075-1225 12 311-375
3CrMo 722M24 H&T 152 680 850-1000 13 269-331
755 930-1080 12 269-331
2.5NiCrMo 826M40 H&T 150 755 925-1075 12 269-331
850 1000-1150 12 293-352
1020 1150-1300 10 341-401
3NiCrMo 830M31 H&T 254 650 850-1000 13 248-302
152 680 850-1000 12 248-302
64 940 1080-1240 11 311-375
1.5MnNiCrMo 945M38 H&T 152 525 690-850 17 201-255
64 680 850-1000 13 248-302
29 850 1000-1160 12 293-352

7
Shigley, Joseph E., Mechanical Engineering Design, pp. 664, McGraw-Hill Inc., 1986
8
British Standards Institution, BS 970: Part 1: 1983
9
HR-Hot rolled and normalised
10
CD-Cold drawn
11
H&T-Hardened and tempered

Page 12 of 12