1

Prepared by: Tuğçe YÜKSEL Note that each stress component which is in the plane with i-surface normal and which is
Room: C-210 Phone: 5267 in the j-direction is represented by σ ij . That is τ xy represents the stress in the plane
E-mail: tyuksel@metu.edu.tr Date: 09/10/2008
whose normal is parallel to x-axis, with y-direction in the { x, y, z} coordinate system.
ME 307 – MACHINE ELEMENTS I
TUTORIAL 2 b. For a stress element, there exists a particular orientation in space for which all shear
“3D Stress State, Thick-Walled Cylinders, Thermal Stresses” components are zero. When an element has this particular orientation, the normals to the
faces correspond to principal directions and the normal stresses associated with these
faces are principal stresses.
Problem 1: y
30 MPa Suppose that, this particular orientation of the element is as shown and can be expressed
in another coordinate system; { x ', y ', z '} .
25 MPa
σ2
35 MPa 40 MPa

20 MPa x

50 MPa
y y'
z
σ1
σ3
x
Consider the cubic stress element taken from a pressure vessel. For the element, with '
the stress components as shown:
z
a. Write the stress matrix. x'
b. Determine the principal stresses for the given stress state. z
c. Draw Mohr’s circle diagram of the principal stresses.
d. Find the maximum shear stress. According to definition, since the shear stress components will be zero for this
orientation, the stress matrix will be diagonal. This corresponds to an eigenvalue problem
Solution: where the magnitudes of the principal stresses will be the eigenvalues and their directions
(directional cosines) will be the eigenvectors. That is:
a. The stress matrix will be;
[σ ]{n} = σ p {n}
σ x τ xy τ xz   −40 25 20 
 
σ = τ yx σ y τ yz  =  25 30 35  which can also be written as:

τ zx τ zy σ z   20 35 50 
  ([σ ] − σ [ I ]) {n} = 0
p

METU – ME 307 Machine Elements I – Fall 2008

 2
Here, [I ] is the identity matrix, σ p is the eigenvalue and {n} is the eigenvector σ i = r ⋅ cosθ i +
I1
, where r and θi can be found from:
corresponding to each eigenvalue. 3
To avoid the trivial solution {n} = 0 the determinant of ([σ ] − σ [ I ]) should be
p 2 2
r = (I1 − 3I 2 ) 2
1

zero. 3
[σ ] − σ p [ I ] = 0 2 I 3 − 9 I 1 I 2 + 27 I 3
cos 3θ = 1 3
−40 − σ p 25 20 σ xx − σ p τ xy τ xz 2
2( I 1 − 3 I 2 ) 2
25 30 − σ p 35 = τ yx σ yy − σ p τ yz Now calculate r and θ , by inserting the numerical values,
20 35 50 − σ p τ zx τ zy σ zz − σ p r = 77.316
cos ( 3θ ) = 0.33024
= σ p3 − (σ x +σ y +σ z )σ p2 + (σ xσ y +σ xσ z +σ yσ z −τ xy2 −τ yz2 −τ zx2 )σ p Here cosine equation has infinitely many solutions,
2 2
−(σ xσ yσ z + 2τ xyτ yzτ zx −σ τ −σ τ −σ τ ) = 0 2 a cos ( 0.33024 ) + 2 k π
x yz y zx z xy θ = , where k = 0,1,2..
3
This is a cubic equation in the unknown σ p where the three solutions are the principal Take 3 of the possible solutions as we have 3 principal stresses.
stresses σ 1 , σ 2 , σ 3 .Note that, the solutions to σ p are independent of the coordinate
system chosen. In other words; principle stresses occur only in one particular a cos ( 0.33024 )
θ1 = = 0.4114 rad
orientation and no matter the coordinate system of the stress element chosen, the 3
solutions to σ p must be the same. Therefore, the coefficients of σ p in the cubic a cos ( 0.33024 ) + 2π
equation are constant:
θ2 = = 2.5058 rad
3
a cos ( 0.33024 ) − 2π
I1 = σ x +σ y +σ z θ3 = = − 1.6830 rad
3
I 2 = σ xσ y +σ xσ z +σ yσ z −τ xy2 −τ yz2 −τ zx2 Then the principal stresses will be
I1
I3 = σ xσ yσ z + 2τ xyτ yzτ zx −σ xτ yz2 −σ yτ zx2 −σ zτ xy2 σ1 = r ⋅ cosθ1 + = 84.198 MPa
3
I
I1, I2 and I3 are called as stress invariants. σ 2 = r ⋅ cosθ2 + 1 = −48.876 MPa
3
Calculating the coefficients yields; I1
σ 3 = r ⋅ cosθ3 + = 4.678 MPa
3
I1 = 40 , I2 = −3950 , I3 = −19250 Arrange σ1, σ2, σ3 such that σ1>σ2>σ3.

Now the roots of the cubic equation can be found from the formula: σ1 = 84.198 MPa ,σ 2 = 4.678 MPa ,σ 3 = −48.876 MPa

METU – ME 307 Machine Elements I – Fall 2008

 3
Of course this solution will be much shorter if software was used. For example, the  −40 25 20 
MATLAB command given below gives the eigenvectors and eigenvalues of the stress σ :=  25 30 35 
matrix.  
 20 35 50 
>> %calculating the eigenvectors and eigenvalues of the  84.198   0.244 0.96 −0.135 
>> %stress matrix using "eig" command : eigenvals ( σ) =  −48.876 eigenvecs ( σ) =  0.603 −0.259 −0.755 
>> stress=[-40 25 20; 25 30 35; 20 35 50]    
 4.678   0.76 −0.103 0.642 
stress =
Eigenvectors can also be found from the following equation:
-40 25 20
25 30 35 ([σ ] − σ [ I ]) {n} = 0
p
20 35 50

>> [eigvec,eigval]=eig(stress) For each value of σ p , there exists a corresponding eigenvector. For example for the first
eigenvalue σ 1 = 84.198 ,
eigvec =
([σ ] − σ [ I ]) {n} = 0
p
0.9604 0.1348 0.2437
-0.2589 0.7546 0.6030  −40 − 84.168 25 20   nx  0 
-0.1026 -0.6422 0.7596  25 30 − 84.168 35   n  = 0
  y  
 20 35 50 − 84.168  nz  0 
eigval =
−124.168nx + 25n y + 20nz = 0 (1)
-48.8757 0 0
0 4.6777 0 25nx − 54.168n y + 35nz = 0 (2)
0 0 84.1979
20nx + 35n y − 24.168nz = 0 (3)
>>
Note that this matrix equation has infinitely many solutions, as det ([σ ] − σ p [ I ]) = 0 ,
these 3 equations are not linearly independent.
The diagonal elements of eigval matrix are the eigenvalues which are the principal
stresses, and the columns of eigvec are the corresponding eigenvectors which are the
From Eq(1) & Eq(2)
direction cosines of the principal stresses.
−4845.88nx + 1958.36n y = 0 ⇒ n y = 2.4745nx
The eigenvalues and eigenvectors can also be obtained using the MATHCAD From Eq(2) & Eq(3)
commands “eigenvals” and “eigenvecs” respectively: −1958.36n y + 1304.2nz = 0 ⇒ nz = 1.5016n y

METU – ME 307 Machine Elements I – Fall 2008

 4
As there are infinitely many solutions say, nx = a then n y = 2.4745 ⋅ a and c. Mohr’s circle for the calculated principal stresses will be

nz = 3.7171⋅ a
Now let’s normalize {n} and find the directional cosines,
We know that nx 2 + ny 2 + nz 2 should be equal to 1, to be the directional cosines.
Then
a
nx = = 0.2815 ⇒ a cos ( 0.2815) = 73.65o
2 2 2
( a ) + ( 2.4745 ⋅ a ) + ( 3.7171⋅ a )
2.4745 ⋅ a
nx = = 0.5408 ⇒ a cos ( 0.5408) = 57.26o
2 2 2
( a ) + ( 2.4745 ⋅ a ) + ( 3.7171⋅ a )
3.7171⋅ a
nx = = 0.8123 ⇒ a cos ( 0.8123) = 35.68o
2 2 2
( a ) + ( 2.4745 ⋅ a ) + ( 3.7171⋅ a )

The directional cosines of the first principal stresses are shown in figure below.

d. Maximum in-plane principal shear stresses will be,

σ2 σ1 − σ 2
τ 1/ 2 = = 39.76 MPa
2
σ −σ3
σ1 τ 2/3 = 2 = 26.77 MPa
2
σ −σ
y τ 1/3 = 1 3 = 66.54 MPa
y' 2
57.26o
x' The maximum shear stress is the radius of the bigger circle,
73.65 o
x σ3 τ max = τ1/3 = 66.54 MPa
35.68o
z
z'

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 5
Problem 2

A horizontal member is supported by two stainless steel members and an aluminum

alloy block is placed between the wall and the horizontal member as shown in Figure

Aluminum
2.1. The structure is initially unstressed and at a temperature of 25oC. If the

Steel
Steel
temperature of the structure is raised to 250oC, determine the stresses induced in the
steel members and the aluminum block. The cross sectional areas are 50 mm2 for the
steel members and 125 mm2 for the aluminum block.
(αal=23.9x10-6 1/oC, αst=17.3x10-61/ oC, Eal=71.7 GPa, Est=190GPa)

Horizontal member

Fst Fal Fst

Figure 2.2
Aluminum

Steel
Steel

From force equilibrium, the forces in the steel members are equal to each other. Also;

Fal=2Fst. (1)

From the geometry, it is observed that the length changes of the block and steel members
should be the same:

δal=δst (2)
Wall
Due to temperature change, members and the block will expand. The axial forces will
Figure 2.1 create expansion in the steel members whereas contraction in the aluminum member.
Then, the total deformations can be written as follows:
Solution
Fal ⋅ l
δ al = α al ⋅ l ⋅ ∆T − (3)
When the coefficients of expansions of aluminum and steel are compared, it is Eal ⋅ Aal
observed that aluminum has a larger coefficient of expansion. Therefore, aluminum
would expand more if it were free to do so. As the aluminum expands, it pulls the
steel members, placing them in tension. The steel members pull back on the
Fst ⋅ l
aluminum, placing aluminum in compression. The resulting forces are shown in δ st = α st ⋅ l ⋅ ∆T + (4)
Figure 2.2. Est ⋅ Ast

where l is the initial length and ∆T is the temperature change in Celsius degrees.

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 6
Inserting (1), (3) and (4) into (2) gives:
Problem 3:
∆T ⋅ (α al − α st )
Fst = (5) Three cube blocks with identical dimensions are placed into a rigid cavity and there is no
1 2
+ clearance and friction between their surfaces and surface-wall contact regions. A
Est ⋅ Ast Eal ⋅ Aal uniformly distributed stress p is applied on the upper surface of cube 1. The cubes have
equal side lengths. The material properties are the same for cubes 2 and 3. Determine the
Inserting the numerical values gives: stress applied by the side wall to cube 2 (σ2x) in terms of the material properties and p.

Fst =
(250 − 25) ⋅ (23.9 − 17.3) ⋅ (10−6 ) = 4521.7 N z
1 2
+
(190) ⋅ (109 )⋅ (50) ⋅ (10− 6 ) (71.7 ) ⋅ (109 )⋅ (125) ⋅ (10− 6 )
The force acting on the aluminum block is:

3 1 2 top view
Fal = 2 ⋅ Fst = 9043.4 N y
The axial stresses on the steel members and the block are:
x
F 9043.4 ( N ) walls
σ al = al = − = −72.3MPa
Aal (125) (mm2 )
Fst 4521.7 ( N )
σ st = = = 90.4 MPa
Ast ( 50 ) (mm 2 ) E3 E1 p E2
v3 v2 side view
v1
y
The stress acting on the aluminum block is compressive and the stresses acting on the
steel members are tensile.
Solution:

The walls are rigid; therefore the strain in x-direction for the cubes is zero.
For the first cube, the strain in x direction is zero. Then;
1 1
ε1x
E1  ( )
⋅  σ1x − ν 1⋅ σ1y + σ1z 
 E  1x
( )
⋅  σ − ν 1⋅ σ1y + p  0

, 1
which gives
(
σ 1x = ν 1 ⋅ σ 1 y + p ) (1)

METU – ME 307 Machine Elements I – Fall 2008

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Note that the stresses on the cubes along y-direction are equal to each other since the Problem 4
cross-sectional areas of the cubes are equal and the forces along y-direction are the
same for all the cubes a. Two cylinders of same material will be press fitted so that the principal stress
with the greatest absolute value is not to exceed half of the yield strength of the
Similarly, the strain in x direction is also equal to zero for the second cube. material. If the cylinders are made of steel with yield strength of 552 MPa,
1 1 E=207 GPa and ν=0.292, determine the maximum acceptable interference
ε2x
E2  (
⋅  σ2x − ν 2⋅ σ2y + σ2z 
 )
E  2x
(
⋅  σ − ν 2⋅ σ 1y  0
 ) pressure and the corresponding radial interference. The nominal dimensions of
, 2 the cylinders shown in the figure are ri=25 mm, R=40 mm and ro=55 mm.
which gives:
σ 2x
σ1 y = (2) ro
ν2
Substituting eqn. (2) into eqn. (1) gives: R
 σ 
σ1x =  p + 2 x  ⋅ν1 (3)
 ν2  ri
Summation of elongations of cubes in y direction is also equal to zero due to rigid
wall. The total elongation in y direction expression can be written in terms of strains
since the side length of cubes are equal to each other.

ε 1y + ε 2y + ε 3y 0 b. Let the open ended composite cylinder of part (a) be made by shrinking a
cylinder of inner radius 40.000 mm on an cylinder with outer radius 40.060 mm.
Since the material properties and the stresses applied by cube 1 are the same for cubes Other dimensions are the same as in part (a). If the composite cylinder is
2 and 3, it can be written as: subjected to an internal pressure of 250 MPa, determine the stress components
1 1 σr, σl, σt at the inner and outer surfaces of the cylinder and at r=40 mm.
ε1 y + 2 ⋅ ε 2 y = 0, σ1 y −ν1 ⋅ ( p + σ1x )  + 2 ⋅
E1   E2
( )
⋅ σ1 y −ν 2 ⋅ σ 2 x = 0 (4)
Solution:
Solving eqn. (2), (3) and (4) simultaneously for unknowns σ1x , σ1y and σ 2 x gives:
a. From Shigley, 8th edition, the tangential stress at the transition radii of the inner
2 member and outer members are:
−E2 − 2⋅ E1 + 2⋅ E1⋅ ν 2 − E2⋅ ν 1
σ1x ν 1⋅ p ⋅ 2 2
2
−E2 + E2⋅ ν 1 − 2⋅ E1 + 2⋅ E1⋅ ν 2
2 (σ t )i r = R = − p R 2 + ri 2 (Eqn. 3-57)
R − ri
1 + ν1 2 2
σ1y −E2⋅ ν 1⋅ p ⋅
2 2 (σ t )o r = R = p ro 2 + R 2 (Eqn. 3-58)
−E2 + E2⋅ ν 1 − 2⋅ E1 + 2⋅ E1⋅ ν 2 ro − R
1 + ν1 It is required that the principal stress with the greatest absolute value is not to exceed half
σ 2x −E2⋅ ν 1⋅ p ⋅ ⋅ν 2 of the yield strength of the material. Therefore, inserting the numerical values to both
2 2 equations:
−E2 + E2⋅ ν 1 − 2⋅ E1 + 2⋅ E1⋅ ν 2

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 8
552 40 + 25 2 2
(207) ⋅ (10 )⋅ (MPa) ⋅ (0.060) ⋅ (mm) ⋅  (55 − 40 )⋅ (40 − 25 )⋅ (mm ) = 56.17MPa
3 2 2 2 2 2
=−p 2 → p = 120.94 MPa p=  
40 − 252 (40)(mm)  2 ⋅ (40 )⋅ (55 − 25 )⋅ (mm ) 
2 2 2 2 2

This interface pressure produces stresses in the non-pressurized composite cylinder,

552 552 + 402 which can be calculated using the thick walled cylinder equations available on the
= p 2 → p = 85.04MPa
2 55 − 402 formula sheet as:
Therefore, the maximum acceptable interference pressure is 85.04 MPa. The
corresponding radial interference can be found from the interface pressure equation:
σ=
[ ]
a 2 ⋅ pi − b 2 ⋅ p o ± a 2 ⋅ b 2 ⋅ ( p o − pi ) / r 2
(-) for σ t and (+) for σ r
p=
(
 2
E ⋅δ c − b ⋅ b − a
⋅
2
)( 2

2 
) b2 − a 2
(
b  2 ⋅ b 2 ⋅ c 2 − a 2  ) For the inner cylinder pi = 0 (since we are calculating stresses for the non-pressurized
case) and po = p , whereas for the outer cylinder pi = p and po = 0 . Using these in the
which is also available in the formula sheet.
given equation for the inner and outer cylinder, the required stresses are found as:

(85.04) ⋅ (MPa ) = (207 ) ⋅ (10 )(MPa )δ ⋅  (55 − 402 )⋅ (40 − 25 )⋅ (mm )

3  2 2 2 2 2 
2 
(40)(mm )  2 ⋅ (40 )⋅ (55 − 25 )⋅ (mm ) 
2 2 Inner Cylinder Outer Cylinder
Residual Stresses r = 25 mm r = 40 mm r = 40 mm r = 55 mm
σr 0 MPa -56.2 MPa -56.2 MPa 0 MPa
from which:
σt -184.4 MPa -128.2 MPa 182.3 MPa 126.1 MPa

δ = 0.091mm Now, consider the composite cylinder with an inner radius of 25 mm and outer radius of
55 mm. The stresses caused by the internal pressure of 250 MPa can be calculated again
b. First of all, no longitudinal stress exists since the cylinder is open ended, i.e.
using the above formula. The outer pressure in this case is 0. Then, the stresses are:
σl = 0 .
Stress r = 25 mm r = 40 mm r = 55 mm
There are two sources for tangential and radial stresses: the stresses that occur due to σr -250.0 MPa -57.9 MPa 0 MPa
the internal pressure and residual stresses in the cylinder caused by shrinking the outer
σt 380.2 MPa 188.2 MPa 130.2 MPa
cylinder on the inner cylinder. These stresses will be calculated separately.

First, consider the non-pressurized press-fitted cylinder. The initial difference between The stresses in the cylinder are the summation of the above calculated stresses, i.e.:
the outer radius of the inner cylinder and the inner radius of the outer cylinder is
40.060-40.000=0.060 mm. That is the total radial interference δ. Using the following
equation from the formula sheet, the interface pressure can be calculated as: Inner Cylinder Outer Cylinder
Residual Stresses r = 25 mm r = 40 mm r = 40 mm r = 55 mm
-250.0 MPa -114.1 MPa -114.1 MPa 0 MPa
p=
E ⋅δ
⋅
( )(
 c 2 − b2 ⋅ b2 − a 2 ) σr
-195.8 MPa 60.0 MPa 370.5 MPa 256.3 MPa
b 2
( 2
 2 ⋅ b ⋅ c − a
2
) 
σt

METU – ME 307 Machine Elements I – Fall 2008