Formula collection Fundamentals of strength analysis Free-body diagramm:

A1 Y

Center of area:

Ys =
b e2 YS
Ys1

Ai Ysi A1 Ys1 + A2 Ys 2 = Ai A1 + A2

e1
Ys2

Moment of inertia: I1 = b h3 2 + e1 A1 12 b h3 2 + e2 A2 I2 = 12 I xx = I1 + I 2

A2

I x = I x + x2 A I y = I y + y2 A

Moment of inertia

S e c ti o n m o d u l u s

Section modulus:

W=

I max. edge distance I xx max(Ys ; b)

Wxx =

Bending:

Torsion:

Shear:

Tension, compression or contact:

Buckling:

M = b Wb

M = t Wt

F a = A

F = A

2 E I = 4 l2

Load cases for bending:

concentrated load
cantilever beam

distributed load
cantilever beam

l
F

Mb = F l

f
double supported beam

=
l

built-in beam

=
F

=
l

F l3 f= 3 E I F l Mb = 4 F l3 f= 48 E I F l Mb = 8 F l3 f= 192 E I

l
F

double supported beam

l
F

built-in beam

F l 2 F l3 f= 8 E I F l Mb = 8 F l3 f= 384 E I F l Mb = 12 F l3 f= 384 E I Mb =
xz yz z

Stresselement and stress tensor:

x S = xy xz
Mohrs circle for plane stress:
c = (x + y)/2 1 x

xy y yz

2 xy 0 2 2

xy 1

y 2

Maximum-Normal-Stress Theory (MNST): fibrous brittle materials, some glases, brittle materials

v = 1 = 0,5 x + y +

y ) + 4 2
2

Maximum-Shear-Stress Theory (MSST): ductile materials, compressing load with brittle materials tri-axial stress state: plane stress:

v = 2 max = 3 1

v = 2 max =

y ) + 4 2
2

Distortion-Energy Theory (DET) von Mises Criterion:

-

ductile materials with plastic deformation before failure dynamic loading with failure by fatigue

tri-axial stress state:

v = (1 / 2 ) (1 2 ) + ( 2 3 ) + (3 1 )
2 2

) = 2 + 2 + 2 ( x y + y z + x z ) + 3( 2 + 2 + 2 x y z xy yz xz
v = 12 + 2 1 2 = 2 + 2 x y + 3 2 2 x y

plane stress:

Cyclic stress:

1 cycle

maximum stress max mean stress m minimum stress min

stress amplitude

0 mean stress stress ratio

stress amplitude:

a =

max min 2

m =

max + min 2

R=

min max

Stress concentration factor:

Kc =

actual maximum stress average

Dynamic stress concentration factor acc. to Thum:

K = K (K C 1) + 1

Material carbon steel (S235JR...S355JR)

k 0 ,4 ...0 ,8 0 ,6 ...0 ,9 0 ,9 ...1 0 ,3 ...0 ,6

KC K = n

heat-treatable steel spring steel light metal

Notch factor:

Size factor:

Surface finish factor:

D,allowable =

D b1 b 2 K

D,allowable =

D b1 b2 K

Strength analysis for dynamic loads: 1.Calculation of maximum stress amplitude: -> max, max, reduced 2.Define the allowable stress: -> D,rel; D,rev (for tension. compression or bending); D,rel; D,rev 3.Integrate the various influence factors: -> D,allowable; D,allowable 4.Verify the given safety against failure: -> S=D,allowable / max Strength analysis for static loads: 1.Calculation of stress in the critical section: -> , , reduced 2.In case of a notch-effect: calculation of maxium stress: -> max=c 3.Define the allowable stress: -> allowable=Re, Rp0,2, Rm 4.Verify the given safety against failure: -> S=allowable / max or S=allowable / max

Design of Axles: Bending Bending Stress: b ,max =

M b ,max u ,b Wb

Required Axle Diameter:

d3

32 M b ,max u ,b

Design of Axles: Surface Pressure Surface Pressure: Pr :

Nm cm 2 s
metallic steel / synthetic

p=

F pu l1 d

Approximate Value:
insufficient = 0 .1 ...0 .3 3 ...1 0 1 ...5

pu

Pr v

Pr = relative bearing power v = running speed

Lubrication mating of material

low = 0 .1 ...0 .3 2 0 ...8 0 1 0 ...4 0

efficient = 0 .1 ...0 .3 8 0 ...2 0 0

Design of Shafts: Torsion

shaft diameter ds over 6 till 8 over 8 till 10 over 10 till 12 over 12 till 17 over 17 till 22 over 22 till 30 over 30 till 38 over 38 till 44 over 44 till 50 over 50 till 58 over 58 till 65 over 65 till 75 over 75 till 95 over 95 till 100 over 110 till 130 depth of groove for feather key hK 1,2 1,8 2,5 3,0 3,5 4,0 5,0 5,0 5,5 6,0 7,0 7,5 9,0 10,0 11,0 d ds hk

Torsional Stress:

t =

Mt u ,t Wt
16 M t u ,t

Required Shaft Diameter:

d3

Realised diameter of a groove shaft:

ds d + h k

Design of Shafts: Bending + Torsion

Effective Stress (DET):

v = 2 b + 3( 0 t ) u ,b
2

Strain Relationship:

0 =

u ,b 1.73 u ,t

Required Shaft Diameter:

d3

32 M v u ,b

Effective Moment:

2 Mv = Mb + 0.75( 0 Mt )2

Elastic Deformation of Shafts Angel of Twist: rad =

Mt l 180 M t l resp. deg = It G It G

d
4

180 32 M

Required Shaft Diameter:

G u l

u/l = 0.25...0.5/m

Deflection:

fu

1 l fu = safe deflection standard value 3000

Determination of the lowest natural frequency Centrifugal Force: Restoring Force:

Fc = m r 2
Fr = c y
c y = m r 2

Equilibrium of Forces: With r = y + e:

m e 2 = (c m r 2 ) y

m: mass of shaft r: excursion of mass : radian frequency c: flexural strength y: excursion of shaft e: eccentricity of gravity centre

At natural radian frequency: c/m-2=0 The Critical Speed: With c = Fw/fw and Fw = mg:
nb ,c

nb , c =

e 1 = 2 2

c m

1 = 2

Fw 1 = f w m 2 E Ib m l3

g fw

The deflection fw is known:

nb ,c =

e: natural radian frequency nb,c: critical speed g: gravitation Fw: weight fw: deflection due to weight E: modulus of elasticity Ib: polar moment of inertia l: length of shaft

Designing Fitting Keys Surface Pressure:

p=

2 Mt Fr p = (h t 1 ) l z d (h t 1 ) l z u
Experimental Values Of The Hub:
torque material 65 115 cast iron steel length L 1.8d ... 2.0d 1.6d ... 1.8d outside diameter D 1.8d ... 2.0d 1.6d ... 1.8d constant

Ulimate Surface Pressure (pu):

material shaft S275JR, E295 E295, hard steel hub S,E,GG S,E,GS 45 75 impulsive