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Azeem Khan

B00230817
Design Analysis 1
Assignment
Bob Bailey
Aim
The aim of this assignment is to produce a design of a structure. The entire
structure is required to have a factor of safety of 3.0. In addition to this, unknown

dimensions are asked to be calculated so that the structure meets the given
conditions.
Calculations supporting the design theory, plus a narrative description of this,
will be included in this report.

Introduction
The purpose of this assignment is, ultimately, to assess how the tensile yield
strength and the load, can affect the design of a structure i.e. How it affects the
size of bolt used, the thickness of materials etc.
Tensile yield strength varies between materials . It is a measure of
the force required to pull a structural beam to the point where it breaks. The
tensile strength of a particular material is the maximum load of stress that it can
take before failure (breaks).
In addition to this, the yield strength is the stress a material can with stand
without permanent deformation. It will cause a permanent deformation of 0.2%
of the original dimension.
Furthermore, the factor of safety is the ratio of the maximum breaking stress
that a structural part can withstand to the estimated maximum stress in ordinary
use.
Finally, the impact of the tensile yield strength and the factor of safety on a
design structure, as well as the different types of stresses (bearing and shear)
are the main principles explored in this assignment.

Calculations
The Question, included in the assignment, is as follows:
A 6m long beam with simply supported ends is required to support a moving point
load of 15 tonnes. The section for the beam is shown in Figure 1 and is
manufactured from mild steel having a tensile yield strength of 425MN/m2. The
beam support arrangement is shown in Figure 2. A side plate is bolted to each
side of the beam by two bolts of diameter D 1. The bolts have a tensile yield
strength of 375MN/m2 and the plates a tensile yield strength of 215MN/m2. The
side plates in turn are supported in a cradle as shown via a hinge pin having a
diameter D2 having a tensile yield strength of 275 MN/m2. The entire structure is
required to have a factor of safety of 3.0.
The design produced should meet the specification given:

Beam Dimensions W, H and T, where H=2*W and T= 20

Bolt Size D1
Side Plate thickness T2 and width W2

Cradle Plate thickness T3 and width W3


Hinge Pin Diameter D2

Take: Bearing Strength = 0.7*Tensile Yield Strength


Shear Strength = 0.5*Tensile Yield Strength
The following method is an outline on how to tackle this problem.
1. Calculate y, and in turn the parallel axis theorem allowing us to determine
the Ixx. The y and the Ixx are calculated in terms of W as no real
numbers are given. From the question, the width is taken as W, the height
as 2W, and the thickness as W/20.
2. With the aid of FBD, SFD and BMD diagrams, the bending moment acting
upon the beam is determined.
3. Calculate the stress acting on the beam from the relationship between the
tensile yield stress of the specific material in question and from the factor
of safety.
4. From the equation,

MY
I

; Since Y and Ixx are in terms of W, this

equation can be rearranged to find W, and hence H and T.


5. To find the diameter D1, there are three different stresses acting on the
bolt. The bearing stress on the beam, the bearing stress on the side plate
and the shear stress on the beam.

2
D
4

F
A

; where the area is equal to

Furthermore, the largest value for D is taken to be the diameter

as this satisfies the max diameter of all the 3 stresses.


6. Using D1 from above, the thickness of the side plate can be calculated. In
addition to this, using this thickness, W2 can be determined.
7. Finally, D2, T3 and W3 can be calculated in that order written as each
dimension is dependent on the value before.
W

2W
W/20
Datum

Shape 1.
Area =

wx

w
20

w2
20

( 12 x W20 )

y = 2W
2

W 79W
x
20
40

Ay =

2W W

1
40

79 W
40

80W W

40
40

79 W
40

Shape 2 and 3.

Area =

Ay =

A =

Ay =

1 2W W
1 40W W

2 1
20 2 20
20

y=

Y=

2W W W

x
1
20 20

) (

40 W W W 39W W 39W 2

x =
x =
20
20 20
20
20
400

1 39W
x
2
20

39 W
40

39 W 2 39 W 1521 W 3
x
=
400
40
16000

W 2 39W 2 39 W 2
+
+
20
400
400

20 W 2 39W 2 39W 2 98 W 2
+
+
=
400
400
400
400

79 W 3 1580 W 3 1580W 3 1580 W 3 1521 W 3 1521 W 3 4622W 3 2311 W 3


+
+
=
+
+
=
=
800
16000
16000
16000
16000
16000
16000
8000

Ay
=
A

2311 W
8000
98W 2
400

Parallel axis theorem.

2311 W
1960

For shape 2 and 3.


2311 W 39 W 2311 W 1911 W 400 W 10W

=
=
1960
40
1960
1960
1960
49

H=

For shape 1
79 W 2311 W 3871W 2311 W 1560 W 39 W

=
=
40
1960
1960
1960
1960
49

H=

A( y )
( 2 )
1

b d 3 +
12

I
( xx + A h2)
Ixx =

[(

1
w
xW x
12
20

[(

W
W
W 39 W
x
+
x
12 8000
20 2401

( )) (
3

)(

+ Wx

W 39W
x
20
49

) )] [(

)] [(
+2

[(

)] [(

[ ( 0.031685 W 4 ) ] +2

[ ( 0.031685 W 4 ) ] +2 [ ( 0.034956 W 4 ) ]

+2

1 W
W
x x 2W
12 20
20

W
40 W W
x

240
20
20

)) ( (

)) ( (
+

[(

)(

59319 W
3900 W
+
1920000
960400

)]

w
W
10 W
x 2W
x
20
20
49

)(

w
40 W W
10 W
x

x
20
20
20
49

W 4 1521W 4
W 393 W 3
w 39 W 10 2 W 2
+
+2
x
+
x
x
96000
48020
240 8000
20
20
2401

)(

)(

)]

) )]
2

) )]
2

[ ( 0.031685 W 4 ) ] +[ ( 0.069912 W 4 ) ]

0.101597 W

Free Body Diagram

L L
F
2 2

o
o

F F
2 2

Shear Force Diagram


F F
2 2

o
o

F F

2
2

Bending Moment Diagram

F L FL
x =
2 2 4
FL
4

o
o

From the bending moment diagram, the bending moment acting on this structure

Force x Length
4

is equal to

Where the Force=Mass x Gravitational Feild Strength=15000 x 9.81=147150 N


M=

So,

F x L 147150 x 6
=
=
4
4

The equation

MY
I

220725 Nm

is employed to calculate the width. Y and I are in

terms of W, since W is the only unknown, the equation can be rearranged to


determine W.
The factor of safety is 3.0. And the tensile yield strength of the beam is 425
N/mm2. This means that the relationship of the direct stress acting upon the
beam is equal to

Tensile Yeild Strenght


Factor of Safety

425
=
3

141.67 N/mm2 ;

M = 220725 x 103 from before.

MY
=
I

141.67

2311
1960
0.101597W 3

220725 x 10 3 x

2311
1960
0.101597 x 141.67
3

220725 x 10 x

W 3=18081590.18
W

3 18081590.18

W = 262.47 mm
Hence,

2311
W
1960
0.101597 W 4

220725 x 10 3 x

141.67

H = 2W = 2 x 262.47 = 524.94 mm
T = W/20 = 262.47/20 = 13.1235 mm

Stress 1. Beam Bearing Stress.

= 0.7 x

F
4A

425
3

= 99.167 N/mm2

4 x D2
4

F
D2
Because 4 bolts so 4 x area

99.167=

147150
D2
147150
x 99. 167

D 2=

= 472.33

D= 472.33=21.73 mm

Stress 2. Side Plate Bearing Stress.

= 0.7 x

F
4A

50.167=

D 2=

215
3

= 50.167 N/mm2

4 x D2
4

147150
2
D
147150
x 50. 167

= 933.67

D= 933.67=30.56 mm

F
2
D

Stress 3. Beam Shear Stress.

= 0.5 x

F
4A

425
3

= 70.83 N/mm2

F
2
4x D
4

F
D2

Because 4 bolts so 4 x area

70.83=

147150
2
D
147150
x 70.83

D =

= 661.29

D= 661.29=25.72mm
Diameter D1 is taken as 30.56 because it is the largest diameter that satisfies
the max diameter of all the 3 stresses acting on the bolt. Since you cant get/buy
a bolt size of 30.56 mm, the bolt size is therefore taken as 32 mm

Thickness T2.

F
4( D1 x T 2)

F/4 because force acting

on 4 bolts

= Side plate bearing stress = 50.167 N/mm 2


50.167

T2

147150
4(32 x T 2)

147150
4 x 32 x 50.167

= 22.92 mm

Width W2.
= Side plate bearing stress = 50.167 N/mm 2

2 side plates = F
so, 2xD1
W2

F
2 ( W 22 D 1 ) x T 2
2 bolts on 1 side plate

1 side plate = F/2

Cross Sectional Area + diameter of bolts = W2

2 (W 22 D 1 ) T 2

( W 22 D1 ) T 2

W 22 D1

W 22 D1

W2

W2

W2

F
x2

F
x 2x T 2

F
x 2x T 2

F
x 2x T 2

147150
50.167 x 2 x 22.92

= 63.988 + 64

W 2 = 127.99 mm

Diameter D2.

2D1

2 x 32


Where A = 2A because the hinge pin goes through 2 holes,
one at each side of the cradle. So, A =

2x

2
D
4

2
D
2

F
A

= Shear stress of hinge pin = 45.835 N/mm2


F

2
D
2

45.835 =

147150
2
D
2
147150

x 45.835
2

= 2043.822

2043.822 = 45.21 mm

D=

Cant get bolt size of 45.21 mm. So, D2 taken as 46 mm

Thickness T3.
= 64.167 N/mm2

F
2( D1 x T 3)

F/2 because force acting on 2 sections of the hinge pin,


at each side of the cradle

T3

147150
2 x 46 x 64.167

= 24.93 mm

Width W3.
= 64.167 N/mm2

F
F /2 for one side of cradle
2 ( W 3 D2 ) x T 3

W3
Cross Sectional Area + diameter of bolts = W3

W3

W3

F
x 2x T 3

147150
64.167 x 2 x 31.89

+ D2

+ 46

W 3 = 35.955 + 46

W 3 = 81.96 mm

For W3 and T3, assume the tensile strength of the cradle is the same as the
hinge pin. This is because the tensile strength for the cradle is not given. Also,
the hinge pin goes through the cradle, so the diameter used satisfies the above
equations.

Discussion
To check that the method for determining Y and I xx are correct; Random values
that still meet the specification are used. Where, the height = 2 x W, and
Thickness = W/20.
100

200
20
Datum
When W = 100, H = 200 and T = 20;

Shape
1
2
3

Y=

Ay
A

Area
200 x 20 = 2000
180 x 20 = 3600
3600
9200

102800
=
9200

Y
190
90
90
370

AY
2000 x 190 = 380000
3600 x 90 = 324000
324000
1028000

112

The Y value calculated for the assignment = 1.179W, where W = 100.


So, 1.179 x 100 = 117.9. A very small difference in Y values is caused by
rounding up numbers.
The parallel axis theorem for shape 1 = 190 112 = 78
For shape 2 and 3 = 112 90 = 22

I
( xx + A h2)
Ixx=

( 121 b d )+( Ay)


3

([ 121 x 100 x 20 )+ (100 x 20 x 78 )]+2 [( 121 x 20 x 180 )+(20 x 180 x 22 )]


3

= [(66666.67 + 12168000) + 2(9720000 + 1742400)]

35159466.67, this value is in terms of the height (because it acts around the
x-axis).

My calculated value is in terms of W, where H = 2W.


So, the above Ixx =

35159466.67
2

= 1.7x107

The Ixx value calculated for the assignment is 0.101595W 4


= 0.101595 x 1004 = 1.1x107
Again, a difference in values can be due to rounding up numbers

Please
turn over
Design
With support from the calculations above, an illustration of the proposed design
is as follows:

H
T
Where,
T = 13.13 mm
524.94 mm

W = 262.50 mm

H=

W2

D1

D2

W3
Where,
W2 = 127.99 mm
46.00 mm

W3 = 81.96 mm

D1 = 32.00 mm

D2 =

Where,

T2

T2 = 22.92 mm
T3 = 24.93 mm

T3

Conclusion
To conclude this assignment, from the calculations, the structure does indeed
have a factor of safety of 3.0 and it does meet the specifications of the structure
with the given dimensions. This design is successful and fulfilling to the original
aim.
Furthermore, the factor of safety is really important when building a structure,
and is very much dependant on the material strength and stresses that act upon
it. E.g. When constructing a plane, the margin of safety for an aeroplanes wings
is 1.5.
This means that the plane wings can take up to 0.5 times more than the design
load. This may not sound so safe compared to the structure of a wardrobe which
may have a factor of safety of 5. Theoretically, the factor of safety being 1 is
generally sufficient. For an aeroplane, the factor of safety may be low for the
following reasons.

Firstly, the design is sufficient in the eyes of the manufacture and in reality
this margin is fine.
And the second reason could be to keep manufacturing costs down.

The smaller the factor of safety, the more likely the cost is lower.

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