MTE 427 Machine Design

Load and Stress Analysis

2nd teaching

Pichet PINIT
 3-5 Cartesian Stress Components
Stress: It is the term used to describe the intensity of internal force
acting over an area.
Stresses have two main components; normal and shear stresses.

The normal stress x acting on the

plane perpendicular to the x direction.
(this also applies to y and z.)

The shear stress has two

components and need two
subscripts;
- The first subscript is the plane in
which the stress acts.
- The second subscript is the
direction in which the stress acts.
Ex: xz is the shear stress in the
plane perpendicular to the x axis in
the z direction.
Stress components

In order to establish state of stress at a point, nine quantities

must be defined; x , y , z , xy , xz , yx , yx , zx and zy .
If stress are slowly varying across the infinitesimal cube,
moment equilibrium about the centroid of the cube requires that

xy yx , xz zx , yz zy Eq. 1

Nine stress components can now reduce to six independent

quantities x , y , z , xy , xz , and zy , which can be written as

x xy xz

ij xy y yz
Eq. 2
xz yz z
 Stress components
In order to establish state of stress at a point, nine quantities must be
defined; x , y , z , xy , xz , yx , yx , zx and zy .

If stress are slowly varying across the infinitesimal cube, moment

equilibrium about the centroid of the cube

xy yx , xz zx , yz zy Eq. 3-7

Nine stress components can now reduce to six independent

quantities x , y , z , xy , xz , and zy , which can be written as
x xy xz

ij xy y yz

xz yz z
Plane stress: stress transformation
Only three stress components are considered .
Stresses acting on an arbitrary plane can be defined as equations
below.
Plane stress: principal stress directions
Directions of principal stresses can be obtained using,

The principal stresses are and .

The planes on which the principal stresses act are called principal
planes.

Directions of maximum planar shear stresses are given using,

The maximum planar shear stresses act on these two plane.

The normal stresses on these plane are equal and of .
Plane stress: principal and shear stresses
The principal stresses can be found using,

The maximum planar shear stress can also be found using,

Plane stress: Mohrs circle
The stress transformation equations can be represented graphically
which is known as Mohrs circle.
 Mohrs circle
A shear stress causing a clockwise rotation about any point in the physical element
is plotted above the horizontal axis of the Mohrs circle.
A point on Mohrs circle gives the magnitude and direction of the normal and shear
stresses on any plane in the physical element.
Normal stresses are plotted along the
x axis, shear stresses along the y axis.
B The stresses on the planes normal to
A
the x and y axes are plotted as points A
and B.
B
The shear stress is zero at points D
E D and E, representing the values of the
principal stresses 1 and 2 respectively.

A The Angle between x and 1 on

Mohrs circle is 2.

Mohrs circle for two-dimensional state of

stress
Plane stress: Mohrs circle properties
The maximum and minimum principal stresses lie on the horizontal axis.
The right most point refers to and the left most point refers to .
A point on circumference represents the 2D state of stress for an
inclined facet of stress element.
The maximum planar shear stress is the circles radius.
On stress element, the principal stresses are 90 apart but in Mohrs
circle they are 180 apart.
Mohrs circle can tell us which directions refer to and by rotating
the line used to create Mohrs circle towards to points lying on the
horizontal axis.
General three-dimensional stress
There are nine stress components but usually requires only six
components.
It is in general to express the stress components in a matrix form and it is
known as stress tensor.
 Equation for determining the 3D principal stresses is in the form of cubic
Three-dimensional principal
equation and known as characteristic stresses1
equation.

3 x y z 2 ( x y y z x z xy2 yz2 xz2 )

Eq. 3-15
( x y z 2 xy yz xz x yz2 y xz2 z xy2 ) 0

3 I 1 2 I 2 I 3 0

I1 x y z
I 2 x y y z x z xy2 yz2 xz2
I 3 x y y 2 xy yz xz x yz2 y xz2 z xy2

I1I, 1I, 2I, 2and

, andI Iare
3
3 are knownasasstress
known stressinvariant.
invariant.
Three-dimensional principal shear stresses4
Principal Shear stresses are given as

Eq. 3-16

When the principal normal

stresses are ordered 1 > 2 >3.

1 3
max 1 / 3
2

In plotting Mohrs circles for three-dimensional stress, the principal normal

stresses are ordered so that 1 2 3.
Elastik Strain
Hookes law states that
for tension
for shear

Stress and strain relation

Uniformly distributed stress
Normal stress

Shear stress
Stress in bending beam
Normal stress

Shear stress
Stress in torsional element
Shear stress

Angle of twist (rad)

Stress concentration1
Stress concentration occurs due to the geometrical discontinuities of
machine elements such as cracks, sharp corners, holes and, changes in
the cross sectional area of the object

Discontinuities are called stress raisers

and the regions in which they occur
are called areas of stress concentration
Stress concentration2
Stress concentration chart.
Stress concentration3
How to use stress concentration factor

Static loading: for ductile material, the stress concentration

factor is not usually applied to predict the critical stress,
because plastic strain in the region of the stress is localized
and has a strengthening effect

Static loading: for brittle material, the stress concentration

factor is applied to nominal stress before comparing it with
strength.

THIS IS SO IMPORTANT!
Example 3-13

Fig. 330
 Example 3-13

Fig. A13 1

2.7

Fig. A13 1
 Example 3-13

2.5
 Example 3-13

From Table A-13 Fig. A13 5

2.5

Fig. A135
3.14 Stresses in Pressurized Cylinders
Thick cylinder
Cylindrical pressure vessels, hydraulic cylinders, gun
barrels,and pipes carrying fluids at high pressures develop both
radial and tangential stresses with values that depend upon the
radius of the element under consideration.
 Stresses in Pressurized Cylinders
Cylinder with inside radius ri, outside radius ro, internal pressure pi,
external pressure po
Tangential and radial stresses,

Fig. 331
 Stresses in Pressurized Cylinders
Special case of zero outside pressure, po = 0

Fig. 332
 Stresses in Pressurized Cylinders

If ends are closed, then longitudinal stresses also exist

 Thin-Walled Vessels
When the wall thickness of cylindrical pressure vessel is about 1/20
or less of the radius,radial stress is quite small compared to
tangential stress

Average tangential stress

Maximum tangential stress

Longitudinal stress (if ends are closed)

Example 3-14:
3-14 An aluminum-alloy pressure vessel is made of tubing having
an outside diameter of 200mm and a wall thickness of 6 mm
(a) What pressure can the cylinder carry if the permissible tangential stress is
82 MPa and the theory for thin-walled vessels is assumed to apply?
(b) On the basis of the pressure found in part (a), compute all of the stress
components using the theory for thick-walled cylinders.

Solution

(a)di = do-2.t = 200 - 2(6) =188mm, ri = di /2 = 188/2 = 94 mm,

ro=do /2= 200/2 =100 mm.

Since t /ri = 6/94 = 0.064>1/20, the theory for thin-walled vessels may not yield
safe results.

From Eq. (352) the allowable pressure.

p(d i t ) 2t ( t ) max 2 0.006) 82
( t ) max p 5.07 MPa
2t (d i t ) 0.188 0.006
from Eq. (354), we nd the average longitudinal stress to be

pd i 2.54 0.188
l 19.9 MPa
4t 4 0.006

(b) The maximum tangential stress will occur at the inside radius, and so
we use r = ri in the rst equation of Eq. (350). This gives

ri 2 pi ro2 ro2 ri 2 0.12 0.094 2

t 2 1 2 pi 2 2.54 2 41.1 MPa
ro ri 2 ri ro ri 2
0.1 0.094 2

Similarly, the maximum radial stress is found, from the second equation
of Eq. (350)

ri 2 pi ro2
r 2 1 2 pi 2.54 MPa
ro ri 2 ri

 Equation (351) gives the longitudinal stress as

pi ri 2 2.54 0.094
l 2 19.28 MPa
ro ri 2
0.1 0.094
2 2

These three stresses,t, r, and l, are principal stresses, since

there is no shear on these surfaces. Note that there is no
signicant difference in the tangential stresses in parts (a) and (b),
and so the thin-wall theory can be considered satisfactory.
 Press and Shrink Fits
Two cylindrical members that have been assembled with a shrink t.. The interference contact
pressure p develops between the members at the nominal radius R, causing radial
stresses r= -p in each member at the contacting surfaces. This pressure is given by

If the two members are of the same material with Eo= Ei= E, o= vi,
Press and Shrink Fits
 Temperature Effects
When the temperature of an unrestrained body is uniformly increased,
the body expands, and the normal strain is

Where is the coefcient of thermal expansion and T is the

temperature change
If a straight bar is restrained at the ends so as to prevent
lengthwise expansion., a compressive stress will develop because
of the axial constraint. The stress is

if a uniform at plate is restrained at the edges and also subjected

to a uniform temperature rise, the compressive stress developed is
given by
 Curved Beams in Bending

In thick curved beams

Neutral axis and centroidal axis are not coincident
Bending stress does not vary linearly with distance from the neutral axis

Fig. 334

Shigleys Mechanical
 Curved Beams in Bending

ro = radius of outer fiber

ri = radius of inner fiber
rn = radius of neutral axis
Fig. 334
rc = radius of centroidal axis
h = depth of section
co= distance from neutral axis to outer fiber
ci = distance from neutral axis to inner fiber
e = distance from centroidal axis to neutral axis
M = bending moment; positive M decreases curvature
Curved Beams in Bending

Location of neutral axis

Stress distribution

The critical stresses occur at the inner and outer surface faces where y
= ci and y =co

These equations are valid for pure bending

Example 3-15: Plot the distribution of stresses across section A-A of the
crane hook shown in Fig.335. The cross section is rectangular, with b = 18
mm and h = 100 mm, and the load is F = 22 kN.

18 mm

150 mm

50 mm
18 mm

50 mm 100 mm

150 mm

Fig.335
 Solution : Since A = bh, we have d A = b dr and, from Eq. (363),

From Fig. 335b, we see that ri = 50mm, r o = 150 mm, r c = 100 mm, and A = 1800 mm2.
Thus, from Eq. (1),
h 100
rn 91 mm
ln r0 / ri 150
ln
50
the e ccentricity is e = r c r n = 100 91 = 9 mm. The moment M is positive and is M =
F. r c = 22(0.1) = 2.2 kN.m. Adding the axial component of stress to Eq. (364) gives

F

My

2.2.10 3


22.10 3 0.091 r
(2)
A Ae rn y ) 1800.10 6 1800.10 6 0.09 r
Substituting values of r from 50 to 150 mm results in the stress distribution shown in
Fig. 335c
123.6 mm

-41.2 mm
Formulas for Sections of Curved Beams (Table 3-
4)
Formulas for Sections of Curved Beams (Table 3-
4)
 Contact Stresses
When two bodies with curved surfaces pressed together, point
or line contact changes to area contact, and The stresses
developed are three-dimensional called contact stresses or
Hertzian stresses

Common examples

Wheel rolling on rail

Mating gear teeth

Rolling bearings

In automotive valve cams

 Spherical Contact Stress
When two solid spheres of diameters d1and d2 are pressed
together with a force F, a circular area of contact of radius a is
obtained.

The radius a is given by the equation

E1,v1 and E2,v2 as the respective elastic constants of the two

spheres,
 Spherical Contact Stress
The pressure distribution within the contact area of each
sphere is hemispherical,

Maximum pressure occurs at the center of contact area

and is

Equations (368) and (369) are perfectly general and

also apply to the contact of a sphere and a plane
surface or of a sphere and an internal spherical surface.
For a plane surface, use d = .

For an internal surface, the diameter is expressed as

a negative quantity Fig. 336
 Spherical Contact Stress
The maximum stresses occur on the z axis, and these are principal
stresses. Their values are

Mohrs circles for the stress state described by Eqs. (370) and (371) are a
point and two coincident circles.
 Spherical Contact Stress

Plot of three principal stress

and maximum shear stress
as a function of distance
below the contact surface
Note that tmax peaks below the
contact surface

Fatigue failure below the

surface leads to pitting and
spalling
For poisson ratio of 0.30,
tmax = 0.3 pmax
at depth of
z = 0.48a
Fig. 337
 Cylindrical Contact Stress
Two right circular cylinders with length l and diameters d1 and d2
Area of contact is a narrow rectangle of width 2b and length l
.Pressure distribution is elliptical
 Cylindrical Contact Stress

The half-width b is given

The maximum pressure is

The equations apply to a cylinder and a plane surface, such

as a rail, by making d = for the plane surface.

The equations also apply to the contact of a cylinder and an

internal cylindrical surface;

for the internal surface.d is negativ Fig. 338

 Cylindrical Contact Stress

The stress state along the z axis is given by the equations

 Cylindrical Contact Stress

Plot of stress components

and maximum shear stress
as a function of distance
below the contact surface
For poisson ratio of 0.30,
tmax = 0.3 pmax
at depth of
z = 0.786b

Fig. 339