Machine Design & CAD І
(ME-322)
Design for Static Loading
Types of Mechanical Loading
(A)-(i) Axial Load - Tensile (A)-(ii) Axial Load - Compressive
(B) Transverse Load (C) Shear Load
Types of Mechanical Stress
Stress
Simple/Direct Indirect Compound
Stress Stress Stress
Tensile Shear Bending Torsion
mpressive
Thermal Stress
Thermal Stress: generated when constraints are
imposed to change in size of a body due to ΔT
Thermal Expansion of a Beam Thermal Analysis of Welds
Ductile to Brittle Transition Temperature
Represents the temperature at which a material’s property
transits from ductile to brittle behavior
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Tested via Charpy Test – helps us in determining the min.
temperature at which the material could bear some pre-
defined amount of energy without fracturing
Stress Concentration Factor
Accounts for the variation in stress from the average/nominal
stress due to geometric/material/load discontinuities
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To be considered for brittle materials (Ԑ<0.05) under static
loading & ductile/brittle materials for fatigue loading
Value of Kt depend upon the material and geometry of the part.
3D Stress Element
In x-plane in the
direction of y
The above normal stresses and shear stress
are calculated by these equations.
Transformation of Plane Stresses
Principal Planes & Stresses
Principal Plane: The plane which solely consists of
normal stresses (σn) – no shear stress (Ƭx’y’) exists
Principal Stresses: The max. & min. value of normal
stresses (σ1,σ2) acting on the principal planes – lie
90° apart from each other
NOTE: Conventionally, θ is taken as +ve in the anti-clockwise direction from x-axis
Maximum Shear Stress
→ →
Having equal magnitudes but would differ in
direction
Planes of max. shear stress would occur at 45° to the
principal planes
Mohr’s Circle for Plane Stress
A graphical tool used to represent the plane stress
transformation equations on a plot
Helps us understand the relation between σx’/ σy’ and
Ƭx’y’ acting on different planes at a point in a body
under stressed state
Provides useful insights for failure analysis including
principal stresses and maximum shear stresses
coupled with their respective planes
Mohr’s Circle for Plane Stress (cont.)
Mohr’s Circle for Plane Stress (cont.)
Mohr’s Circle for Plane Stress (cont.)
Numericals
Question # 1
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Two plates subjected to a tensile force of 50 kN, are fixed together by means of
three rivets. The plates and rivets are made up of plain carbon steel having a tensile
yield strength of 250 N/. Given that the yield strength in shear is 50% of the tensile
yield strength and the factor of safety for these designed plates is 2.5, determine
the (a) diameter of rivets and (b) thickness of plates.
Numericals (cont.)
Question # 2
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A cotter is a pin/wedge used to hold rods firmly together. In this problem we will be
determining the smallest thickness (t) of the cotter and the smallest diameter (d) of
the rods. All parts are made up of steel for which the failure normal stress () is 500
MPa whereas the failure shear stress () is 375 MPa. Use a factor of safety of 2.5 in
tension while 1.75 in shear.
Numericals (cont.)
Question # 3
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For the flat tension bar with a stepped cross section as shown in the figure, the
fillets are quarter circles having the radius consistent with the two widths D and d
i.e. . Given that an axial tensile force of 15 kips is applied to the bar having a larger
width of 4 inches and thickness of 1 inch, find
(a) the max. normal stress in the bar if the smaller width is 3 inch
(b) The min. width of d that can be used for a reduced-width cross section so that
the max. normal stress in the bar doesn’t exceed the value of 8.5 ksi
Numericals (cont.)
Numericals (cont.)
Question # 4
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For the state plane stress consisting of a 90 MPa tensile stress on the x-plane, a 60
MPa compressive stress on the y-plane and a shear stress of +20 MPa, determine
the principal planes, principal stresses, max shear stress plane, max. shear stress
and the corresponding normal stresses by using
(a) the transformation equation for plane stresses
(b) Mohr’s circle
Static Failure Theories
Applied to applications under constant load
These theories are characterized on the basis of
material type – generally defined by yielding for
ductile and fracture for brittle materials
Based upon the comparison of component’s
strength with the material property () obtained
through a simple tensile test
Maximum Normal Stress Theory
Predicts that failure occurs when the maximum principal stress at any
point in the component surpasses the ultimate tensile strength of the
material
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Used for brittle materials – limited by their tensile strengths
Maximum Shear Stress Theory
Predicts that failure occurs when the maximum shear stress at any point
in the component surpasses the shear strength at yield of the material
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Used for ductile materials – limited by their shear strengths
Maximum Distortion Energy Theory
Based upon the strain energy produced within the body after
deformation
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Devised by classifying strain energy density into two components –
hydrostatic volume changing energy and angular distortion energy
Yielding primarily occurs due to distortion energy
Maximum Distortion Energy Theory (cont.)
Predicts that failure occurs when the strain energy density due to
distortion at any point of the component surpasses the strain energy
density due to distortion at yield of the material
Used for ductile materials – limited by their shear strengths
=
Maximum Distortion Energy Theory (cont.)
Numericals (cont.)
Question # 5
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A hot-rolled steel has a yield strength of = 100 kpsi and a true strain at fracture of
= 0.55. Estimate the F.O.S for the following stress state having = -40 kpsi, = -60 kpsi
and = 15 kpsi by using relevant failure theories
Question # 6
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A single horizontal force of 150 lb is applied to end D of lever ABD. Determine (a)
the normal and shearing stresses on an element at point H (b) the principal planes
and stresses at point H.
Numericals (cont.)
Question # 7
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A force F is applied at D near the end of a 15-in lever shown in Figure. This force
results in certain stresses in the cantilevered bar OABC which is made up of AISI
1035 steel, forged and heat-treated so that having a minimum yield strength of 81
kpsi. Find the max force F that can be applied without any failure. Ignore any stress
concentration. The lever DC is strong enough and failure may occur at point A. Use
Max. Distortion / Von Mises Theory
