Professional Documents
Culture Documents
Solution:
The solution to this homework problem follows the stress analysis procedure presented in lecture
and in the course text book. The six steps are: (1) draw free-body diagrams to determine the external
loads acting on the shaft; (2) draw shear force, bending moment, and torque diagrams; (3) determine the
locations of the critical section(s) or plane(s); (4) superimpose the stress patterns on the critical sections;
(5) determine the critical elements (or points) of the shaft; and (6) apply the appropriate theories of
failure to determine the factor(s) of safety at the critical element(s).
Step (1): The free body diagrams of the shaft in the x-y and the x-z planes are shown in figure 1 below.
y
222.7 lb
A
8
1000 in-lb
B
8
350 lb
127.3 lb
451 lb
D
6
1000 in-lb
B
123 lb
z
x-y plane
z-axis pointing out of the paper
6
D
C
1000 in-lb
x-z plane
y-axis pointing out of the paper
1000 in-lb
8
328 lb
Step (2): The shear-force and bending-moment diagrams for the shaft in the x-y and x-z planes and the
torque diagram are shown in Figure 2 below. Note that the sign conventions are presented on page 75 in
the book.
127.3 lb
123 lb
A
C
-222.7 lb
D
-328 lb
Shear Force
1968 in-lb
984 in-lb
C
D
A
-763.8 in-lb
-1781.6 in-lb
Bending Moment
x-z plane
x-y plane
1000 in-lb
Torque
A
Figure 2. Shear force, bending moment and torque diagrams for the shaft
Step (3): The bending moments in the x-y plane on sections B and C are
x =
trans =
torsion =
In this problem it is sufficient to know that the maximum normal stress due to bending (referred to
simply as the bending stress) and the maximum shear stress due to torsion (referred to simply as the
torsional stress) will occur somewhere on the surface of the shaft in the critical plane at C. The exact
location on the surface of the shaft does not matter when the material is homogeneous and isotropic
(page 60). However, in other problems when the stresses vary with time (fatigue) and the shaft also
rotates, the exact locations of the maximum stresses will become very important because the time
history determines the damage and likelihood of failure. So we will use this problem to illustrate how
one would identify which element (point) on plane C is the critical element (point).
The normal stresses on sections B and C in the x-direction due to the bending moments will add.
This means that the maximum bending stress on these two sections can be obtained from the resultants
of the bending moments on these sections.
Consider the critical plane (that is, the plane to the left of section C) as shown in Figure 3 below
where the x axis points out of the paper.
MC
My
f
Mz
P1
P2
TC
x
Neutral axis
Figure 3. The critical plane to the left of point C.
The neutral axis of the cross-section of the shaft at C is obtained as follows. Recall that the bending
moments at section C, about the y-axis and the z-axis, respectively, are
M y = +1968 in-lb
and
M z = 763.8 in-lb
Since the resultant moment acts about the neutral axis then the orientation of the neutral axis, with
respect to the y-axis, is
The bending moment M C produces a tensile normal stress x at P1 and a compressive normal
stress x at P2. The clockwise torque TC (into the paper) produces a torsional shear stress tors at P1
and at P2 . These stress patterns are shown in the following Figure 4.
y
tors
tors
P1
trans
P2
tors
tors
Neutral axis
Figure 4. The critical plane to the left of point C.
(The x axis points out of the paper)
The transverse shear stress (due to bending) is also shown slightly shaded on the figure. Note that the
maximum transverse shear stresses for this problem do not necessarily occur at points P1 and P2. Since
the length/diameter ratio for this shaft is probably much greater than 5, we will initially neglect the
effects of the transverse shear stresses at points P1 and P2 assuming they are negligibly small. After we
have estimated the appropriate diameter for the shaft based on this assumption, we will calculate the
magnitude of the peak transverse shear stress on the section to confirm the validity of this assumption.
The above discussion leads to the state-of-stress element for the critical point P1 as shown in the
following Figure 5. Since the torsional shear stress is not in the y-direction or in the z-direction then we
will omit the direction subscripts.
tors
tors
x
Figure 5. The biaxial state of stress of element P1.
The x-axis points out of the paper. (The face on the top of the element is the free surface).
Step (5): The material specification calls for AISI 1035 CD. The 10 indicates that this is a plain
carbon steel without other alloying elements (see page 45), and the CD indicates it is cold drawn. The
drawing process work hardens the material and increases its strength. From Table A-20, see page 1040,
the yield strength for this material is S y = 67 kpsi and the elongation is listed as 12%. Recall that
5
materials with elongations greater than 5% are considered ductile (see page 238), so the best failure
theory here is the distortion energy (von Mises) theory. This theory is more accurate than the maximum
shear stress failure theory (and, therefore, generally preferred), however, it is slightly less conservative.
Calculations based on both theories will be included here.
According to Von-Mises theory, see Equation (5-19), page 224, the design equation is
Sy
(1)
ny
The von-Mises stress for a biaxial state of stress, see Equation (5-15), page 223, can be written as
= x2 x y + y2 + 3 xy2
(2a)
For the problem here, the normal stress y = 0, therefore Eq, (2a) reduces to
2
= x2 + 3 tors
Substituting x =
(2b)
21502
5093
psi and torsion = 3 psi into Eq. (2b), the von-Mises stress is
3
d
d
21502
5093
=
+ 3 3
3
d
d
(3)
Note that here we have neglected the transverse shear stress at point P1 . Simplifying Eq. (3) gives
23, 241
d3
(4)
Then substituting the yield strength and Eq. (4) into Eq. (1) gives
(5)
x =
21,502 21,502
=
= 30,999 psi
d3
0.88523
torsion =
trans =
5093
5093
=
= 7342 psi
3
d
0.88523
300.5
300.5
=
=383.5 psi
2
d
0.88522
6
(6)
Note that the transverse shear stress is small, only about 5.2% of the torsional shear stress. Note also
that the material fails at 67,000 psi normal stress, and with our factor of safety of 2.0, the safe limit
(often called an allowable stress) is 67,000/2 or 33,500 psi. So the normal stress, at about 31,000 psi, is
doing most of the damage here.
The slightly less accurate (but more conservative) maximum shear stress theory. The design equation
for maximum shear stress theory is given by Equation (5.3), see page 220, that is
max =
Sy
(7)
2n y
The maximum shear stress is given by Equation (3.14), see page 82, that is
2
= x + tors
2
2
max
Substituting x =
(8)
21502
5093
psi and torsion = 3 psi into this equation gives:
3
d
d
2
max
(9)
max =
11,896
d3
(10)
(11)
Note that this solution is less than 1% greater than (more conservative) the distortion energy solution.
Because the distortion energy theory is more accurate than the maximum shear stress theory, and about
as easy to calculate, it is the generally preferred theory.
Step (6): For a yield factor of safety, ny = 1, the distortion-energy failure-theory design equation reduces
to
= Sy
which gives
23, 241
= 67, 000 psi
d3
Rearranging this equation, the diameter is
7
d = 0.7026 inches
Note the power of the d3 terms. A 26% change in the diameter (from 0.7026 to 0.8852) doubles the
factor of safety from 1 to 2.