Mechanical Design of Machine Elements

Complete after watching Module 24: Simple Example Distortion Energy Theory

Module 24 Example: Distortion Energy Theory

1) The rod below is subjected to a torque T = 100 lbf*in, a load P = 250 lbf in the
negative x-direction, and a load F = 25 lbf in the positive y-direction. The rod is
machined out of an AISI 4130 steel bar, and has a diameter of d = 0.5 in, and
ef > 0.05.
A) Find the effective stress s at point A.
B) Find the factor of safety at point A.
Y

20 in
A

P X

T
Z

Assumptions:
Isotropic, homogenous material at room temperature

Thoughts:
There are four possible types of stress due to these loads: torsional shear stress due to torque T,
bending stress due to load F, transverse shear stress due to load F, and axial compressive stress due to
load P.

At point A, the rod is experiencing axial compressive stress due to P, a tensile bending stress due to F,
and a torsional shear stress due to T. As it is at the top edge of the bar, point A does not experience a
transverse shear stress.

Think about how the rod will deflect due to load F. It will be pushed upward, causing point A to be
pushed into compression, and the bottom of the rod to be pulled into tension. Therefore, the neutral
axis is along the x-z plane. Load F applies a bending moment to the rod, which at point A will be M =
F*20 in. Additionally, the rod will be twisted due to torque T.
Mechanical Design of Machine Elements
Complete after watching Module 24: Simple Example Distortion Energy Theory

Module 24 Example: Distortion Energy Theory

1) The rod below is subjected to a torque T = 100 lbf*in, a load P = 250 lbf in the
negative x-direction, and a load F = 25 lbf in the positive y-direction. The rod is
machined out of an AISI 4130 steel bar, and has a diameter of d = 0.5 in, and
ef > 0.05.
A) Find the effective stress s at point A.
B) Find the factor of safety at point A.
Y

20 in
A

P X

T
Z

Y
Stress states along surface of the rod
A. t due to torsion

t due to transverse shear

X
sx due to bending

sx due to axial

Z Stress states at top of rod at point A

. X
A

Z
Mechanical Design of Machine Elements
Complete after watching Module 24: Simple Example Distortion Energy Theory

Module 24 Example: Distortion Energy Theory

1) The rod below is subjected to a torque T = 100 lbf*in, a load P = 250 lbf in the
negative x-direction, and a load F = 25 lbf in the positive y-direction. The rod is
machined out of an AISI 4130 steel bar, and has a diameter of d = 0.5 in, and
ef > 0.05.
A) Find the effective stress s at point A.
B) Find the factor of safety at point A.
Y

20 in
A

P X

T
Z

F
Analysis:

At point A:
Axial stress sx = F/A = 4P/(pd2) = (4*(-250 lbf))/[p*(0.5 in)2] = -1270 psi = -1.3 ksi

Bending stress sx = [(Mc)/I]

M = P*lOA = (25 lbf)*(20 in) = 500 lbf*in (drawing a bending moment diagram would
indicate the bending moment is positive)
Md 64 32M 32(500 lbf * in )
sx * 4 40743.7 psi 40.7 ksi
2 pd pd 3
p (0.5 in )3
Acting in compression!

Torsional stress txz

T = 100 lbf*in in the negative x-direction
Tr Td 32 16T 16(100 lbf * in )
t xz * 4074.4 psi 4.1 ksi
J 2 pd 4 pd 3 p (0.5 in )3
sx = -1.3 ksi 40.7 ksi = -42 ksi
(Note the minimal impact that axial load has on total stress in the x-direction!)

txz = -4.1 ksi

Mechanical Design of Machine Elements
Complete after watching Module 24: Simple Example Distortion Energy Theory

Module 24 Example: Distortion Energy Theory

1) The rod below is subjected to a torque T = 100 lbf*in, a load P = 250 lbf in the
negative x-direction, and a load F = 25 lbf in the positive y-direction. The rod is
machined out of an AISI 4130 steel bar, and has a diameter of d = 0.5 in, and
ef > 0.05.
A) Find the effective stress s at point A.
B) Find the factor of safety at point A.
Y

20 in
A

P X

T
Z

F
Analysis:
0 0
s =[sx2 sxsz+ sz +3(txz2)]1/2
2

s =[sx2 +3(txz2)]1/2

s = [(-42 ksi)2 + 3(-4.1 ksi)2]1/2 = 42.6 ksi

Factor of safety n
From MIL HNBD 5J, since d = 0.5 in > 0.188 in, Fty = Sy = 70

n = Sy/ s = 70/42.6 = 1.6