Stress Analysis of Shaft
Stress Analysis of Shaft
Stress Analysis of Shaft
Homework 1 Solutions
6.8 The shaft shown in sketch c is subjected to tensile, torsional, and bending loads. Determine
the principal stresses at the location of stress concentration. Ans. 1 = 52.99 MPa, 2 = 0,
3 = -12.27 MPa.
r = 3 mm
D = 45 mm
100 N-m
1000 N
d = 30 mm
150 mm
120 mm
500 N
P
Mc
1000 N
(500 N)(0.120 m)(0.015 m)
+ Kc2
= (1.9)
+ (1.65)
= 40.0 MPa
A
I
2
(0.03 m)
(0.030 m)4
4
64
where the stress concentration factors of 1.9 and 1.65 are obtained from Figure 6.5 (a) and
(b). The shear stress is
= Kc
(100 Nm)(0.015 m)
Tc
= (1.4)
= 26.45 MPa
J
(0.030 m)4
32
Notes: The fracture toughness for these materials is obtained from Table 6.1 on page 232.
The nominal stress that can be sustained is then given by Eq. (6.4).
Solution: From Table 6.1 on page 232, Kci for AISI 4340 is 50.0 MPa-m1/2 . For Al 2024T351, Kci is 36 MPa-m1/2 . Therefore, the stress in the steel is given by Eq. (6.4) as:
Kci = Y nom a
nom =
Kci
50.0 MPa
p
= 631 MPa
=
Y a
(1) (0.002)
nom =
Kci
36.0 MPa
p
= 454 MPa
=
Y a
(1) (0.002)
Kci = Y nom a
6.22 A machine element is loaded so that the principal normal stresses at the critical location for
a biaxial stress state are 1 = 20 ksi and 2 = -15 ksi. The material is ductile with a yield
strength of 60 ksi. Find the safety factor according to
(a) The maximum-shear-stress theory (MSST) Ans. ns = 1.714
(b) The distortion-energy theory (DET) Ans. ns = 1.97
Notes: Equation (6.6) is used to obtain the safety factor for the MSST. Equation (6.11)
gives the safety factor for the DET after the von Mises stress is calculated from Eq. (6.9). If
the stress is biaxial, then one principal stress is zero.
Solution: First of all, since the stress state is biaxial, then one normal stress is zero. Therefore, the three principle stresses are properly referred to as 1 = 20 ksi, 2 = 0 and 3 = 15
ksi, since 1 2 3 . For the maximum shear stress theory, Eq. (6.6) gives the safety
factor as:
Sy
Sy
60 ksi
1 3 =
= 1.714
ns =
=
ns
1 3
(20 ksi + 15 ksi)
The von Mises stress is obtained from Eq. (6.9) as:
i1/2
1/2
1 h
1
e = (2 1 )2 + (3 1 )2 + (3 2 )2
= (20 ksi)2 + (35 ksi)2 + (15 ksi)2
2
2
or e = 30.4 ksi. Therefore, the safety factor is, from Eq. (6.11),
e =
Sy
ns
ns =
Sy
60 ksi
=
= 1.97
e
30.4 ksi
6.32 The shaft shown in sketch j is made of AISI 1020 steel. Determine the most critical section
by using the MSST and the DET. Dimensions of the various diameters shown in sketch j are
d = 30 mm, D = 45 mm, and d2 = 40 mm.
r = 9 mm
d2
r = 6 mm
d
1 kN
10 kN
40 mm
40 mm
T = 50 N-m
40 mm
Notes: This problem requires the incorporation of stress concentration effects into the component stresses before determining the principal stresses.
Solution:
(a) Fillet. First, considering the location of stress concentration 80 mm from the wall:
J=
J
= 3.98 108 m4
2
A = d2 /4 = 7.07 104 m2
Also, from statics, V = 1 kN, M = 40 Nm, N = 10 kN, T = 50 Nm. The bottom location
is critical, since the bending and tensile stresses are additive at this location. Also, there
is no shear stress due to shear at the extreme location. The stress concentration due to
bending is obtained from Fig. 6.5(b) as 1.4, while for tension it is Kc = 1.55 from Fig.
6.5(a). The stress concentration for torsion is Kc = 1.2 from Fig. 6.5(c). Therefore,
1 = 458 MPa and 2 = 28 MPa.
(b) Groove For the location 40 mm from the wall, N = 10 kN, M = 80 Nm T = 50
Nm, Kc (bending) = 1.45, Kc (tension) = 1.5, Kc (torsion) = 1.2 (all from Fig. 6.6).
Therefore, 1 = 31.2 MPa and 2 = 0.76.
This means that the critical location is 80 mm from the wall, as the stresses are higher.
7.3 The shaft shown in sketch a rotates at high speed while the imposed loads remain static. The
shaft is machined from ground, high-carbon steel (AISI 1080). If the loading is sufficiently
large to produce a fatigue failure after 1 million cycles, where would the failure most likely
occur? Show all necessary computations and reasoning.
P
3 in.
3 in.
2 in.
2 in.
1 14 in.
1 in.
1 in.
1 in.
y
1
P/2
r =
16 in.
r = 8 in.
r = 8 in.
P/2
the radius is smaller for the left shoulder than the right one, it will have a higher stress
concentration factor, and the right shoulder doesnt have to be considered. In terms of the
analysis to be followed, there are no differences between the locations in the shaft in terms
of manufacturing method, size effects, temperature effects, reliability, etc, except that the
fatigue stress concentration factor must be calculated. Also, from the inside front cover, AISI
1080 steel has an ultimate strength of 89 ksi.
(a) Left Shoulder. Taking a section at point a, the moment is M = (P/2)(1 in.), with
the diameter equal to 1 in. The stress concentration is obtained from Fig. 6.5b, using
D/d = 1.25 in./1 in. = 1.25 and r/d = (1/16 in.)/1 in. = 0.0625 so that Kc = 1.75.
From Fig. 7.9, qn is about 0.75. Therefore, from Eq. (7.19),
Kf = 1 + (Kc 1)qn = 1 + (1.75 1)(0.75) = 1.56
The maximum stress at a is:
= Kf
Mc
(0.5P )(1 in.)(0.5 in.)
= (1.56)
= (7.94 in.2 )P
I
4
(1 in.)
64
(b) Midpoint of Shaft. At the midpoint, the bending moment is M = (P/2)(3 in.) =
(1.5 in.)P . The diameter of the shaft is 1.25 in. at this location. There is no stress
concentration here, so the maximum stress is given by Eq. (4.48) as:
=
Mc
[(1.5 in.)P ] (1.25 in./2)
=
= (7.82 in.2 )P
I
4
(1.25 in.)
64
(c) Groove. Taking a section at the groove, the moment is M = (P/2)(2 in.) = (1 in.)P .
Although the diameter is not specified at this location, it is reasonable to approximate
it as 1 in. Kc is obtained from Fig. 6.6b, using D/d = 1.25 in./1 in. = 1.25 and
r/d = (1/8 in.)/1 in. = 0.125, so that Kc = 1.7. From Fig. 7.9, qn is around 0.85.
Therefore, from Eq. (7.19),
Kf = 1 + (Kc 1)qn = 1 + (1.7 1)(0.85) = 1.595
The maximum stress is
= Kf
Mc
[(1 in.)P ] (0.5 in.
= (1.595)
= (16.2 in.2 )P
I
4
(1 in.)
64
(d) Summary. Since the stress is largest at the groove, this is the most likely fatigue failure
location.
7.4 For each of the AISI 1040 cold-drawn steel bars shown in sketches b and c determine
(a) The static tensile load causing fracture,
(b) The alternating (completely reversing) axial load P that would be just on the verge of
producing eventual fatigue failure.
r = 2.5 mm
25 mm
25 mm
25 mm
30 mm
25 mm
r = 2.5 mm
P
(b)
(c)
The size factor is ks = 1 for axial loading. All other factors are ignored. Therefore, from
Equation (7.16),
Se = kf ks kr kt km Se0 = (0.86)(1)(234 MPa) = 201 MPa
For the notched bar, from Fig. 6.4a for H/h = 30/25 = 1.2 and r/h = 2.5/25 = 0.1, we get
Kc = 2.35. From Fig. 7.9 we get for Sut = 520 MPa and r = 2.5 mm that qn = 0.75 (approx).
Therefore, Eq. (7.19) gives
Kf = 1 + (Kc 1)qn = 1 + (2.35 1)(0.75) = 2.01
For the unnotched bar, there is no stress concentration, so we set the applied stress equal to
the endurance limit:
all = Pall /A = Se
For the notched bar, the endurance limit must be reduced by the factor Kf :
all =
P
Se
=
A
Kf
P =
Se A
(201 MPa)(0.025 m)2
=
= 62.5 kN
Kf
2.01
Note that slightly different answers are acceptable; numbers read off charts can be slightly
different, and there can be small discrepancies between using Eq. (7.21) versus Fig. 7.10.