MECG1019 Handout

A Tubular Machine Part Under Combined Loading

MECG1019, 2018-II C.G. Helguero

Problem statement: The cantilevered tube shown in Figure 1 is made of 2014-T4 aluminum alloy with
a yield strength of Sy = 290 MPa. (cf. Appendix 9 on p.734, Mott’s textbook 5th Ed) The stock-size
mechanical tubing from Appendix 15-19 (p.766, Mott’s textbook 5th Ed) are to be used in this design, using
a design factor of safety N = 4 as a reference. The bending load is F = 1.7 kN, the axial tensile load is
P = 9.0 kN, and the torsion is T = 70 N·m, as illustrated in Figure 1.

Find a mechanical tubing, based on Appendix 15-19, that satisfies the design requirements. What is the
actual factor of safety of your final design based on the stock size?

y
12
A 0m
m

F
B
z

T P
x
Figure 1: A cantilever tube subject to an uniaxial tension, torsion, and bending

Note: When parameters in the SI units are given, it is in general a good idea to employ the MKS unit system
with meters, kg, sec, and their derived units in calculation. In addition, M P a = 106 P a = 106 N/m, and
GP a = 109 P a = 109 N/m.

Solution: The geometric properties of tube are:

π 2
A = (d − d2i ) (1)
4
π 4
I = (d − d4i ) (2)
64
π 4
J = (d − d4i ) (3)
32
Following the procedures of the handout, we first find that the maximum normal stress due to bending is at
the point A, as shown in Figure 1. The shear stress due to torsion, T , is also maximum at the outer radius of
the tube. Hence, we will consider point A for our design, as illustrated in Figure 3. (Why choose point A?
See the Remarks.) The normal stress at A due to the uniaxial force, P , and the bending force, F , is
P Mc 4P 64 F (0.120)(d/2) 11460 2078 d
σx = (σx )P + (σx )F = + = 2 + 4 = 2 2 + 4 (4)
A I 2
π(d − di ) 4
π(d − di ) d − di d − d4i

1
In addition, σz = 0. The torsional stress at the same point A is
Tr 32 T (d/2) 356.5 d
τxz = = 4 = 4 (5)
J 4
π(d − di ) d − d4i
Next, we can apply the failure theory for the design. Note that the design with the designated factor of
safety, N = 4, is satisfied with the design stress (σd ) at
Sy 290
σd ≤ = = 72.5 M P a (6)
N 4
Note that the equations for calculating the design stress, with σz = 0, are listed in the following.

I. Mohr’s circle: When σz = 0 in the plane stress state of xz, we can use the Mohr’s circle method, as
presented in the handout, to find the principal stresses analytically
s
σx − σz 2
 r 
σx + σz 2 =
σx σx 2 2
σ1 , σ2 = ± + τxy ± + τxy (7)
2 2 2 2
Here, the design stress is the maximum principal stress σd = σ1 .

II. von Mises Stress and the Distortion Energy Theory: When σz = 0 in plane stress state of xz, we can
also use the following equation to calculate the von Mises stress, σ 0 . That is,
S
q q
0 2 2
σ = σ1 − σ1 σ2 + σ2 = σx2 + 3τxy 2 = y (8)
N

Once a choice of tube size is selected from Appendix 15-19, the stresses can be determined by equations
(4) and (5). Next, equation (7) or (8) can be used to calculate the design stress. This can be done iteratively
with different choices of tube size to find one that satisfies the design requirements.

A spreadsheet program can facilitate the calculation of several candidates of tube selection. A spread-
sheet is shown in the following for 8 different tube candidates from Appendix 15-19. The columns with
“Mohr” and “DE” denote the design stress calculated from the Mohr’s circle (σ1 ) and the distortion-energy
theory (σ 0 ), respectively.

Figure 2: Spreadsheet listing results of design for various tubes of stock size

From the results of the spreadsheet, a few observations are in order:

• Based on equation (6) and the results in the table, tubes of stock size 45 × 4 mm, 60 × 4 mm, and
60 × 6 mm will satisfy the design requirements and can be chosen. However, the size of 45 × 4 is the
best candidate given the prescribed parameters. That would be the design choice. The actual factor of
safety is N = 4.5.

2
 stress element A stress element B stress element
τxy τxy τxy
(σx)P (σx)P (σx)P
x x x
(σx)F (σx)F=0 (σx)F

z z z
Figure 3: The three points on the tube, to be considered for design stress: (A) tensile stresses along the x
direction due to the uniaxial tension, P , and the bending force, F , add together; (B) tensile stress due to
bending is zero; (C) the bending force produces a compressive stress along the x direction at A0 , causing a
smaller resultant stress along the x direction. All stress elements have the same shear stress (ccw), τxy .

• The distortion energy theory results in a slightly more conservative design in this case, as seen by a
higher stress calculation and a lower factor of safety. Nevertheless, the difference is so small that the
two methods give practical the same answer in this case.

Remarks:
• The stress state of the plane element at point A is shown in Figure 3(A). First of all, point A has the
largest bending moment, resulting in maximum normal stress. Next, the two normal stresses in the
x direction resulting from the axial tension, P , and bending force, F , are both tensile and are added
together to produce a larger tensile stress, σx . For a point A0 (hidden and not shown in Figure 1) on the
opposite side of the point A, the stress state is shown in Figure 3(C). As opposed to the stress element
in Figure 3(A), the bending stress (σx )F is compressive, and cancels part of the tensile stress (σx )P .
This results in smaller principal stresses, in spite of the same shear stress, τxy . The stress element at
the point B, shown in Figure 3(B), has zero normal stress due to bending. Thus, the principal stress at
this location is smaller than that at the point A. Therefore, point A represents the worst-case scenario
in this design, and is chosen for the consideration of design.

• Note that equations (4) and (5) can also be written in a more useful general form of
P P 4P
(σx )P = = π 2 2 = (9)
A 4 (d − di ) π(d − d2i )
2

Mc M (d/2) 32 M d
(σx )F = = π 2 2 ) = π(d4 − d4 ) (10)
I 64 (d − di i
Tr T (d/2) 16 T d
τxz = = π 4 4 = π(d4 − d4 ) (11)
J 32 (d − di ) i

In this cantilever bending problem, the bending moment is M = F L.

• For a solid cylinder shown in Figure 4, equations (9) and (10) can be written as follows
P P 4P
(σx )P = = π 2 = (12)
A 4d πd2
Mc M (d/2) 32 M
(σx )F = = π 4 = (13)
I 64 d πd3

3
 Likewise, the shear stress due to the direct torque on the surface of the cylinder becomes
Tr 16 T
τxz = = (14)
J πd3

• It is important to employ the MKS unit system with meters, kg, sec, and their derived units in calcu-
lation when the SI units are used. As an example, the design with the 45 × 4 mechanical tubing will
have the following stress calculation from equations (12) to (14), as follows

4P 4(9000)
(σx )P = = −3
= 17, 490, 000 Pa = 17.49 MPa
π(d2 2
− di ) π[(45 × 10 )2 − (37 × 10−3 )2 ]
32 M d 32(1700 × 0.120)(45 × 10−3 )
(σx )F = = = 42, 000, 000 Pa = 42.0 MPa
4
π(d4 − di ) π[(45 × 10−3 )4 − (37 × 10−3 )4 ]
16 T d 16(70)(45 × 10−3 )
τxz = = = 7, 206, 000 Pa = 7.21 MPa
π(d4 − d4i ) π[(45 × 10−3 )4 − (37 × 10−3 )4 ]

The resultant normal stress is (σx )P + (σx )F = 59.49 MPa. The results are the same as those in the
table listed earlier.

• Now, you can consider the case with the same loading conditions, except that the tube is replaced by a
solid cylinder, as illustrated in Figure 4. Repeat the failure design and compare the stock size in your
design. Can you list the advantages and disadvantages of using the mechanical tubing?

y
12
A 0m
m

F
B
z

T P
x
Figure 4: A solid cylinder with the same loading conditions as those in Figure 1