1

Prepared by: Mümin Özsipahi

Room: C-206 Phone: 210 7232
   x   y   z      x y   x z   y z      
2 2
xy
2
xz
2
yz  
E-mail: ozsipahi@metu.edu.tr Date: 13.11.2013 I1 I2

ME 307 – MACHINE ELEMENTS I 

  x y z  2 xy xz yz         z xy2  0
2
x yz
2
y xz 
TUTORIAL 7 – PART 1 I3
“STATIC DESIGN CRITERIA”
Thus, the equation becomes,

Question 1: A steel machine part is statically loaded and has a yield  3  I1 2  I 2  I3  0
strength of 350 MPa. For each of the following stress states find the a) Inserting the stress values given in part(a), the coefficients of the
factor of safety using the maximum normal stress theory, the maximum above equation is found as,
shear stress theory and the distortion energy theory.
I1  120
a)  x  110MPa  y  80MPa  z  90MPa  xy  40MPa
I 2  7700
I 3  936000
 80 25 0 
 
b)  ( MPa)   25 30 0  Thus,
0 0 50 

c) y
 3 120 2  7700  936000  0

Where the roots of the above equation gives the principal stresses.
20 MPa
Using the polyroots command in MathCad or applying the solution
method for cubic polynomials described in the lectures, one can simply
40 MPa x found these stresses as,

20 MPa
1  118MPa &  2  90MPa &  3  88MPa

Now, let’s calculate factor of safety for each failure theories.

Solution: a.1) The Maximum Normal Stress Theory:

Since steel is a ductile material, it is needed to apply ductile static
failure theories. First of all principal stresses should be calculated for Recall that this theory states that failure occurs if any of the principal
the given stress state. stresses exceeds the yield strength of the material. Thus,

METU – ME 307 Machine Elements I – Fall 2013

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Sy 350MPa Sy
 max  n  2.97 n 1/2
 1.81
n 118MPa   1   2 2   1   3 2   2   3 2 
 
 2 
a.2) The Maximum Shear Stress Theory:
Note that the maximum shear stress gives the minimum factor of safety,
Recall that, theory states that yielding starts whenever the maximum n=1.7
shear stress at any point becomes equal to the maximum shear stress in
a tension test specimen of the same material when that specimen starts Note also that
yielding.
nMSST  nDET  nMNST
Sy 1   3
 max    max   103MPa
2n 2
b)
n
350
 1.7   x  xy  xz 
2 103  
 ( MPa)   xy  y  yz 
  xz  yz  z 
a.3) The Distortion Energy Theory:  

Recall that theory states that yielding occurs whenever the distortion is the matrix representation of the stress state of an element. The
energy in a unit volume reaches the distortion energy in the same solution can be found as in part (a) using the third order equation or
volume corresponding to the yield strength in tension or compression. more simply the principal stresses can be calculated from eigenvalues
of the given matrix. (Using eigenvals command in MathCad)
The von Misses stress is,
 80 25 0    85.4 
   
  1   2 2   1   3 2   2   3 2 
1/ 2 eigenvals   25 30 0     35.4 
Sy
 '    0
 0 50   50 
 2  n

1  85.4MPa &  2  50MPa &  3  35.4MPa

Then,
Now, let’s calculate factor of safety for each failure theories.

METU – ME 307 Machine Elements I – Fall 2013

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b.1) The Maximum Normal Stress Theory: Note that the maximum shear stress gives the minimum factor of
safety, n=2.9
Sy 350MPa
 max  n  4.1 Note also that
n 85.4MPa
nMSST  nDET  nMNST
b.2) The Maximum Shear Stress Theory:

Sy 1   3 c) The principal stresses can be found as in part (a) using the third order
 max    max   60.4MPa equation. But instead let’s draw a Mohr’s circle and find the principal
2n 2
stresses from there. The given stresses are,
350
n  2.9  x  40MPa
2  60.4
 x  20MPa
b.3) The Distortion Energy Theory:  xy  20MPa

Recall that theory states that yielding occurs whenever the distortion The center on abscissa is
energy in a unit volume reaches the distortion energy in the same
volume corresponding to the yield strength in tension or compression.  x  y
 ave   10MPa
2
The von Misses stress is, Then the radius becomes,
1/ 2
  1   2 2   1   3 2   2   3 2  Sy R  x   ave    xy 2
2
 36.1
 '  
 2  n
Hence, the principal stresses can be found just by adding the radius to
Then, the σave term.
Sy
n 1/2
 3.25  1  10  36.1  46.1
  1   2 2   1   3 2   2   3 2   3  10  36.1  26.1
 
 2 
Note that the other principal stress is  2  0

METU – ME 307 Machine Elements I – Fall 2013

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Then,
Now, let’s calculate factor of safety for each failure theories. Sy
n 1/2
 5.53
c.1) The Maximum Normal Stress Theory:   1   2 2   1   3 2   2   3 2 
 
 2 
Sy 350MPa
 max  n  7.6
n 85.4MPa Question 2: A force of 1 kN is applied on a cylinder which has a diameter of 60 mm
and a length of 20 mm. The cylinder is resting on a beam as shown on the figure. The
beam has a yield strength of 600 MPa. For the given beam, find the factor of safety
c.2) The Maximum Shear Stress Theory:
using the maximum normal stress theory, the maximum shear stress theory and the
Sy 1   3 distortion energy theory. (Ecylinder =210 GPa, cylinder =0.32, Ebeam =220 GPa,
 max    max  R   36.1MPa
2n 2 beam =0.29)
350 1 kN
n  4.85
2  60.4

c.3) The Distortion Energy Theory:

40 mm y
Recall that theory states that yielding occurs whenever the distortion
energy in a unit volume reaches the distortion energy in the same
volume corresponding to the yield strength in tension or compression. z
500 mm

The von Misses stress is, 1000 mm

1/ 2 Crosssection of the Beam

  1   2 2   1   3 2   2   3 2  Sy
 '  
 2  n 40 mm

20 mm

METU – ME 307 Machine Elements I – Fall 2013

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Solution : The given forcing causes compressive normal stress along Afterwards, the stresses due to the contact between the cylinder and
the y direction at the contact point. To obtain this normal stress, the the beam should be obtained. For this purpose,
bending moment at the contact point should be obtained. From the
symmetry,
1 kN (1  cyl 2 )(1  beam 2 )
 (1  0.322 ) (1  0.292 )

2 F Ecyl Ebeam 2  (1000) 210000 220000
b   
40 mm y  1

1   (20) 1 1

d cyl dbeam 60 
0.5 kN z 0.5 kN b  0.127 mm
500 mm
The maximum pressure is,
1000 mm

So, the bending moment at the contact point is, 2 F 2  (1000)

pmax    250.8 MPa
 b   (0.127)  20
M  (500)(0.5)  250 N.m
Then, the contact stresses along the x, y and z directions can be obtained
Then, the normal stress along the y direction at the contact point is, using the following formulas,

Mc  z2 z 
 y ,bending   x ,contact  2 beam pmax  1   
I  b 2 b 

 
(0.02)(0.04)3  m4  and c  0.02 m . So,
1 z2
where, I   1 2 2 
z
  pmax 
12 b
 y ,contact 2
 z2 b
 250  0.02   1 2 
 y ,bending   b 
1
(0.02)(0.04)3  pmax
12  z ,contact 
z2
 y ,bending  46.875 106 Pa  46.9 MPa 1 2
b
Note that, the normal stress found due to bending is compressive at the
Note that, z is the distance from the surface of the beam and the contact
contact point.
stresses are all compressive (negative).

METU – ME 307 Machine Elements I – Fall 2013

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The shear stress caused by the vertical contact force is zero at the Sy 600MPa
contact point and can be negligible below the surface. Also, there are no  max  n  2.02
n 297.6MPa
other shear stresses. Therefore, the stress state of the beam is,
a.2) The Maximum Shear Stress Theory:
 x   x,contact
 y   y ,contact   y ,bending Recall that, theory states that yielding starts whenever the maximum
shear stress at any point becomes equal to the maximum shear stress in
 z   z ,contact
a tension test specimen of the same material when that specimen starts
   min
Considering that all of these stresses are compressive (negative) and yielding. Maximum shear stress is obtained using  max  max .
using the previous equations, the magnitudes of these stresses are 2
plotted as follows, From the previous figure,  min is always equal to  x but  max changes
between  y and  z . Considering these,  max is plotted as,
300
x (MPa)
140
250 y (MPa) max(MPa)
z(MPa) von (MPa)
120
200

100
150

80
100

60
50

40
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35
z (mm) 20
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35
z (mm)
1) The Maximum Normal Stress Theory:

Recall that this theory states that failure occurs if any of the principal So, from the figure, the maximum of the  max is at z=0 which is
stresses exceeds the yield strength of the material. From the previous  max  76.1MPa .
figure, the maximum principal normal stress is the value of y at z=0 S Sy 600MPa
which is  y  297.6MPa .  max  y  n   3.94
2n 2 max 2  76.1MPa 

METU – ME 307 Machine Elements I – Fall 2013

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a.3) The Distortion Energy Theory: Question 3: The figure shows a belt
pulley mechanism which is loaded
Recall that theory states that yielding occurs whenever the distortion statically. The shaft is made of AISI
energy in a unit volume reaches the distortion energy in the same 1030 steel with the yield strength of 480
volume corresponding to the yield strength in tension or compression. MPa. Using the maximum shear stress
theory, determine the diameter of the
shaft with a factor of safety of 2.
The von Misses stress is,

1/2
  1   2 2   1   3 2   2   3 2 
' 
 2  Solution : To solve this problem free body diagram should be sketched
and all reaction forces should be determined. According to vertical
As stated before,  min is always equal to  x but  max changes between shear diagram and bending-moment diagram the critical section is
 y and  z . Considering these,  ' is plotted and given in the previous found.
figure.

From this figure, the maximum of the  ' is at z=0 which is

 '  135.0MPa .

Then,

Sy Sy 600MPa
'  n   4.44
n ' 135.0MPa

Note that the maximum normal stress theory gives the minimum factor
of safety, n=2.02.

METU – ME 307 Machine Elements I – Fall 2013

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Point C and D have to be checked.

M  Mx  My
2 2

M C  2.7 kNm
M D  2.25 kNm

Point C is the critical section since the largest moment occurs at C

The Maximum Shear Stress Theory:

Sy 480
 all    120 MPa
2n 2(2)
 all   max
all is the shear stress value that the shaft material can carry safely so
max should not exceed it. To find max , the following formula is used.

 x  y
2

 max      xy 2 (from textbook)
 2 

 x  y
2
  
2

 all      xy 2  all   x    xy
2

 2   2 

Due to bending,

d
M
Mc 2  32M
 x   bending  
I d4 d 3

64
Due to Torsion,

METU – ME 307 Machine Elements I – Fall 2013

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d
T
Tc 2  16T
 xy   torsion  
J d 4 d 3

32
Note that vertical shear is zero on the surface of the shaft.
2 2
 16M   16T 
 all   3   3 
 d   d 
16
 all  3 M2  T2
d

At last the following formula which gives the diameter is obtained

16 16
 (2.7)(10 )    (0.6)(10 ) 
2 2
d3  M 2 T 2  6 6

 all  (120)

d=48.9 mm => 50 mm

METU – ME 307 Machine Elements I – Fall 2013