Stress Analysis

Part I
October 2009
Suat Kadıoğlu
(updated October 2020)
 Solution Steps
• For the Mechanical design and analysis of components
and structures, conventionally the following steps are
followed.
– Force analysis
• Free body diagrams, support reactions, joint forces
• Internal forces in members, shear force, bending moment, axial force, torque
diagrams
– Stress analysis
• Determination of critical points
• Determination of stresses at the critical points
• Setting up the stress state (cubic element with stresses applied on
its faces) and finding principal stresses, maximum shear stress,and
their orientations.
– Application of static or fatigue failure criteria
2
 Analysis and Design
• As a result of this procedures,
– In analysis problems where the component or the structure is
fully defined, a prediction can be made whether it is safe (no
failure) or not.
– In design problems, dimensions and material can be chosen
such that the component or the structure can function without
failure.
• Statics analysis, force analysis and fundamentals of
stress analysis (for 2D cases) has already been covered
in ME 205 and ME 206.
• Now the concept of stress analysis will be reviewed and
extended to full 3D stress state.
3
STRESS ANALYSIS
Design of many machine elements is governed by the stress state at the
critical points.
Hence the designer should be able to:
• Determine the critical points
• Determine the stress state at these points

Critical point(s) : The points on the machine element which are most
likely to fail under given loads.
Failure : Yielding or Fracture (In this context)
Plastic deformation Breaking, disintegrating
Permanent shape change

Question : How do we identify critical points then?

Answer : Locations of maximum stress, locations of minimum
strength, and locations where stresses are high and
strength is low are candidates.

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Example: For an end loaded cantilever beam, critical points are at the
location of support at the top and bottom surfaces of the beam, since the
bending moment and consequently the bending stress are maximum
there.

Furthermore if the beam has different tensile and compressive strengths

(like concrete) one of these locations may be even more critical.

NOTE THAT strength as well as stresses can change from point to point
on a body. Hence there may be more than one critical point on the body.
All of them should be checked.

5
Stress State: Now take a cut through B, which
Consider a point B on a prismatic member.
Take a cut perpendicular to the axis of the
makes an angle b with the x-axis.
member through point B. F Rt Rn s
F b
B t
F
y

B B
x
s1
F F
F
F
F acting on A'c is produced as the
Resultant of normal stress over resultant of Rt and Rn. In turn Rt and Rn
the cross sectional area, Ac, are the resultants of stresses s and t
gives force F. acting on A'c.

Average stress or recognizing Question: How are s and t at point B

that the stress is uniform, related to s1 ?

Answer: Using static equilibrium equations or

s1=F/Ac MOHR CIRCLE
6
Consider a very small cubic element around point B.
y
b Given the uniaxial stress state s1.
s1 n We want to find the normal and
shear stresses on the surface
y whose normal is n.
B
Zero stress here
x
s1

t (+ CW)

s1 y
b
x s s1 y y
n
s
s
t B x
B t
2b
n
s1 7
Example: Consider a thin walled cylindrical pressure vessel with a helical weld
line. Let it be given that the weld line is critical. sall (on weld line), tall (on weld
line), r and t are given. Maximum safe internal pressure is asked.

2sttl=P2lr
N st
T st=Pr/t sL
B r
P
45 sL2ptr=Ppr2
sL=Pr/(2t)
l t

Bi-axial stress state Mohr Circle sn=(sL+2sL)/2=1.5sL tn=(2sL-sL)/2=0.5sL

t (+ CW) 1.5 Pr/(2t)=s 0.5 Pr/(2t)=tall
all
st=2sL
P=min{4tsall/(3r), 4ttall/r} y
N b
y 45
sL= s2 s1 =st =2sL
sN sN
B x sL
sL
B tN
tN
st
90 8
 Example:Consider a cylinder subjected to torsion and tension
Points on the surface are critical. t=Tr/J s=P/A Take a section through B.
T T
T
y txy
P
B
P B sx
P s sx B x
t (+ CW) t
O:(sx/2,0)
x
txy R=[(sx/2)2 +txy2]1/2
R a=tan-1(2txy/sx)
s2 a s1
O sx s1,2=(sx/2)[(sx/2)2 +txy2]1/2
-txy
a/2
s2
y s1

B
s2 s1

9
 Upto this point all the cases considered were two dimensional. (Bi-axial)
The stresses considered were all acting on planes whose normals are in x-y planes.
(stresses are in x-y plane)
Hence stresses can be represented
on a cubic element as in the figure
or in an array form as shown below.
s xx t xy 
t s 
 yx yy 

The cube and/or the array

represent the 2-D stress state
at a point.
By using equilibrium it can be shown
that txy=tyx.

Maximum Shear Stress and Principal Stresses:

 s - sy 
2
sx + sy
tmax =  x  + txy
2
s1,2 =  tmax
 2  2
10
 Example: 2D stress state (Stresses in units of MPa)
y 2
 50 - (-30) 
tmax =   + 30
2
x 30  2 

30 tmax = 50

50 50 - 30
s1,2 =  50
2

s1 = 60 s2 = -40

s xx t xy  50 30 
t   30 -30
 yx s yy   

11
In the general 3-D case, there will be Note that txy=tyx, txz=tzx, tzy=tyz.
3 more stress components as shown
in the figure. Name convention: sij
i: direction of normal vector of the surface on
which stress acts.
j:direction of stress itself
Sign convention:
• tensile stresses are (+),
• compressive stresses are (-).
A shear stress is (+) if it is in;
1. (+) direction, on a surface whose outward
normal is in (+) direction.
2. (-) direction, on a surface whose outward
3-D stress state at a point is also normal is in (-) direction.
represented by the array below. Otherwise shear stress is (-).
s xx t xy t xz 

t yx s yy t yz  All the stresses shown above are positive.
 t zx t zy s zz  12

 Example: Principal stresses in 3-D are
obtained by solving the following
sxx=10 szz=0
eigen value problem:
syy=-5 tyz=6 s xx t xy t xz       

txy=-3 txz=0 t yx s yy t yz  m = s m
 t zx t zy s zz   n   n 


where
 10 - 3 0 
 - 3 - 5 6  
 
  m  is the direction cosine vector,
 0 6 0  
 n 
s xx - s t xy t xz
(eigen vector) of principal stress, s (eigen value). Therefore, t yx s yy - s t yz = 0
t zx t zy s zz - s
then characteristic equation is
s xx s xy s xz
s 3 - (s xx + s yy + s zz )s 2 + (s xxs yy + s xxs zz + s yys zz - s yx 2 - s yz 2 - s xz 2 )s - s yx s yy s yz = 0
s zx s zy s zz
A simple special case of 3D stress state occurs when two opposite sides of the stress
element are free from shear stresses. Then, the normal stress on these faces is a
principal stress. The two other principle stresses can be found by 2D Mohr Circle
13
analysis. (This is because superposition is applicable.)
 Solution Procedure by Calculator
s3 -  sx + s y + sz  s2 +  sx sy + sx sz + sysz - txy 2 - tyz 2 - tzx 2  s -  sx sysz + 2txy tyz tzx - sx tyz 2 - sy tzx 2 - sz txy 2  = 0

I1 = s x + s y + s z I2 = s xs y + s xs z + s ys z -t xy 2 -t yz 2 -t zx2 I3 = s xs ys z + 2t xyt yzt zx - s xt yz 2 - s yt zx2 - s zt xy 2

2 I 13 - 9 I 1 I 2 + 27 I 3 1 2𝐼13 − 9𝐼1 𝐼2 + 27𝐼3 2𝜋

cos 3 = 3 𝜃𝑖 = arccos 3 + (𝑖 − 1) (𝑖 = 1,2,3) 𝜃𝑖 𝑖𝑛 𝑟𝑎𝑑𝑖𝑎𝑛𝑠
3 3
2( I 1 - 3 I 2 )
2 2 2(𝐼12 − 3𝐼2 )2

I1 I1 I1 2 2
σ1 = r cos θ1 + σ2 = r cos θ2 + σ3 = r cos θ3 + r= I − 3I2
3 3 3 3 1

Example: I1 = 10 - 5 + 0 = 5 I2 = (10)(-5) + (10)(0) + (-5)(0) - (-3)2 - (6)2 - (0)2 = -95

 10 - 3 0 I3 = (10)(-5)(0) + 2(-3)(6)(0) - (10)(6)2 - (-3)(0)2 - (0)(-3)2 = -360
 - 3 - 5 6
 
 0 6 0  
- - + -  + (1 - 1) 2p
3
1 2(5) 9(5)( 95) 27( 360)
 1 = arccos 
3  3
 3
 2((5) - 3( - 95)) 2
2


 1 = 0.688927  2 = 2.78332  3 = 4.87772 r=11.73788

s 1 = 10.7275 s 2 = - 9.3259 s 3 = 3.59847

14
Stresses at a point acting on a given plane is found from equilibrium of an
infinitessimal element, shown below. SFx=0, SFy=0,SFz=0.

C n=li+mj+nk

T
sxx
syz B n
syy
y s
B
A
szy t
x szz C

A
 s xx t xy t xz     
T = t yx s yy t yz  m , T is the traction vector (stress vector).
 t zx t zy s zz   n 

 
s = T .n , t = T 2 - s 2 where T=T. 15
 In 3-D (triaxial stress state) Mohr circle can be drawn only after finding the
principal stresses by solving the eigen value problem.
let s1>s2>s3 be the principal stresses. Max. shear stress is given by the largest
of the 3 circles.
t
tmax
tmax=(s1-s3)/2

s3 s2 s1 s

2D Cases which we have considered earlier are special cases of the general 3-D
case where one (or two) of the principal stresses is zero.
Uniaxial tension: s2=s3=0 tmax
y
s1 s1
x 16
Thin walled pressure vessel:(Bi-axial tension)
s3=0
s1 tmax
y
s2 s2 s1
B x
2-D Mohr
s1 Circle
Combined tension and torsion:(Bi-axial stress,s2=0) Note that the 2-D Mohr
tmax circle drawn may or may
s3 not give the maximum
y shear stress (which is used
in design criteria).
s1 s3 s2 s1 Therefore always draw the
B x 3-D Mohr circle by taking
one principal stress as zero
after a two dimensional
s3
analysis to find tmax.
Mohr circle obtained
by 2D- analysis
17
 STRAIN C’
0
D D’
C
 = 0
F F a
90 B’
A B A’

Normal Strain: Shear Strain:

 - 0  p
= =  = -a
0 0 2
HOOKE'S LAW:
Uniaxial loading: s = E E is Young's Modulus.

Shear loading: t = G G is Modulus of Rigidity.

w
lateralstrain 
 =- (loading is axial)
axial strain
w/ w
 is called Poisson Ratio.  =- -1   0.5
/ 
0.5 corresponds to incompressible materials. Materials with negative
18
Poisson ratio are called auxetic materials.
 y
 yy = -xx  zz = -xx E F
G= F
2(1+ ) x

z
General Stress Strain relations for İsotropic Homogeneous Materials:
s zz
z

x y
s xx
s yy
s yy s zz
s xx  yy =  zz =
 xx = E
E E
By superposition (strains in terms of stresses):  xx = -yy  xx = -zz
s yy s
 
 xx = s xx -syy -szz 
1  xx = - xx = - zz

E E
E
t
 yy = s yy -sxx -szz   xy = xy
1 Mohr Circle for strains can be
E G drawn similar to stresses but t must
t be replaced with /2, s must be
 zz = s zz -syy -sxx   xz = xz  yz =
t
1 yz
replaced with . 19
E G G
 Normal stresses in terms of given strains:

 E   x  1 -  +  E    y +  z  
sx =  
1 -  - 2 2

 E  y  1 -   +  E    x +  z  
sy = 
1 -  - 2 2

 E   z  1 -   +  E    x +  y  
sz =  
1 -  - 2 2

20
 PLANE STRESS and PLANE STRAIN problems

Plane Stress: szz=txz=tyz=0 Plane Strain: zz=0 (or constant in

generalized p. strain) , xz=yz=0
Thickness of the member in z-direction
is small, loading is in x-y plane.
Thickness of the member in z-direction is

 xx =
1
s xx -syy   yy =
1
s yy -sxx  very large, loading is in x-y plane and
it is not a function of z.
E E

 xy =
t xy   zz = 0 =
1
s zz -syy -sxx 
 zz = - (s xx +s yy ) E
G E
s zz = (s yy +s xx )
One can solve sxx and syy in terms of
xx and yy to obtain,  xx =
E
1
s xx -syy - 2 (s xx +s yy )

s xx =
E
 xx +yy   xx =
1- 2 
s
 xx -

s

yy 
1- 2
E  1- 
1- 2    t xy
s yy =
E
 yy +xx   yy = s yy - s xx   xy =
1-  G
1- 2
E 

One can again solve sxx and syy in

terms of xx and yy. 21
 THICK WALLED CYLINDERS
Po


r

z Pi O O
a
sr
b s

Stress state at a point in the cylinder is to be determined.

Assumptions:
1 zz is constant. (Plane sections remain plane subsequent to loading.)
2) Problem is axisymmetric. (Stresses and diplacements are independent of . sr=0)
3) srz=sz=0
4) Ends are free. (szz=0, If ends were closed, szz would be constant.)

22
 sr+dsr SFy=0 : (sr+dsr) 2 (r+dr)-2 r sr-2 dr s =0
y
rdsr/dr+sr-s=0 .....(1)
sr
Projected area
(Note dr2 terms are neglected) (unit depth)
s s
1
Consider zz:  zz = c = s z -sr -s  sr+s=C (=Ec'/ )
E
0
then s=C - sr .....(2)

From (1) and (2),

rdsr/dr+2sr=C (1st order O.D.E.) Solution is given as follows:

sr=C/2+B/r2 and from (2), s=C/2-B/r2 Let C/2=A, and we obtain;

sr=A+B/r2
s=A-B/r2
23
 Boundary Conditions:

sr= -Pi, r=a , sr= -Po , r=b then, A =

Pi a 2 - Po b 2 a b Po - Pi 
2 2
B=
b -a
2 2
b2 - a2

Pi a 2 - Pob 2 1 a 2b 2 Po - Pi  Pi a 2 - Pob 2 1 a 2b 2 Po - Pi 

sr = + 2 s = - 2
b -a
2 2
r b -a
2 2
b -a
2 2
r b2 - a 2

If ends of the cylinder are closed

szz
Po Pi -szz(b2-a2)-Pob2+Pia2=0 Pi a 2 - Pob 2
s zz =
b2 - a 2
( Valid away from the ends !)

24
Stress distributions in a thick walled cylinder subjected to internal pressure

25
 PRESS and SHRINK FIT PROBLEMS

c b- b+ b
a

A contact pressure P is created at r=b. =b+-b- and b+> b >b-

Inner cylinder outer circumference reduces to 2p b from 2p b+.
Outer cylinder inner circumference expands to 2p b from 2p b-.

2pb - 2pb + b - b + b - b +  i b - b- b - b-  o
  i = =  =  o = -
 =
2pb +
b +
b b b b b
Initial Interference, =b+-b- = -(b-b+) + (b-b-) =o-i So, =o-i .
 = b o - b i At this point assume szz=0.
 1  1 
 = b s  o - o s r o  - b s  i - i s r i  ........... (1)
 Eo   Ei 
26
 c2 + b2
For the outer cylinder, at r=b : (s  ) o = 2 P and (s ) = - P ................(2)
c -b 2 r o

b2 + a 2
For the inner cylinder, at r=b : (s  ) i = - 2 P and (s r ) i = - P ................(3)
b -a 2

Substituting (2) and (3) in (1),

1  c2 + b2  1  b2 + a 2 
 = Pb  2 +  o  +  2 - i 
 c -b b -a
2 2
 Eo  Ei 
given , P can be found and vice versa.

It is assumed that members are of the same length, otherwise stress concentration
occurs at the ends.

27