DESIGN LIMITATIONS & ASSUMPTIONS:

1. Isotropic material
2. Prismatic member
3. Saint – Venant principle
4. Static equilibrium
5. Load applied is within elastic limit, consequentially, deformation is elastic
6. Outer perimeter of the beam must be a multiple of 5
7. Thickness must be in whole numbers
8. Material to be used is Aluminum Alloy (6061 T6)
INTRODUCTION:
This report includes the design of cantilever beam under uniformly varying load. Four iterations
are performed by changing the cross-sectional dimensions to fulfil the design requirements and
to optimize the conditions and he bet among them is chosen. Calculations are based on some
assumptions.

FORMULATION OF EQUATIONS:
The support reactions at the fixed support were first found out by summation of forces and
moments. This was followed by the development of shear force and bending moment diagrams
to find the maximum values of shear force and bending moment, which were to be used in the
design of the beam.

ΣFy = 0 (static equilibrium)

Hence,
1∗3∗1000
Ry - =0
2

Thus,
Ry = 1500 N h3
And ΣM = 0
1∗3∗1000
∗2∗3
Hence, M - ( 2 )=0
3

M = 3000 N.m.
As there is only a single load applied, taking a section at an arbitrary length, x from the fixed
support and formulating the equations

ΣFy = 0 (0 ≤ x ≤ 3 )
-V – 1500 = 0
Hence,
V = 1500 N
ΣM = 0
-M + 3000 = 0
Hence,
M = 3000 N.m.

SHEAR AND BENDING DIAGRAM:

For the given beam, assuming
Edge length = h
and Thickness = t (meters)
h h
For the given hollow beam, the centroid lies at the center at (xc , yc) = ( , )
2 2
1∗b
Moment of inertia = 12 *h
3
+ Ady2
Where,
A = Geometry area,
b = base
h = height
dy = vertical distance from centroid
Hence for the given geometry, Moment of Inertia =
1∗h 3 1∗(h−2 t ) 1 1
[ *(h ) + (h2 * 02) ] + [ *(1 – 2t)3 + ((h – 2t)2 * 02) ] = *h4 - *(h – 2t)4
12 12 12 12
1
= [ h4 – h4 – 16t4 – 24h2t2 + 8h3t + 32ht3 ]
12
4 8 2
Ix = -2h2t2 - 3 t4 + 3 ht3 + 3 h3t
We know that bending stress is given by,
M∗c
Bending stress : σ= I ,
Where,
M = bending moment,
c = vertical centroidal distance to the top surface,
I = moment of inertia,
3000∗h
2
Thus, σ =
2 2 4 t 8 h t 3 2 h3 t
4
−2 h t − + +
3 3 3
 4500 h
σ = −6 h2 t2−4 t 4 +8 h t 3 +2 h3 t h

Now,
VQ
τ= ¿
,

Where, V = maximum shear force,

Q = First moment about neutral axis (centroid)
I = moment of inertia,
t = thickness

Now, Q = ΣAý
= A1y1 + A2y2 + A3y3 = A1y1 + 2 A2y2
h t a a t
= ht ( − ) + 2 [ ( −t) t ( − ) ]
2 2 2 4 2

t(h−2 t)4
=
4
2 2 2
h t h t t ( h−2 t )
= − +
2 2 4
2 2 2
ht 3 2 h t ht
= −t −h t + −
4 2 2

3 h2 t 3 3 h t 2
= +t −
4 2

2
3 h 2 3 ht
1500 [ +t − ]
4 3
Hence, τ = 3 4 3
2h t 4 t 8ht
−2 h2 t t− +
3 3 3
2 2
562.5[3 h +4 t −6 ht]
τ= 2 2 4 3 3
−6 h t −4 t +8 h t +2 h t
Now, using Tresca criteria, we have:
Y
=σ e
2

Or, after simplification, we have

( √ σ 2+ 4 τ 2 )
σ e=
2

But at the TOP OF THE BEAM,

τ = 0,

and at the center, σ = 0.

We need to evaluate which stress is more critical and influences the design more.
Hence,

Y =FoS √ σ ∨Y =FoS √ 4 τ
2 2

Performing iterations in excel sheet, we observe that bending stress is more critical as compared
to shear stress.

Hence, FINAL DESIGN WILL BE DEVELOPED USING THE EQUATION ,

Y =FoS √ σ ,
2

Where FoS is the Factor of Safety.

DESIGN ITERATIONS:
Previous Table continuing to right side:

After performing the iterations, the following beam was selected:

S.No.: Property Value

1 Thickness 1 mm

2 Edge length 130 mm

3 Perimeter 520 mm

4 Second Moment of Inertia 1431212 mm4

5 Volume 1548000 mm3

6 Weight 40.9601 N

7 FoS based on bending 2.018

8 FoS based on shear 24.28

9 Strength / weight ratio

DRAWING PACKAGE