1

Prepared by: Bekir Bediz

Room: B-175 Phone: 210 5256
σ − (σ x + σ y + σ z ) ⋅ σ + (σ xσ y + σ xσ z + σ yσ z − τ − τ − τ
2 2
xy
2
xz
2
yz ) ⋅σ
E-mail: bbediz@metu.edu.tr Date: 07.11.2008
 

 

I1 I2

ME 307 – MACHINE ELEMENTS I (

 

)
− σ xσ yσ z + 2τ xyτ xzτ yz − σ xτ yz2 − σ yτ xz2 − σ zτ xy2 = 0
TUTORIAL 7 – Part I I3
“ STATIC DESIGN CRITERIA ”
Thus, the equation becomes,

Question 1: A steel machine part is statically loaded and has a yield σ 3 − I1σ 2 + I 2σ − I 3 = 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) σ x = 110 MPa σ y = −80MPa σ z = 90MPa τ xy = 40MPa
I 2 = −7700
I 3 = −936000
⎛ 80 25 0 ⎞
⎜ ⎟
b) σ ( MPa ) = ⎜ 25 −30 0 ⎟ Thus,
⎜0 0 50 ⎟⎠
⎝
y σ 3 − 10σ 2 − 4200σ − 63900 = 0
c)

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 σ 1 = 118MPa & σ 2 = 90MPa & σ 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 2008

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Sy 350 MPa Sy
σ max = ⇒n= = 2.97 n= 1/ 2
= 1.81
n 118MPa ⎡ (σ 1 − σ 2 ) 2 + (σ 1 − σ 3 ) 2 + (σ 2 − σ 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 σ1 − σ 3
τ max = ⇒ τ max = = 103MPa
2n 2
b)
350 ⎛ σ x τ xy τ xz ⎞
n= = 1.7
2 ⋅103 ⎜ ⎟
σ ( MPa ) = ⎜τ xy σ y τ yz ⎟
⎜ τ xz τ yz σ 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 ⎞
⎜ ⎟ ⎜ ⎟
⎡ (σ − σ ) 2 + (σ 1 − σ 3 ) 2 + (σ 2 − σ 3 ) 2 ⎤
1/ 2 eigenvals ⎜ ⎢⎢ 25 −30 0 ⎥⎥ ⎟ = ⎜ −35.4 ⎟
Sy
σ '=⎢ 1 2 ⎥ = ⎜⎢ 0
⎝⎣ 0 50 ⎦⎥ ⎟⎠ ⎜⎝ 50 ⎟⎠
⎢⎣ 2 ⎥⎦ n

σ 1 = 85.4MPa & σ 2 = 50MPa & σ 3 = −35.4MPa

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

METU – ME 307 Machine Elements I – Fall 2008

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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 350 MPa
σ max = ⇒n= = 4.1 Note also that
n 85.4 MPa
nMSST < nDET < nMNST
b.2) The Maximum Shear Stress Theory:

Sy σ1 − σ 3 c) The principal stresses can be found as in part (a) using the third order
τ max = ⇒ τ max = = 60.4 MPa 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 σ x = 40MPa
2 ⋅ 60.4
σ x = −20MPa
b.3) The Distortion Energy Theory: τ 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. σx +σ y
σ ave = = 10 MPa
2
The von Misses stress is, Then the radius becomes,
1/ 2
⎡ (σ 1 − σ 2 ) 2 + (σ 1 − σ 3 ) 2 + (σ 2 − σ 3 ) 2 ⎤ Sy R= (σ x − σ ave ) + τ xy 2
2
= 36.1
σ '=⎢ ⎥ =
⎢⎣ 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 σ 1 = 10 + 36.1 = 46.1
⎡ ( σ 1 − σ 2 ) 2 + ( σ 1 − σ 3 ) 2 + (σ 2 − σ 3 ) 2 ⎤ σ 3 = 10 − 36.1 = −26.1
⎢ ⎥
⎢⎣ 2 ⎥⎦
Note that the other principal stress is σ 2 = 0

METU – ME 307 Machine Elements I – Fall 2008

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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: ⎡ ( σ 1 − σ 2 ) + ( σ 1 − σ 3 ) 2 + (σ 2 − σ 3 ) 2 ⎤
2

⎢ ⎥
⎢⎣ 2 ⎥⎦
Sy 350 MPa
σ max = ⇒n= = 7.6
n 85.4 MPa
Question 2: Using the maximum shear stress and maximum normal
stress theory, find the minimum yield strength to be used for the beam
c.2) The Maximum Shear Stress Theory: shown in the figure. Choose an appropriate material accordingly.
T=300 N.m, M=250 N.m, F=800 N. (Take the safety factor as 2.5).
Sy σ1 − σ 3
τ max = ⇒ τ max = R = = 36.1MPa
2n 2

350
n= = 4.85
2 ⋅ 60.4

Solution:
c.3) The Distortion Energy Theory:
Stresses due to the bending can be seen from the figure below.
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.

The von Misses stress is,

1/ 2
⎡ (σ 1 − σ 2 ) 2 + (σ 1 − σ 3 ) 2 + (σ 2 − σ 3 ) 2 ⎤ Sy Forces are applied in a manner which creates tension in the shaft.
σ '=⎢ ⎥ =
⎢⎣ 2 ⎥⎦ n

METU – ME 307 Machine Elements I – Fall 2008

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The bending moment can be calculated as, σx +σ y

σ1 = + τ max = 36.6 MPa
2
d σx +σ y
M
Mc 2 = 27.9 MPa σ3 = − τ max = −7.7 MPa
σ bending = = 2
I d4
π σ2 = 0
64
Torsional shear stress can be calculated as;
d a) Using the maximum normal stress theory
T
Tc
τ torsion = = 24 = 16.8 MPa Sy
J
π
d σ1 = → S y = σ 1.n = 91.4 MPa
32 n
Stress due to the applied force is;
b) Using maximum shear stress theory
F
σ tension = = 0.94 MPa
Sy
A
τ max = → S y = τ max .2n = 110.7 MPa
2n
As seen from the figures given in the beginning part of problem, the
lower part of the beam is more critical. So the calculations should be Hence a material that has a yield strength greater than 110.7 MPa
done for this part of the shaft. should be selected. For example AISI 1018 steel can be used. (from
your textbook)
σ x = σ bending + σ tension = 28.9 MPa

σ y = 0 MPa

τ xy = τ torsion = 16.8 MPa

Then the maximum shear stress and principal stress can be found using
the equations obtained from the Mohr’s circle,

2
⎛ σ x −σ y ⎞
τ max = ⎜ ⎟ + τ xy = 22.1 MPa
2

⎝ 2 ⎠

METU – ME 307 Machine Elements I – Fall 2008

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Question 3: The figure shows a belt
pulley mechanism which is loaded
statically. The shaft is made of AISI
1030 steel with the yield strength of 480
MPa. Using the maximum shear stress
theory, determine the diameter of the
shaft with a factor of safety of 2.

Solution : To solve this problem free body diagram should be sketched

and all reaction forces should be determined. According to vertical
shear diagram and bending-moment diagram the critical section is
found.

METU – ME 307 Machine Elements I – Fall 2008

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Due to Torsion,
Point C and D have to be checked. d
T
Tc 16T
τ xy = τ torsion = = 24 = 3
M = Mx + My
2 2
J d πd
π
32
M C = 2.7 kNm Note that vertical shear is zero on the surface of the shaft.
2 2
M D = 2.25 kNm ⎛ 16M ⎞ ⎛ 16T ⎞
τ all ≥ ⎜ 3 ⎟ +⎜ 3 ⎟
⎝ πd ⎠ ⎝ πd ⎠
Point C is the critical section since the largest moment occurs at C 16
τ all ≥ 3 M2 + T2
The Maximum Shear Stress Theory: πd

Sy At last the following formula which gives the diameter is obtained

480
τ all = = = 120 MPa
2 n 2( 2)
τ all ≥ τ max d3 =
16
πτ all
M2 + T2 =
16
π(120)
((2.69)(10 )) + ((0.6)(10 ))
6 2 6 2

τall is the shear stress value that the shaft material can carry safely so
τmax should not exceed it. To find τmax , the following formula is used. d=48.9 mm => 50 mm
2
⎛ σx − σy ⎞
τ max = ⎜⎜ ⎟⎟ + τ xy 2 (from textbook)
⎝ 2 ⎠

2
⎛ σx − σy
2
⎞ ⎛σ ⎞
≥ ⎜⎜ ⎟⎟ + τ xy 2 2
τ all τ all ≥ ⎜ x ⎟ + τ xy
⎝ 2 ⎠ ⎝ 2 ⎠

Due to bending,

d
M
Mc 2 = 32M
σ x = σ bending = =
I d4 πd 3
π
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METU – ME 307 Machine Elements I – Fall 2008