Name: Abdul Karim

Reg: No: 2017006

CEP: Design Of Thin-walled Hollow
Member under Torsional Loading
Subject: Stress Analysis
Submitted to Dr. Khalid Rehman

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Table of Content
Topics Page number
1. Problem Statement-----------------------------------------------------------------------------------------3
1.1. Requirements and Limitations---------------------------------------------------------------------3
1.2. Material -------------------------------------------------------------------------------------------------3
1.3. Assumptions -------------------------------------------------------------------------------------------3
2. Solution -------------------------------------------------------------------------------------------------------3
2.1. Structure Shape --------------------------------------------------------------------------------------4
2.2. Formulas -----------------------------------------------------------------------------------------------4
2.3. Solution 1 ----------------------------------------------------------------------------------------------5
2.4. Solution 2---------------------------------------------------------------------------------------------- 8
2.5. Solution 3---------------------------------------------------------------------------------------------- 10
2.6. Solution 4 ---------------------------------------------------------------------------------------------12
2.7. Checking of solutions Ratios between
cross section dimension and thickness ≥ to 20---------------------------------------------14
2.8. Checking of solutions ------------------------------------------------------------------------------14
2.9. Comparison among solutions --------------------------------------------------------------------14
3. Proper drawn design with dimensions --------------------------------------------------------------15
4. Conclusion --------------------------------------------------------------------------------------------------16

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1. Problem Statement
Design a non-circular hollow thin-walled member, with multiple compartment and one end
fixed that can stand up to the torque, T, of 30 kNm applied to the free end.

1.1. Requirements and Limitations

The member must withstand the torsion load of 30 kNm with a minimum factor of safety of
2.5 under Von-Mises failure criteria for ductile material. It is required that the length of the
beam should be kept L=1m and angle of twist β must be less than or equal to 0.01 radians,
along with that the ratio between cross-section dimension and thickness must be greater than
or equal to 20 since the member is this walled. However, the value of thickness, t, must be an
integer greater than or equal to 5 mm. It is also required that mean perimeter dimensions
must be divisible of 5.

1.2. Material
This material has already been designated as Aluminum 6061 T6 with the following material
properties:
 Density = 2.7 x 103 kg/m3
 Yield Strength = 275 MPa
 Ultimate Tensile Strength = 310 MPa
 Poisson’s Ratio = 0.33
 Young’s modulus = 69 GPa
1.3. Assumptions
 Shear thickness is constant, shear stress is constant around the boundary.
 Shear stress is constant through the thickness.
 Shear stress on the face in any section of the beam is constant.

2. Solution
Analysis of the structure on different lengths and thicknesses to find the solution which is light
weight and fulfilling all the requirements. The structure contain one rectangle cross section
and along with rectangle, triangle cross section is attached to make it multi compartment
structure.

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 2.1. Structure shape

Figure 1. Cross section of Structure with labeling (hand drawn)

In figure 1 multi compartment of the beam’s cross section show to get to know on which the
solution is done.

2.2. Formulas
These below formulas are used for calculating factor of safety, angle of twist along with mass
of structure.
𝐴1 = 𝑙1 𝑙2
𝐴2 = 𝑙1 𝑏
𝐸
𝐺=
1+𝑣

𝑏 = √(𝑙1 /2)2 + 𝑙32

𝑇 = 2𝐴1 𝑞1 + 2𝐴2 𝑞2
1 (2𝑙1 + 𝑙2 )𝑞1 𝑙1 (𝑞1 −𝑞2 )
𝜃= ( + )
2𝐺𝐴1 𝑡1 𝑡2

1 (2𝑙3 )𝑞2 𝑙1 (𝑞2 −𝑞1 )

𝜃= ( + )
2𝐺𝐴1 𝑡3 𝑡2
𝑞1 𝑞2
𝜏𝑚𝑎𝑥 = 𝑜𝑟
𝑡1 𝑡2
𝑌
𝑆. 𝐹. =
𝜏𝑚𝑎𝑥 × √3
𝛽 = 𝜃𝐿
𝑚 = 𝜌𝑉

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2.3. Solution 1

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2.4. Solution 2

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2.5 Solution 3

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2.6. Solution 4

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2.7. Checking of solutions Ratios between cross section dimension and thickness ≥ to 20
Ratio Solution 1 Solution 2 Solution 3 Solution 4
𝑙1 /𝑡1 20 22.5 28.57 35
𝑙2 /𝑡1 34.286 35 38.57 49.167
𝑙1 /𝑡2 23.33 22.5 45 42
𝑙3 /𝑡3 20 27.143 31.67 40
Table 1: Checking of solutions Ratios between cross section dimension and thickness ≥ to 20

In table 1 it is shown that using mean lengths all solutions ratios are greater than or equal to
20, hence cross section dimension to thickness ratios will be greater than or atleast equal to
20. Hence minimum cross section to thickness ratio is greater than or equal to 20.

2.8. Checking of solutions

Requirements Solution 1 Solution 2 Solution 3 Solution 4
Thickness in Pass Pass Pass Pass
integer
Mean perimeter Pass Pass Pass Pass
is divisible by 5
𝑺. 𝑭. ≥ 𝟐. 𝟓 Pass Pass Pass Pass
𝜷 ≤ 𝟎. 𝟎𝟏 Fail Pass Pass Pass
Length=1 Pass Pass Pass Pass
Ratio between Pass Pass Pass Pass
minimum cross
section
dimension to
thickness > or =
to 20
Table 2: checking of solutions

Table 2 shows which solution is fulfilling all the essential requirements to be considered for
selection and from this we can assure that Solution 1 is not entertaining all the requirements.

2.9. Comparison among solutions

Requirements Solution 2 Solution 3 Solution 4
Mean perimeter (mm) 1120 1120 1200
S.F. 5.136 4.84 4.718
Angle of twist (radian) 0.00943 0.00947 0.009194
Mass (kg) 26.9217 23.4792 19.6695

Table 3: comparison among solutions

In table 3 solution 1 is excluded because of not fulfilling all requirements and by comparing
solution 2 and 3 having same mean perimeter but variation in mass because of thickness
reduction. Comparing solution 3 and 4 shows that by reducing the thickness and increasing
mean perimeter gives prominent results in reduction of mass of total structure and satisfy all
the requirements same as if we compare solution 2 and 4.

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3. Proper drawn design with dimensions

Figure 2: Drawing of final design with dimensions (ISO Standards)

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4. Conclusion

In conclusion, the above thin wall member of 1 m length is designed. 4 iterations were done
to find the best solution according to given conditions. Solution 1 fails satisfy angle of twist
condition of less or equal to 0.01 radian, solution 2, 3 and 4 are fulfilling all the requirements
as shown in Table 2. Now in comparison of remaining 3 choices, solution 4 is the best one
because of low mass, low angle of twist and satisfying factor of safety as per requirements.
Comparison among solutions is shown in Table 3.

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