2.

0 STRESS ANALYSIS

CLO1
Analyze well-defined the concept of design
process of engineering product or component.
2.1 Describe the direct stresses
2.1.1 Differentiate between direct tension and
direct compression of stresses.
2.1.2 Determine direct stress in the round bar.
2.2 Explain the deformation under direct axial loading
2.2.1 Compute the strain due to a direct axial
tensile load or due to a direct axial compressive
load.
2.3 Describe the shear stress
2.3.1 Determine direct shear stresses on a key.
2.3.2 Determine the torsional shear stress formula
on a shaft.
2.3.3 Formulate relationship among torque, power
and rotational speed.
FACTOR OF SAFETY
FACTOR OF SAFETY
FACTOR OF SAFETY
 Guideline for selection of quantities values for
factor of safety are as follow
Material fs
1 Cast iron component, failure due to maximum stress 3-5
2 Ductile material (steel, Al) subjected to external static 1.5-2
force. Has proper heat treatment and small plastic
deformation
3 Ductile material subjected to external fluctuating 1.3-1.5
force, fatigue failure
4 Component cam and follower, gears, bearing. Failure 1.8-2.5
cause by small pit.
5 Component piston rod, power rod, power screw or 3-6
stud. Sudden large lateral deflection. Critical bucling
load.
 Factor of Safety
Equipment
- FOS -
Aircraft components 1.5 - 2.5
Boilers 3.5 - 6
Bolts 8.5
Cast-iron wheels 20
Engine components 6-8
Heavy duty shafting 10 - 12
Lifting equipment - hooks .. 8-9
Pressure vessels 3.5 - 6
Turbine components - static 6-8

Turbine components - rotating 2-3

Spring, large heavy-duty 4.5
Structural steel work in buildings 4-6
Structural steel work in bridges 5-7
Wire ropes 8-9
STRESS
 When the mechanical component is subjected to
external force, a resisting forces is set up within the
component. The external resisting forces per unit area
of the component recognize as a stress.

 In the physical sciences and engineering, the force per

unit area within materials that arises from external
forces

 Stress is expressed as the quotient of a force divided by

an area
𝑃
σ=
𝐴

P = load or force acting on the body

A = cross – sectional area of the body
Unit = N / m2
DIRECT STRESS
 Stress which are normal to the plane on which they
act are called direct stresses and they are either
tensile or compressive. Normally direct stress
occur when there is load applied with no bending.

 The simple type of load is directly pull or push,

known technically as Tension and Compression

TENSION STRESS

COMPRESSION STRESS
DIRECT TENSION

TENSION STRESS
DIRECT STRESS IN THE ROUND BAR
 Figure below shows a bar of constant cross-
sectional area A. The end of the bar carry
uniformly distributed normal loads of
intensity p. We know from static that:

when the loading is uniform, its resultant

passes through the centroid of the loaded area

 Therefore the resultant P=Σp of each end P

p
load acts along the central axis of the bar. In Area= A

the case of uniform loading the internal

forces acting on all cross sections are also
uniformly distributed. p

 Therefore, the normal stress acting in any

point on a cross section is
𝑃
σ =
𝐴
DIRECT COMPRESSION
 The fibers of the component tend to shorten due to
external forces

COMPRESSION STRESS

𝑃
σc=
𝐴

𝑁
σc= compression stress
𝑚𝑚2
P=External Force(N)
A=Crosectional area of The rod (mm2)
DIRECT STRESS IN THE ROUND
BAR

P
DEFORMATION UNDER DIRECT AXIAL LOADING
Strain

 Strain also known as deformation, in general term a

strain is a geometrical quantity that measures the
deformation of a body.

 Whenever a single force acts on a body, it undergoes

some deformation. This deformation per unit length is
known as strain. Mathematically strain may be
defined as the deformation per unit length.

Types of strain
1. Normal strain: characterizes dimensional changes
2. Shear strain: describe as distortion ( changes in
angles)
DEFORMATION UNDER DIRECT
AXIAL LOADING
 DEFORMATION UNDER DIRECT AXIAL
LOADING

 Deformation
1. Deform Uniformly –
L represent the axial strain
O. .A undeformed every where in the bar.
the axial strain is the
same at all point
x Δx

L+ 2.Deform not Uniformly –

Δ d
ε = lim =
O. .A deformed Δx→0 Δx dx

Δx + Δ elongation bar
𝐿 𝐿
=‫׬‬0 𝑑𝑥= ‫׬‬0 εdx
 Compressive (shortening) carries a negative sign
(example Є=-0.001)
MODULUS OF ELASTICITY E
E is the tendency of an object to deform along an axis when opposing
forces are applied along that axis; it is defined as the ratio of tensile
stress to tensile strain. Elastic materials always spring back into
shape when released.
σ
E =
ε

If P is the total tensile load in a bar, A its cross- sectional area, and
L0 its length , then

σ 𝑃/𝐴
E = =
ε 𝑒/𝐿0

Where e is the extension of the length L0. Thus the expansion is

given by
𝑃𝐿0
e =
𝐸𝐴
P= total tensile load
A= cross-sectional Area
L0= Length
PROBLEM 1
A steel bar of rectangular cross-section, 3 cm by 2 cm, carries an axial load of
30kN.
Estimate the average tensile stress over a normal cross-section of the bar.

30kN
30kN

Solution:

The area of normal cross-section of the bar is:

A = 0.03 x 0.02 = 0.6 x 10-3 m2

The average tensile over this cross-section is then

𝑃 30 𝑥 103
σ = 𝐴 = 0.6 𝑥 10−3 = 50MN/m2
PROBLEM 2
 PROBLEM 3
 A cylindrical block is 30 cm long had
has a circular cross-section 10cm in
diameter. It carries a total compressive 70 kN
load 70kN, and under this load it 10cm
diameter

contracts by 0.02cm. Estimate the

average compressive stress over a

30cm
normal cross-section and the
compressive strain.

70 kN
PROBLEM 3
A cylindrical block is 30 cm long had has a circular
cross-section 10cm in diameter. It carries a total
compressive load 70kN, and under this load it
contracts by 0.02cm. Estimate the average compressive
stress over a normal cross-section and the compressive
strain.
70 kN
10cm
Solution: diameter
π
A= 0.10 2 = 7.85 X 10−3m2
4

30cm
The average compressive stress over this cross-section
is then
𝑃 70 𝑥 103
σ = = −3 = 8.92 MN/m
2
𝐴 7.85 𝑥 10

The average compressive strain over the length of the

70 kN
cylinder is
0.02 𝑥 10−3
ε= −3 = 0.67 x 10
−3
30 𝑥 10
PROBLEM 4
A circular bar of diameter 2.5cm is
subjected to an axial tension of 20kN.
If the material is elastic with a
Young’s Modules E=70GN/m2,
estimate the percentage elongation.
 PROBLEM 4
A circular bar of diameter 2.5cm is subjected to an axial tension of 20kN. If the
material is elastic with a Young’s Modules E=70GN/m2, estimate the
percentage elongation.
Solution:
The cross section area of the bar is
π
A= 4 0.025 2 = 0.491 𝑥 10−3 𝑚2

The average tensile stress is then

𝑃 20 𝑥 103
σ = 𝐴 =0.491 𝑥 10−3 = 40.7MN/m2

The longitudinal tensile strain will therefore be

σ 40.7 𝑥 106
ε=𝐸= = 0.582 x 10−3
70 𝑥 109

The percentage elongation will therefor be (ε=δ/L)

δ= (0.582 x 10−3)100 = 0.058%
PROBLEM 5
PROBLEM 6
A steel tensile specimen has a cross section area of
100mm2 and a gauge length of 50mm,the gradient
of the elastic section 410x103N/mm. determine the
modulus of elasticity

Solution:
σ 𝐹 𝐿 50
E= = 𝑥 = 410 𝑥 103𝑥 = 205 000N/mm2
ε 𝑥 𝐴 100
PROBLEM 7
A steel columm is 3m long and 0.4m diameter it carries
a load of 50MN. Given that the modulus of elasticity is
200GPa, calculate the compressive stress and determine
how much the column is compressed
Solution
π𝑑2 π𝑥0.42
A= = = 0.126m2
4 4

𝐹 50 𝑥 106
σ= = = 397.9 x 106 Pa
𝐴 0.126

σ σ 397.9 𝑥 106
E= 𝑠𝑜 ε= = = 0.001989
ε ε 200 𝑥 106

δ
ε= 𝑠𝑜 δ = ε𝐿 = 0.001989 x 3000mm=5.97mm
𝐿
 Problem 8

A tensile test is carried out on a bar of mild steel of

diameter 2cm. The bar yields under load 80kN. It
reaches a maximum load of 150kN, and breaks finally
at a load of 70kN
Estimate:
1. The tensile stress at the yield point

2. The ultimate tensile stress

3. The average stress at the breaking point, if the

diameter of the fractured neck is 1 cm.

Solution:
SHEAR STRESS
Shear stress arises from forces that
are parallel to the plane of cross
section

Shear stress can be computed from

𝐹
τ=
𝐴
in common practical practice to
assume that the shear force F is
uniformly distributed over the
shear area A.
 DIRECT SHEAR STRESS ON A KEY
Key: one of the machine element which is used to
connect the transmission shaft to rotating machine
element like pulley, gear, sprocket or fly wheel.

Key Joint : consist of shaft, hub and key

Function of Key:
 To transmit torque from the shaft to the hub of
mating element
 To make sure the components rotates
simultaneously. In the most of the cases, key
also prevent axial motion between two
element.
DIRECT SHEER STRESS ON A KEY

Key classification:
1. Saddle key and sunk key
2. Square key and flat key
3. Taper key and parallel key
4. Key with and without Gib-head

Selection of key
1. Power to be transmitted
2. Tightness of fit
3. Stability of connection
4. cost
STRESS EQUATION OF THE KEY
P’

A P
h
P B

C
P’

Mt

l
P

B
h
A

P
Crushing area in the shaft
STRENGTH EQUATION OF KEY
 LENGTH OF SQUARE KEY

4. The failure of shaft occurs due to torsional shear stress

𝜏𝐽
M t= where 𝜋𝑑4
𝑟 𝐽=
32
𝑑
r=
𝜋𝑑 3 𝜏 2
Mt =
16
RELATIONSHIP AMONG TORQUE, POWER
AND POWER TRANSFER ROTATIONAL
SPEED

 The relationship among the power (P), the

rotational speed(n), and the torque (Mt)in a shaft
described by the equation:

𝑃
Mt=
𝜔

In SI unit
𝑁.𝑚
P = power (watt or )
𝑠
𝑟𝑎𝑑
𝜔 = Rotational speed ( 𝑠
)
RELATIONSHIP AMONG TORQUE,
POWER AND POWER TRANSFER
ROTATIONAL SPEED

Power is the rate of doing work;

𝑃𝑜𝑤𝑒𝑟 = 𝑓𝑜𝑟𝑐𝑒 × 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 𝐹𝑣 = 𝑀𝑡𝜔

Where;
F = force, N
v = velocity, m/s
𝑀𝑡 = torque, Nm
𝜔 = rotational speed, rads
TORSIONAL SHEER STRESS FORMULA ON A SHAFT

l
Mt

Mt θ

θ=angle of twist(radians)
l= length of the shaft (mm)

Mt
τ
r

kW=transmitted power(kW)
Mt= Torque(N-mm)
n =speed of rotational (rpm) τ
EXAMPLE 1
Compute the maximum torsional shear stress in a
shaft having diameter at 10mm when caries torque
of 4.1 Nm

𝑀𝑡𝑟
𝜏=
𝐽
10 4
4
𝜋𝐷 𝜋 2
𝐽= = = 982mm4
32 32

10𝑚𝑚
4.10𝑁.𝑚 103𝑚𝑚
𝜏= 4
2
= 20.9 N/mm2 = 20.9 MPa
982𝑚𝑚 𝑚
QUIZ 1

QUESTION 1
In engineering design, there are three types of design. Briefly explain on adaptive design. (C2)
(2 Marks)

QUESTION 2
Determine with the aid of diagram (2) ergonomics consideration to design a children chair. (C2)
(4 Marks)

QUESTION 3
Compare two (2) the usage of plastic and wood as material selection in school desk for children. (C4) (4
Marks)