MEC 3416 Design II

Stress

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 Stress
• Loads result in stress
• Normal stress is normal to a surface, designated by s
• Tangential shear stress is tangent to a surface,
designated by t
• Normal stress acting outward on surface is tensile
stress
• Normal stress acting inward on surface is
compressive stress
• SI units of stress are newtons per square meter (N/m2)
• 1 N/m2 = 1 pascal (Pa)

• U.S. customary units of stress are pounds per square

inch (psi)
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Axial loading

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• P/A is average formula for uniformly distributed loads
• This assumption requires:
• Section considered from the ends
• Load applied along the axis of the bar
• Bar is straight cylinder, no residual stress, in stable
equilibrium when loaded
• Bar is homogenous (not composite material)
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• Suppose load is 600 N, the six welds are expected to
carry the same load of 100 N.
• However, path to 1 and 2 are much stiffer, and may
carry much more load than the others.
• Adding side plates to stiffen the paths to 3-6.
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Shear loading

• Colinear forces causes shear stress

• Average shear stress τ =P/A for location 1
• If tightened, shear stress at 2 and 3

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Shear loading

• P/A is a conservative estimation of working stress

• To produce shear fracture, of a ductile member, the
load must simultaneously overcome the shear
strength in every element in the shear plane.

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Torsional loading

• The stress vary linearly from zero at the axis to a

maximum at the outer surface. The shear stress
intensity at any radius r is τ =Tr/J
• J is the polar moment of inertia of the cross
MECH section
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Torsional loading
• For solid round bar of diameter d, J=πd4/32
• Assumptions:
• Bar straight and round
• Material homogenous
• Cross section sufficiently remote from point of load and from
stress raisers (e.g. holes)

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Torsional loading
• Example of rectangle cross section

• Based on τ =Tr/J, max stress at location 2

• Actual max stress at location 1
• Caution: assumption is straight and round
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Bending Loading
• For pure bending, the resulting stresses are given by
σ=My/I where y is the distance from the neutral axis

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Example: Lathe machine

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Stress on the shaft
• Axial stress
σ =P/A

• Shear Stress:
τ =P/A

• Torsional stress:
τ =Tr/J

• Bending stress:
σ=My/I=32M/πd3

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Stress Concentration

• The strength of a machine member is

influenced by many items such as stress
concentration, fatigue or variable loading,
shock, surface finish and size of part.
• Any discontinuity in a machine part alters the
stress distribution in the surrounding area and
results in an increase of stress locally. The
regions in which they occur are called areas of
stress concentration

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Stress Concentration

P P

(a) Tensile load P applied at both ends of bar with hole in middle.

savg

savg smax

(b) Stress distribution in bar.

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 Concept of Stress Concentration
Theoretical stress
concentration factor, Kt

Maximum stress at the discontinuity

Nominal stress, max stress

with no discontinuity

Kt is used for normal

stresses and Kts for
shear stresses.
Ken Youssefi
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Factor
• Theoretical stress concentration factor, Kt is
defined as:
• smax= Ktsnom and tmax= Kttnom
• The value of Kt is difficult to calculate and in
most cases, it is determined experimentally.
• Kt is dependent only upon geometry and type of
discontinuity.
• Kt  1.0
• Stress concentration may be found in rotating
shafts with shoulders, key slots, splines, bolts
and screw threads, parts with holes, oil grooves,
notches, springs, welds, press fits, etc.

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Stress Concentration Factor
Stress concentration factor is found using experimental methods.
• Photoelasticity – a plane polarized light is passed thru a
photoelastic material (all transparent plastics) resulting in a
colorful fringe pattern indicating the intensity of the stress.

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Photoelasticity
.

Ken Youssefi MECH 3416

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Bending – shaft with fillet

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Axially Loaded – shaft with fillet

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Torque - shaft with fillet

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Factor
• Stress concentration graphs are in dimension-
less ratio
• Stress concentration factors are different for
axial, bending and torsional loading.
• Stress concentration factor graphs pertain to the
maximum stress, existing at the surface of the
stress raiser. Lower values of stress elsewhere
can be determined by other approaches.

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Bending – Shaft with grove

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Axial Loading – Shaft with grove

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Torque – Shaft with grove

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Shaft with radius hole

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Bending – Bar with shoulder fillet

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Axial Loading – Bar with shoulder
fillet

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Bending - Notched Flat Bar

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Axially Loaded - Notched Flat Bar

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Bending – Plate with central hole.

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Axially Loaded – Plate with central
hole.

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Axial Load – T member

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When to use
• Fatigue, All Materials
– Fatigue is the failure of a structure by fracture due to
repeated cycles of stress or strain.
– Examples: connecting rods and crankshafts of engines,
steam turbine or gas turbine blades, connections or supports
for bridges, railroad wheels, and axles.
– Fatigue fractures begin with a minute (usually microscopic)
crack at a critical area of high local stress which enlarges
and spreads throughout the structure
• Impact, All materials
– Impact occurs when one object strikes another such that
large forces are developed between the objects during a
very short period of time.
– Impact loading is also called shock, sudden or impulsive
loading
• Static Loading – only non Ductile materials. Why
?
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Static Load + Ductile Material

• Why is Kt not relevant ?

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Summary
• Stress concentrates around
discontinuities in geometries.
• smax= Ktsnom and tmax= Kttnom
• Use Kt for all impact and fatigue loading
cases.
• Static Loading
– Only for non-ductile/brittle material
– Use for ductile material with caution

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