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DESIGN OF A CANTILEVER BEAM UNDER NONUNIFORM DISTRIBUTED LOAD

Preprint · January 2021

DOI: 10.13140/RG.2.2.19302.65604

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Ghulam Ishaq Khan Institute of
Engineering Sciences and
Technology

CEP2020
CANTILEVER BEAM
NONUNIFORM DISTRIBUTED LOAD

Zayan bin Shahid-2018522

ME-314: Mechanics of Solids II
Faculty of Mechanical Engineering
Ghulam Ishaq Khan Institute (GIKI)
Design of a Cantilever Beam under non-uniform distributed loading

Zayan bin Shahid-2018522

Faculty of Mechanical Engineering, Ghulam Ishaq Khan Institute

ME314: Mechanics of Solids II

Prof. Massab Junaid

January 18th, 2020

 TABLE OF CONTENTS

PROBLEM STATEMENT……………………………………………………………………………………………………………………… 4

DESIGN LIMITATIONS……………………………………………………………………………………………………………..............4

ASSUMPTIONS………………………………………………………………………………………………………………………………….. 4

PROCEDURE……………………………………………………………………………………………………………………………………….5

CALCULATION…………………………………………………………………………………………………………………………………… 6

FINITE ELEMENT ANALYSIS (FEA) ……………………………………………………………………………………………………. 12

Procedure……………………………………………………………………………………………………………………………………….. 12

CAD Modelling……………………………………………………………………………………………………………………………..12

FEA procedure…………………………………………………………………………………………………………………………….. 14

COMPARISON…………………………………………………………………………………………………………………………………. 32

CONCLUSION………………………………………………………………………………………………………………………………….. 32
PROBLEM STATEMENT
A Cantilever beam is to be designed, as shown in Figure 1, which is under non-uniform distributed
loading. The data provided is as follows:

• The beam is fixed on one end by solid surface and the other end is free to move.
• Total length of the beam is 3 m.
• The load on the beam is distributed as follows
o At x = 0 m, F = 0 N/m.
o At x = 3 m, F = 1000 N/m.

Based upon all the data given, multiple iterations are to be performed, among which a final design
should be selected based upon the design requirements discussed in Section 2. The final design should
include following parameters

• Reaction Forces,
• Cross-sectional dimensions,
• Maximum stress value and location by
distortion energy theory,
• Maximum displacement value and A B
location,
• Factor of safety,
• Strength to weight ratio, Figure 1 Cantilever Beam
• Manufacturing drawing,
• Finite Element Analysis (FEA).

DESIGN LIMITATIONS
The design requirements are as follows

• Beam has Square cross section with

o Outer perimeter as a multiple of 5,
o Thickness of wall greater than 1 mm and in whole numbers.
• Factor of Safety greater than 2, using distortion energy theory,
• Material: Aluminum Alloy 6061-T6 (SS) with following properties
o Density: 2700 kg/m3.
o Yield Strength: 275 MPa.
o Ultimate Tensile Strength: 310 MPa
o Poisson’s Ratio: 0.33
o Elastic Modulus: 69 GPa
• Maximum Strength to weight ratio
𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆ℎ
χ=
𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊ℎ𝑡𝑡 𝑜𝑜𝑜𝑜 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏

ASSUMPTIONS
The assumptions made to simplify the analysis of the beam for design are as follows

• The weight of the beam is ignored, as it has very less value compared to stresses.
• The material is Isotropic and Homogeneous.
• The material obeys Hooke's law.
 • The beam is initially straight with a constant cross section throughout.
• The beam has an axis of symmetry in the plane of bending.
• The beam is under static equilibrium i.e.
o Σ F = 0 (x, y, z)
o Σ M = 0 (x, y, z)

PROCEDURE
The problem-solving strategy adopted for the analysis can be put as follows

1. Using equilibrium conditions to determine the reactions at the fixed end,

2. After the reactions have been found, use method of section to derive the general formula for
shear force and bending moment as a function of length,
3. Construct Shear force and Bending moment diagrams for the beam, and extract the point of
maximum shear force and bending moment,
4. Determine the equations for beam deflection and displacement.
5. Form equations for the following cross-sectional properties with keeping length and thickness
of cross section as variables
a. First Moment of inertia, Qxy
b. Second Moment of inertia, Ixx
6. Using section properties form equations for
a. Normal stress, σxx
b. Shear stress, τxy
7. Use normal and shear stresses in the equation of von Mises theory to determine the effective
stress and Factor of Safety equations in form of iteration variables i.e., length and thickness
of the cross section.
8. Use all the equations formed to perform iterations and determine suitable design parameters.

The following formulas shall be used in the calculations

𝑉𝑉𝑉𝑉
1. Shear stress, 𝜏𝜏 =
𝐼𝐼𝐼𝐼
𝑀𝑀𝑀𝑀
2. Bending Stress, 𝜎𝜎 =
𝐼𝐼
3. von Mises stress for plane stress state, 𝜎𝜎𝑒𝑒 = √𝜎𝜎 2 + 3𝜏𝜏 2
𝑆𝑆𝑌𝑌
4. Factor of Safety, 𝑛𝑛 =
𝜎𝜎𝑒𝑒
5. First Moment, 𝑄𝑄 = ∑(𝐴𝐴 × 𝑦𝑦�)
1
6. Second Moment for Square at centroid, 𝐼𝐼 = × 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙ℎ4
12
𝑑𝑑 2 𝑦𝑦
7. Beam displacement, 𝐸𝐸𝐸𝐸. = 𝑀𝑀(𝑥𝑥)
𝑑𝑑𝑥𝑥 2
CALCULATION
For Reaction forces

∑ 𝐹𝐹𝑌𝑌 = 0 ; ∑ 𝑀𝑀𝑍𝑍 = 0
𝐿𝐿 𝐿𝐿2
𝑅𝑅𝐴𝐴 = 𝜔𝜔𝑂𝑂 × ; 𝑀𝑀𝐴𝐴 = 𝜔𝜔𝑂𝑂 ×
2 3

Solving above equations gives, RA = 1500 N and MA = 3000 Nm

ωOL
MA

RA (2/3)L

Figure 2 Free Body Diagram

Now, using the method of sections and equilibrium conditions with the sign conventions,

MA ωx

V M
RA x

Figure 3 Method of Section

For Shear force,

𝜔𝜔𝑂𝑂 𝑥𝑥
𝑉𝑉 − 𝑅𝑅𝐴𝐴 + � . 𝑥𝑥� . � � = 0
𝐿𝐿 2
𝜔𝜔𝑂𝑂 . 𝐿𝐿 𝜔𝜔𝑂𝑂 . 𝑥𝑥 2
𝑉𝑉 = − … (1)
2 2𝐿𝐿
For bending moment,
𝜔𝜔𝑂𝑂 . 𝑥𝑥 𝑥𝑥 𝑥𝑥
𝑀𝑀 + 𝑀𝑀𝐴𝐴 − 𝑅𝑅𝐴𝐴 . 𝑥𝑥 + � �.� �.� � = 0
𝐿𝐿 2 3
𝜔𝜔𝑂𝑂 . 𝑥𝑥 3
𝑀𝑀 = 𝑅𝑅𝐴𝐴 . 𝑥𝑥 − 𝑀𝑀𝐴𝐴 + � �
6𝐿𝐿

𝜔𝜔𝑂𝑂 . 𝐿𝐿 𝜔𝜔𝑂𝑂 . 𝐿𝐿2 𝜔𝜔𝑂𝑂 . 𝑥𝑥 3

𝑀𝑀 = . 𝑥𝑥 − +� � … (2)
2 3 6𝐿𝐿
 Constructing the Shear force and bending moment diagrams and finding the point of maximum shear
force and bending moment,

1500 0

Bending Moment (Nm)

1250 0 0.5 1 1.5 2 2.5 3
-500
Shear Force (N)

1000 -1000
750 -1500
500 -2000
250 -2500
0 -3000
0 0.5 1 1.5 2 2.5 3 Beam Length (m)
Beam Length (m)
Figure 4 Shear force and Bending Moment Diagrams

From above diagrams we find that at x = 0 m, V = 1500 N and M = 3000 Nm which are the maximum
values.

Determining the deflection and displacement formulas,

𝑑𝑑 2 𝑦𝑦
𝐸𝐸𝐸𝐸. = 𝑀𝑀(𝑥𝑥)
𝑑𝑑𝑥𝑥 2
From Eqn. (2)

𝑑𝑑 2 𝑦𝑦 𝜔𝜔𝑂𝑂 . 𝐿𝐿 𝜔𝜔𝑂𝑂 . 𝐿𝐿2 𝜔𝜔𝑂𝑂 . 𝑥𝑥 3

𝐸𝐸𝐸𝐸. = . 𝑥𝑥 − + � �
𝑑𝑑𝑥𝑥 2 2 3 6𝐿𝐿

𝑑𝑑𝑑𝑑 𝜔𝜔𝑂𝑂 . 𝐿𝐿 𝑥𝑥 2 𝜔𝜔𝑂𝑂 . 𝐿𝐿2 𝜔𝜔𝑂𝑂 𝑥𝑥 4

𝐸𝐸𝐸𝐸. = . − . 𝑥𝑥 + . + 𝑐𝑐1
𝑑𝑑𝑑𝑑 2 2 3 6𝐿𝐿 4
𝜔𝜔𝑂𝑂 . 𝐿𝐿 𝑥𝑥 3 𝜔𝜔𝑂𝑂 . 𝐿𝐿2 𝑥𝑥 2 𝜔𝜔𝑂𝑂 𝑥𝑥 5
𝐸𝐸𝐸𝐸. 𝑦𝑦 = . − . + . + 𝑐𝑐1 . 𝑥𝑥 + 𝑐𝑐2
4 3 3 2 24𝐿𝐿 5
Now using the boundary conditions for cantilever beam,

For x = 0 m, θ = 0; and at x = 3 m, y = 0 m,

1 𝜔𝜔𝑂𝑂 . 𝐿𝐿 𝑥𝑥 2 𝜔𝜔𝑂𝑂 . 𝐿𝐿2 𝜔𝜔𝑂𝑂 𝑥𝑥 4

𝜃𝜃 = � . − . 𝑥𝑥 + . + 𝑐𝑐1 �
𝐸𝐸𝐸𝐸 2 2 3 6𝐿𝐿 4

1 𝜔𝜔𝑂𝑂 . 𝐿𝐿 𝑥𝑥 3 𝜔𝜔𝑂𝑂 . 𝐿𝐿2 𝑥𝑥 2 𝜔𝜔𝑂𝑂 𝑥𝑥 5

𝑦𝑦 = � . − . + . + 𝑐𝑐1 . 𝑥𝑥 + 𝑐𝑐2 �
𝐸𝐸𝐸𝐸 4 3 3 2 24𝐿𝐿 5

Above equation implies that c1 = 0 and c2 = 0, now

1 𝜔𝜔𝑂𝑂 . 𝐿𝐿. 𝑥𝑥 2 𝜔𝜔𝑂𝑂 . 𝐿𝐿2 . 𝑥𝑥 𝜔𝜔𝑂𝑂 . 𝑥𝑥 4

𝜃𝜃 = � − + � … (3)
𝐸𝐸𝐸𝐸 4 3 24𝐿𝐿

1 𝜔𝜔𝑂𝑂 . 𝐿𝐿. 𝑥𝑥 3 𝜔𝜔𝑂𝑂 . 𝐿𝐿2 𝑥𝑥 2 𝜔𝜔𝑂𝑂 . 𝑥𝑥 5

𝑦𝑦 = � − + � … (4)
𝐸𝐸𝐸𝐸 12 6 120𝐿𝐿
Now calculating for section properties with outer length of cross section as ‘a’ and thickness of wall as
‘t’,
a
For First moment of inertia from neutral axis till top (Figure 4),

𝑄𝑄 = 𝐴𝐴 × 𝑦𝑦� t

a
𝑎𝑎 𝑡𝑡 𝑎𝑎 1 𝑎𝑎 y
𝑄𝑄 = 𝑎𝑎. 𝑡𝑡 � − � + 2 �� − 𝑡𝑡 − 𝑦𝑦� × 𝑡𝑡 × � − 𝑡𝑡 − 𝑦𝑦��
2 2 2 2 2 N.A

𝑎𝑎2 . 𝑡𝑡 𝑎𝑎. 𝑡𝑡 2 𝑎𝑎 2
𝑄𝑄 = − + 𝑡𝑡 × � − 𝑡𝑡 − 𝑦𝑦�
2 2 2
𝑎𝑎2 . 𝑡𝑡 𝑎𝑎2 𝑎𝑎 𝑎𝑎
𝑄𝑄 = − 𝑎𝑎. 𝑡𝑡 2 + 𝑡𝑡 × � + 𝑡𝑡 2 + 𝑦𝑦 2 − 2. . 𝑡𝑡 + 2𝑡𝑡𝑡𝑡 − 2. . 𝑦𝑦� Figure 5 Beam Cross sectional view
2 4 2 2

𝑎𝑎2 . 𝑡𝑡 𝑎𝑎. 𝑡𝑡 2 𝑎𝑎2 . 𝑡𝑡

𝑄𝑄 = − + + 𝑡𝑡 3 + 𝑡𝑡. 𝑦𝑦 2 − 𝑎𝑎. 𝑡𝑡 2 + 2𝑡𝑡 2 . 𝑦𝑦 − 𝑎𝑎. 𝑡𝑡. 𝑦𝑦
2 2 4
3𝑎𝑎2 . 𝑡𝑡 3𝑎𝑎. 𝑡𝑡 2 𝑎𝑎
𝑄𝑄 = − + 𝑡𝑡 3 + 𝑡𝑡. 𝑦𝑦 2 + 𝑦𝑦(2𝑡𝑡 2 − 𝑎𝑎𝑎𝑎) 𝑤𝑤ℎ𝑒𝑒𝑒𝑒𝑒𝑒 0 < 𝑦𝑦 < � − 𝑡𝑡� … (5)
4 2 2
For Second Moment of Inertia
1 4 1
𝐼𝐼 = 𝑎𝑎 − (𝑎𝑎 − 2𝑡𝑡)4
12 12
1 4
𝐼𝐼 = [𝑎𝑎 − (𝑎𝑎 − 2𝑡𝑡)4 ]
12
1 4
𝐼𝐼 = [𝑎𝑎 − (𝑎𝑎4 − 4. 𝑎𝑎3 . 2𝑡𝑡 + 6. 𝑎𝑎2 . (2𝑡𝑡)2 − 4. 𝑎𝑎. (2𝑡𝑡)3 + (2𝑡𝑡)4 )]
12
1
𝐼𝐼 = [8𝑎𝑎3 𝑡𝑡 − 24𝑎𝑎2 𝑡𝑡 2 + 32𝑎𝑎𝑡𝑡 3 − 16𝑡𝑡 4 ]
12
2𝑎𝑎3 𝑡𝑡 8𝑎𝑎𝑡𝑡 3 4𝑡𝑡 4
𝐼𝐼 = − 2𝑎𝑎2 𝑡𝑡 2 + − … (6)
3 3 3
Now calculating Bending and shear stresses

For Bending stress,

𝑀𝑀𝑀𝑀
𝜎𝜎 =
𝐼𝐼
We know that bending stress is maximum at point most distant from the neutral axis i.e., c = a/2, and
using Eqn. (6)
𝑎𝑎 3 1
𝜎𝜎 = 𝑀𝑀 × × � 3 �
2 2𝑡𝑡 𝑎𝑎 − 3𝑎𝑎 𝑡𝑡 + 4𝑎𝑎𝑡𝑡 2 − 2𝑡𝑡 3
2

3𝑀𝑀𝑀𝑀
𝜎𝜎 = … (7)
4𝑎𝑎3 − 12𝑎𝑎2 𝑡𝑡 + 16𝑎𝑎𝑡𝑡 2 − 8𝑡𝑡 3
For Shear stress
𝑉𝑉𝑉𝑉
𝜏𝜏 =
𝐼𝐼𝐼𝐼
We know that shear stress is maximum at neutral axis where y = 0 and t = 2t, using Eqn. (5) and (6),
𝑉𝑉 𝑡𝑡 3 1
𝜏𝜏 = × (3𝑎𝑎2 − 6𝑎𝑎𝑎𝑎 + 4𝑡𝑡 2 ) × � 3 �
2𝑡𝑡 4 2𝑡𝑡 𝑎𝑎 − 3𝑎𝑎 𝑡𝑡 + 4𝑎𝑎𝑡𝑡 2 − 2𝑡𝑡 3
2

3𝑉𝑉 3𝑎𝑎2 − 6𝑎𝑎𝑎𝑎 + 4𝑡𝑡 2

𝜏𝜏 = ×� 3 � … (8)
16𝑡𝑡 𝑎𝑎 − 3𝑎𝑎2 𝑡𝑡 + 4𝑎𝑎𝑡𝑡 2 − 2𝑡𝑡 3

Now calculating effective stress for distortion energy theory at point of maximum bending stress and
maximum shear stress,

𝜎𝜎𝑒𝑒 = �𝜎𝜎 2 + 3𝜏𝜏 2

For point of maximum bending stress (at y = a/2), we know that the shear stress is zero, hence above
equation becomes,

𝜎𝜎𝑒𝑒 = �𝜎𝜎 2
𝜎𝜎𝑒𝑒 = 𝜎𝜎
3𝑀𝑀𝑀𝑀
𝜎𝜎𝑒𝑒 = … (9)
4𝑎𝑎3 − 12𝑎𝑎2 𝑡𝑡+ 16𝑎𝑎𝑡𝑡 2 − 8𝑡𝑡 3
For point of maximum shear stress (at y = 0), we know that the bending stress is zero, hence

𝜎𝜎𝑒𝑒 = �3𝜏𝜏 2

3√3𝑉𝑉 3𝑎𝑎2 − 6𝑎𝑎𝑎𝑎 + 4𝑡𝑡 2

𝜎𝜎𝑒𝑒 = ×� 3 � … (10)
16𝑡𝑡 𝑎𝑎 − 3𝑎𝑎2 𝑡𝑡 + 4𝑎𝑎𝑡𝑡 2 − 2𝑡𝑡 3

From above two equations we observe that the point of maximum bending stress (at y = a/2) is more
critical than other points, then for Factor of Safety,
𝑆𝑆𝑌𝑌
𝑛𝑛 = … (11)
𝜎𝜎𝑒𝑒
Since all the equations are in form of iteration variables i.e., cross sectional length ‘a’ and thickness
‘t’. So, considering the parameter requirements (see section 2) and using eqn. (5), (6), (7), (8), (9), (10),
and (11) following table is constructed.
 Table 1 Design Iterations

Cross
Second Max Shear
Perimeter Section Thickness Volume Mass First Max Normal Effective Stress Strength
Moment, I FoS Stress, τ FoS
(m) Length (m) (m) (m3) (kg) Moment, QNA Stress, σ (Pa) (Pa) (Pa/N)
(m4) (Pa)
1.00E-03 1.5180E-03 4.0986 0.00001200 0.000001349607 1.417078757E+08 1.941 6.6697E+06 1.15522292E+07 23.805 7710049.2
2.00E-03 3.0120E-03 8.1324 0.00002363 0.0000026362 7.254729910E+07 3.791 3.3610E+06 5.82139641E+06 47.240 3885741.9
3.00E-03 4.4820E-03 12.1014 0.00003488 0.0000038618 4.952349657E+07 5.553 2.2582E+06 3.91125166E+06 70.310 2611301.8
0.1275

4.00E-03 5.9280E-03 16.0056 0.00004577 0.0000050283 3.803439317E+07 7.230 1.7068E+06 2.95626902E+06 93.023 1974334.5
0.510

5.00E-03 7.3500E-03 19.845 0.00005630 0.0000061378 3.115957402E+07 8.826 1.3760E+06 2.38334277E+06 115.384 1592361.2
6.00E-03 8.7480E-03 23.6196 0.00006648 0.0000071919 2.659223344E+07 10.341 1.1555E+06 2.00143720E+06 137.401 1337889.2
7.00E-03 1.0122E-02 27.3294 0.00007632 0.0000081928 2.334373908E+07 11.780 9.9805E+05 1.72867946E+06 159.081 1156278.9
8.00E-03 1.1472E-02 30.9744 0.00008581 0.0000091421 2.091977286E+07 13.145 8.7996E+05 1.52413275E+06 180.430 1020210.5
9.00E-03 1.2798E-02 34.5546 0.00009497 0.0000100416 1.904571128E+07 14.439 7.8811E+05 1.36505407E+06 201.457 914506.5
1.00E-03 1.5330E-03 4.1391 0.00001224 0.000001390010 1.389378004E+08 1.979 6.6044E+06 1.14392029E+07 24.040 7634608.4
2.00E-03 3.0420E-03 8.2134 0.00002410 0.0000027158 7.111279347E+07 3.867 3.3279E+06 5.76400534E+06 47.710 3847421.0
3.00E-03 4.5270E-03 12.2229 0.00003559 0.0000039792 4.853303064E+07 5.666 2.2357E+06 3.87240205E+06 71.015 2585344.5
0.12875

4.00E-03 5.9880E-03 16.1676 0.00004670 0.0000051825 3.726506038E+07 7.380 1.6897E+06 2.92668784E+06 93.963 1954551.6
0.515

5.00E-03 7.4250E-03 20.0475 0.00005746 0.0000063274 3.052219249E+07 9.010 1.3622E+06 2.35932115E+06 116.559 1576276.7
6.00E-03 8.8380E-03 23.8626 0.00006786 0.0000074158 2.604219626E+07 10.560 1.1438E+06 1.98112102E+06 138.810 1324265.1
7.00E-03 1.0227E-02 27.6129 0.00007791 0.0000084498 2.285554302E+07 12.032 9.8785E+05 1.71100950E+06 160.724 1144407.4
8.00E-03 1.1592E-02 31.2984 0.00008761 0.0000094311 2.047746666E+07 13.429 8.7090E+05 1.50844726E+06 182.307 1009649.3
9.00E-03 1.2933E-02 34.9191 0.00009698 0.0000103615 1.863865052E+07 14.754 7.7995E+05 1.35091214E+06 203.566 904960.5
1.00E-03 1.5480E-03 4.1796 0.00001248 0.000001431212 1.362481589E+08 2.018 6.5404E+06 1.13283669E+07 24.275 7560629.7
2.00E-03 3.0720E-03 8.2944 0.00002458 0.0000027969 6.972041280E+07 3.944 3.2954E+06 5.70773463E+06 48.180 3809848.5
3.00E-03 4.5720E-03 12.3444 0.00003630 0.0000040991 4.757197518E+07 5.781 2.2137E+06 3.83431633E+06 71.721 2559898.2
0.520

0.130

4.00E-03 6.0480E-03 16.3296 0.00004764 0.0000053397 3.651882349E+07 7.530 1.6730E+06 2.89769240E+06 94.903 1935161.2
5.00E-03 7.5000E-03 20.25 0.00005863 0.0000065208 2.990415335E+07 9.196 1.3486E+06 2.33577842E+06 117.734 1560514.0
6.00E-03 8.9280E-03 24.1056 0.00006925 0.0000076444 2.550902941E+07 10.780 1.1323E+06 1.96121251E+06 140.219 1310915.6
7.00E-03 1.0332E-02 27.8964 0.00007951 0.0000087122 2.238247822E+07 12.286 9.7786E+05 1.69369634E+06 162.367 1132777.3
 8.00E-03 1.1712E-02 31.6224 0.00008943 0.0000097262 2.004901144E+07 13.716 8.6203E+05 1.49308042E+06 184.183 999304.5
9.00E-03 1.3068E-02 35.2836 0.00009901 0.0000106882 1.824446687E+07 15.073 7.7195E+05 1.33705915E+06 205.675 895611.8
1.00E-03 1.5630E-03 4.2201 0.00001272 0.000001473220 1.336358670E+08 2.058 6.4777E+06 1.12196579E+07 24.511 7488070.8
2.00E-03 3.1020E-03 8.3754 0.00002506 0.0000028796 6.836852394E+07 4.022 3.2635E+06 5.65255181E+06 48.651 3773002.8
3.00E-03 4.6170E-03 12.4659 0.00003701 0.0000042212 4.663917754E+07 5.896 2.1922E+06 3.79697221E+06 72.426 2534948.0
0.13125
4.00E-03 6.1080E-03 16.4916 0.00004859 0.0000055001 3.579476767E+07 7.683 1.6566E+06 2.86926547E+06 95.843 1916151.7
0.525

5.00E-03 7.5750E-03 20.4525 0.00005980 0.0000067182 2.930468245E+07 9.384 1.3352E+06 2.31270041E+06 118.909 1545063.3
6.00E-03 9.0180E-03 24.3486 0.00007065 0.0000078775 2.499205074E+07 11.003 1.1210E+06 1.94169954E+06 141.629 1297832.6
7.00E-03 1.0437E-02 28.1799 0.00008114 0.0000089799 2.192392672E+07 12.543 9.6806E+05 1.67672931E+06 164.010 1121381.1
8.00E-03 1.1832E-02 31.9464 0.00009127 0.0000100273 1.963383598E+07 14.006 8.5334E+05 1.47802263E+06 186.059 989169.6
9.00E-03 1.3203E-02 35.6481 0.00010106 0.0000110216 1.786262422E+07 15.395 7.6412E+05 1.32348638E+06 207.785 886454.2
1.00E-03 1.5780E-03 4.2606 0.00001297 0.000001516042 1.310979871E+08 2.098 6.4161E+06 1.11130154E+07 24.746 7416891.5
2.00E-03 3.1320E-03 8.4564 0.00002555 0.0000029640 6.705557212E+07 4.101 3.2323E+06 5.59842562E+06 49.121 3736862.9
3.00E-03 4.6620E-03 12.5874 0.00003774 0.0000043458 4.573354097E+07 6.013 2.1710E+06 3.76034823E+06 73.132 2510479.3
0.1325

4.00E-03 6.1680E-03 16.6536 0.00004955 0.0000056637 3.509202291E+07 7.837 1.6405E+06 2.84139052E+06 96.784 1897512.1
0.530

5.00E-03 7.6500E-03 20.655 0.00006099 0.0000069195 2.872304392E+07 9.574 1.3222E+06 2.29007350E+06 120.083 1529915.6
6.00E-03 9.1080E-03 24.5916 0.00007206 0.0000081154 2.449061221E+07 11.229 1.1100E+06 1.92257045E+06 143.038 1285008.2
7.00E-03 1.0542E-02 28.4634 0.00008277 0.0000092531 2.147930176E+07 12.803 9.5846E+05 1.66009815E+06 165.653 1110212.0
8.00E-03 1.1952E-02 32.2704 0.00009313 0.0000103347 1.923139818E+07 14.300 8.4482E+05 1.46326471E+06 187.936 979238.2
9.00E-03 1.3338E-02 36.0126 0.00010313 0.0000113619 1.749261399E+07 15.721 7.5644E+05 1.31018543E+06 209.894 877482.0
The following iteration is selected based upon the design requirements as discussed in Section 2,
Table 2 Selected Design Parameters

Value
Outer Perimeter 520 mm
Length 130 mm
Thickness 1 mm
Volume 1548000 mm3
Second Moment of Inertia 1431212 mm4
Weight 40.9601 N
Maximum Normal Stress 136.25 MPa
Maximum Shear Stress 6.54 MPa
Factor of Safety 2.018
Strength 7560629.7 Pa/N

Using eqn. (3) and (4) we construct Deflection and Displacement diagrams, see Figure 6. We observe
that for cantilever beam maximum deflection and displacement occur at free end. Hence, calculating
maximum deflection and displacement from above section properties, see Table 2, at x = 3 m,

0 0
Beam Displacement (m)

0 0.5 1 1.5 2 2.5 3 0 0.5 1 1.5 2 2.5 3

-0.5
Beam Deflection

-0.02
-1
-1.5 -0.04
-2
-0.06
-2.5
-3 -0.08
Beam Length (m) Beam Length (m)

Figure 6 Beam Deflection and Displacement

• Θmax = -0.03417596 rad = -1.958˚

• ymax = - 75.19 mm

FINITE ELEMENT ANALYSIS (FEA)

The CAD modelling and the Finite Element Analysis was performed using Dassault System’s Solidworks
2021 SP0.

Procedure
The procedure used for modelling and simulation is discussed in this section.

CAD Modelling
1. Cross Section of beam was constructed on Right plane
2. Extrude command was used to give length to the beam of 3000 mm

3. Apply material to the beam ‘Aluminium Alloy 6061-T6 (SS)’.

FEA procedure
PRE-PROCESSING
1. Load the Solidworks Simulation Add-in.
2. Start a new study

3. Right click on the Part name in the Feature Manager Tree and select ‘Treat as Beam’, Two nodes
will be created on both ends of the beam.
4. Click on Joint Group from the Tree, select ‘All’ for all bodies and then check the ‘Neutral axis’ and
‘Shear centre’ boxes to display the axis. A black and red line will be generated marking that both
shear centre and neutral axis coincide due to symmetry, hence no twisting will occur.

5. Now, select ‘Fixture’ from the tree and apply fixed geometry fixture to any one of the two nodes.
6. Now right click load from the tree and select force, the click on beam selection and select the
beam, then click on face tab and select top face of the beam to apply the load.

7. Now tick mark the ‘Nonuniform Distribution’ box and select ‘Table Driven Load Distribution’ from
the drop-down menu. Then select distance as reference.
8. Now add the values in table as a function of distance, check the ‘Flip origin’ box to change the
direction of load.

9. Right click on ‘Mesh’ from Tree and click on ‘Create Mesh Quality Plot’. From the menu check
‘Render beam profile’ box and click ok to generate mesh. Again, right click on the mesh from the
tree and click on ‘Details’ to view the Mesh details.

10. Click on Run this study button to run the calculations.

POST-PROCESSING
11. After calculations are finished and results are loaded, right click on ‘Results’ in the tree to load the
plots (Stresses, strains, FoS, Shear and Bending diagrams).
12. Click on the ‘Report’ button from the tool bar to generate report of the results obtained. Add the
descriptions and click on ‘Publish’.
SIMULATION OF A SQUARE
BEAM
 Faculty of Mechanical Engineering
Description
Design a beam with one end fixed and to withstand the
distributed loading of 1 kN/m, applied across the beam.
Design Limitations and requirements:
1. Length of the member is 3 m.
2. Allowable thickness 1 mm or more, but in whole
numbers.
3. Minimum factor of Safety 2.0 according to distortion
energy theory.
4. Mean perimeter dimensions must be a factor of 5.
5. Cross-section of the beam must be square.
Simulation of a Square
Beam
Date: 2 January 2021
Designer: Zayan bin Shahid
Study name: Bending
Analysis type: Static
Table of Contents
DESCRIPTION………….…………………………….20
ASSUMPTIONS……………………………………….21
MODEL INFORMATION………….………………21
STUDY PROPERTIES………….………………….22
UNITS………….…………………………………………22
MATERIAL PROPERTIES………….……………23
LOADS AND FIXTURES………….………………23
MESH INFORMATION………….…………………24
RESULTANT FORCES……….……………………24
BEAMS………….………………………………………..24
STUDY RESULTS………….………………………..25
CONCLUSION………….………………..……………30
 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Assumptions
1. The material is Isotropic and Homogeneous.
2. The material obeys Hooke's law.
3. The beam is initially straight with a constant cross section throughout.
4. The beam has an axis of symmetry in the plane of bending.
5. The beam is under static equilibrium i.e.
a. Σ F = 0 (x, y, z)
b. Σ M = 0 (x, y, z)

Model Information

Model name: Square Beam

Current Configuration: Default
Beam Bodies:
Document Name and Document
Formulation Properties
Reference Path/Date Modified
SolidBody 1(Boss- Section Standard-Custom D:\University\Zayan\
Extrude1) Section Area: 0.000516m^2 Semester
Length:3,000mm 5\ME314\CEP\FEA\Sq
Volume:0.001548m^3 uare Beam
Beam – Uniform C/S
Mass Density:2,700kg/m^3 SW\Square
Mass:4.1796kg Beam.SLDPRT
Weight:40.9601N Jan 2 13:17:55
2021
 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Study Properties
Study name Bending
Analysis type Static
Mesh type Beam Mesh
Solver type Automatic
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Result folder SOLIDWORKS document
(D:\University\Zayan\Semester
5\ME314\CEP\FEA\Square Beam SW)

Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2
 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Material Properties
Model Reference Properties Components
Name: 6061-T6 (SS) SolidBody 1(Boss-
Model type: Linear Elastic Extrude1)(CEP part)
Isotropic
Default failure Max von Mises Stress
criterion:
Yield strength: 2.75e+08 N/m^2
Tensile strength: 3.1e+08 N/m^2
Elastic modulus: 6.9e+10 N/m^2
Poisson's ratio: 0.33
Mass density: 2,700 kg/m^3
Shear modulus: 2.6e+10 N/m^2
Thermal expansion 2.4e-05 /Kelvin
coefficient:
Curve Data:N/A

Loads and Fixtures

Fixture name Fixture Image Fixture Details
Entities: 1 Joint(s)
Type: Fixed Geometry

Fixed-1

Load name Load Image Load Details

Entities: 1 Beam (s)
Reference: Face< 1 >
Values: Table Driven
Non uniform load options: Table Driven Load
Force-1 Distribution (Distance)
Values: (m, N/m)
(0, 0)
(3, 1000)
 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Mesh information
Mesh type Beam Mesh

Mesh information - Details

Total Nodes 87
Total Elements 85
Time to complete mesh(hh;mm;ss): 00:00:01
Computer name:

Resultant Forces
Reaction forces
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N 0 1,500 0 1,500
Reaction Moments
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 3,000 3,000
Free body forces
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N 0 0 0 0
Free body moments
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 0

Beams
Beam Forces
Beam Axial
Joints Shear1(N) Shear2(N) Moment1(N.m) Moment2(N.m) Torque(N.m)
Name (N)
Beam- 8.06795e-
1 0 0 -2.74113e-09 0 0
1(Boss- 07
Extrude1) 2 0 0 -1,500 -3,000 0 0
Beam Stresses
Upper bound axial
Beam Bending Bending Torsional
Joints Axial(N/m^2) and
Name Dir1(N/m^2) Dir2(N/m^2) (N/m^2)
bending(N/m^2)
Beam- 1 0 0.000124491 0 0 0.000124491
1(Boss-
2 0 -1.36248e+08 0 0 1.36248e+08
Extrude1)
 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Study Results

Name Type Min Max

Stress1 Axial and bending 2.818e+04N/m^2 1.362e+08N/m^2
Element: 1 Element: 85

Square Beam-Bending-Stress-Stress1
 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Name Type Min Max

Displacement1 URES: Resultant Displacement 0.000e+00mm 7.572e+01mm
Node: 86 Node: 1

Square Beam-Bending-Displacement-Displacement1
 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Name Type
Shear-Moment Plot1 Moment about Dir1

Square Beam-Bending-Shear-Moment Plot-Shear-Moment Plot1

 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Name Type
Shear-Moment Plot2 Shear Force in Dir2

Square Beam-Bending-Shear-Moment Plot-Shear-Moment Plot2

 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Name Type Min Max

Factor of Safety1 Automatic 2.018e+00 9.760e+03
Node: 85 Node: 1

Square Beam-Bending-Factor of Safety-Factor of Safety1

 Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021

Name Type Min Max

Stress2 Shear in DIR 2 3.733e-03N/m^2 6.940e+06N/m^2
Element: 1 Element: 85

Square Beam-Bending-Stress-Stress2

Conclusion
A hollow square cantilever beam was to be designed with multiple design constraints as discussed in the
above sections. After analysing the beam with multiple cross section dimensions, following parameters
are selected which could provide a strength to weight ratio of 7568340.898 Pa/N and an FoS of 2.0184:
• cross section width: 130 mm
• cross section thickness: 1 mm
Faculty of Mechanical Engineering Zayan bin Shahid
02-Jan-2021
COMPARISON
The results obtained from FEA analysis and manual calculations are approximately same with relative
error calculated as follows,
Table 3 FEA and Manual calculations comparison

Manual Calculations FEA Calculations Relative Error

Length 130 mm 130 mm 0%
Thickness 1 mm 1 mm 0%
Volume 1548000 mm3 1548000 mm3 0%
Weight 41.001876 N 40.9601 N 0.102%
Maximum Normal Stress 136.248 MPa 136.24816 MPa 0.00012%
Maximum Shear Stress 6.5404 MPa 6.9396985 MPa 5.754%
Displacement 75.19 mm 75.721008 mm 0.701%
Factor of Safety 2.01838 2.0184 0.001%
Strength 7560629.7 Pa/N 7568340.898 Pa/N 0.102%

The differences in the calculations could arise due to the assumptions made. The error in weight was
due to different values of gravitational acceleration ‘g’ used i.e., 9.8 m/s2 in FEA and 9.81 m/s2 in
manual calculations. Moreover, the weight of the beam was also ignored which could serve a purpose
in the error in shear stress and other values.

CONCLUSION
A cantilever beam was to be designed which was under non-uniform distributed load with a maximum
value of 1000 N/m, the beam was to be made of Aluminium Alloy 6061-T6 (SS). The selection of Final
Design was done by judging all the iterations based on design requirements provided as discussed in
section 1 and 2. All the iterations were performed with setting outer perimeter of cross section and
calculating length from it and using variable thicknesses, considering all these parameters the
iterations were compared with each other (see Table 2) and the limitations provided. After a thorough
review and consideration, the final design was selected as the one with outer perimeter equal to 520
mm. Other parameters of Final Design are as follows:

• V = 1500 N • Volume = 1548000 mm3

• M = 3000 Nm • σmax = 136.24816 MPa
• Perimeter = 520 mm • τmax = 6.9396985 MPa
• Cross sectional length = 130 mm • ymax = 75.721008 mm
• Wall thickness = 1 mm • FoS = 2.0184
 Material: Aluminum Alloy 6061-T6

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