Stress/strain analysis of a thin cylinder

By Tomas Dubec
 1. Introduction
The analysis of stress and strain in engineering structures is a critical aspect of ensuring the
safety and reliability of components under various loading conditions. This experimental
study focused on the stress and strain analysis of a thin cylinder subjected to internal
pressure. The primary objective was to measure surface strains using experimental apparatus
and integrate the relevant theoretical concepts to gain insights into the mechanical behaviour
of the cylinder. The "thin cylinder theory" formed the basis of the examination, emphasizing
principal stresses such as hoop stress and axial stress. Understanding these principal stresses
is crucial for assessing the structural integrity of thin-walled cylindrical components.
Furthermore, the report delves into Young's modulus, which establishes the relationship
between stress and strain in a component subjected to uni-axial loading. This fundamental
material property is essential for characterizing the deformations experienced by the thin
cylinder under various conditions. Poisson's ratio is another key aspect considered in this
experiment. It explains the relationship between longitudinal and lateral strain in a
component subjected to uni-axial loading. The investigation extends to complex stress and
strain scenarios, exploring the relationship between principal stresses and principal strains in
a component subjected to bi-axial loading. This complexity is addressed through the
application of Mohr's circle of strain, a graphical method that aids in visualizing and
understanding stress and strain relationships. The integration of experimental measurements
with theoretical concepts will enhance our understanding of the mechanical behaviour of
thin-walled cylinders and contribute to the broader field of structural engineering.

2. Objectives
This experimental study aimed to investigate the mechanical behaviour of a thin cylinder
subjected to internal pressure. The primary objectives are as follows:

● Determination of Young’s Modulus: Utilizing an experimental apparatus to measure

strains on the surface of the thin cylinder, the primary goal is to determine the
Young’s modulus of the material.
● Determination of Poisson’s Ratio: This value will be compared to the known or
expected Poisson’s ratio to evaluate the material's deformation characteristics under
pressure.
 ● Calculation of Principal Stresses: Using measured principal strain values, the
experimental determination of principal stresses on the cylinder walls will be carried
out.
● Application of Failure Theories: The application of appropriate theories of failure will
be employed to determine the 'factors of safety' for the thin cylinder at its maximum
operating pressure.
● Construction and Comparison of Mohr’s Circle of Strain: A Mohr’s circle of strain
will be constructed using the principal strain gauge values. The non-principal strain
gauge readings will then be compared to those obtained from Mohr’s circle.

Throughout these objectives, a comprehensive understanding of the mechanical properties

and structural behaviour of the thin cylinder under internal pressure will be gained,
combining experimental findings with established theoretical principles.

3. Equipment
The SM1007 Thin Cylinder apparatus was a specialized piece of equipment designed to
investigate the behaviour of thin-walled aluminium cylinders under diverse stress conditions.
The apparatus comprised a thin-walled aluminium cylinder with an 80mm inside diameter
and a 3mm wall thickness. This cylinder was pressurized with oil using a hydraulic pump,
and six sensors on its surface measured strain. Additionally, a mechanical pressure gauge and
an electronic sensor were employed to measure hydraulic pressure within the cylinder.

Components of the Equipment

● Thin-Walled Aluminium Cylinder: Diameter: 80mm, Wall Thickness: 3mm, Material:

Aluminium
● Hydraulic Pump: Operated to pressurize the cylinder with oil.
● Strain Sensors: Six sensors on the cylinder surface measured strain, providing
valuable data on deformations and stresses.
● Mechanical Pressure Gauge: Measured hydraulic pressure within the cylinder,
providing a crucial parameter for understanding the stress state.
● Hand Wheel: Adjusted the apparatus configuration, allowing for the selection of
either open-end or closed-end setups.
● Release Valve: Facilitated the controlled release of hydraulic pressure.
 ● Socket Communications Cable: Connected electronic sensors to data acquisition
systems for real-time monitoring and recording of data.

Fig-1 Equipment setup

Apparatus Setup:

● Open-End Configuration: In the open-end configuration, axial loads were borne by

the frame, eliminating direct axial stress on the cylinder. The hand wheel was fully
screwed in, ensuring that the axial force generated by the pressurized oil was
transmitted into the frame rather than the cylinder.
● Closed-End Configuration: In the closed-end configuration, axial loads were borne by
the cylinder, creating direct axial stress on the thin-walled aluminium cylinder. The
hand wheel was wound out, allowing pistons to move outward against the cylinder
end caps. This ensured that there was no contact with the frame, and the axial force
was transmitted into the cylinder itself.

4. Method / Test Procedure

● The hydraulic pump was utilized to vary the pressure on the apparatus. The values at
which the pressure was set depended on the specific experimental requirements. The
six surface sensors on the cylinder measured strain, providing valuable data on its
response to different loading conditions.
● Hydraulic pressure was monitored using a mechanical gauge and an electronic sensor,
ensuring accurate and redundant measurements. Results were recorded based on the
readings obtained from the strain gauges and hydraulic pressure sensors.
 ● The recorded data was analysed to determine the response of the cylinder under uni-
axial and bi-axial loading conditions. Strain measurements and hydraulic pressure
values for both configurations were compared.
● By following this experimental method, comprehensive insights into the behaviour of
the SM1007 Thin Cylinder apparatus under different loading conditions were
obtained.

5. Results
Below is a summary of the thin cylinder apparatus results:

Open End Condition

Strain Gauge Readings
Pressure 1 2 3 4 5 6
0 0 0 0 0 0 0
0.5 93.7 -28.6 2.5 32.7 62.8 95.3
1 190.3 -59.5 2.9 66.3 127.7 193.4
1.51 289.5 -91.2 2.7 100.9 195.2 293.1
1.98 379.7 -120.2 2.3 132.2 256.2 383.8
2.51 481.9 -153.6 1.7 167.5 324.8 487
3.03 583.2 -188 1.2 202.7 393.2 589.6

Closed-End Condition
Strain Gauge Readings / 1 x 10-6
Pressure 1 2 3 4 5 6
3.01 477.9 103.2 191.3 297.6 384.5 493.1
Table 1 Gauge value tabulation
 6. Calculations

6.1 Young's Modulus - Determined using the ‘open ends’ condition.

Pressure Stress Strain

0.00 0.00 0.00

0.50 7.000 95.00

1.00 13.00 192.0

1.51 20.00 291.0

1.98 26.00 382.0

2.51 33.00 484.0

3.03 40.00 586.0

Table 2 Stress and strain determination
 45
43
41
39
37
35
33
31
29
27
Stress in MNm-2

25
23
21
19
17
15
13
11
9
7
5
3
1
0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575 600

Strain in 𝜖𝐻/X10-6
 Fig-2 Stress v/s strain plot

σ H Δy y 2− y 1 y 2−0 40 ×1 06 N m−2 9 −2
Youngs Modulus(E)= = = = = =68.2 ×1 0 N m
ϵ H Δx x 2−x 1 x 2−0 586 ×1 0
6

6.2 Poisson’s Ratio- Determined using the ‘open ends’ condition.

Longitudinal
Pressure Lateral Strain Strain

0 0 0

0.50 -28.60 93.70

1.00 -59.50 190.3

1.51 -91.20 289.5

1.98 -120.2 379.7

2.51 -153.6 481.9

3.03 -188.0 583.2

Table 3 Strain determination
 Poisson’s Ratio
50

40

30
Literal strain in MNm-2

20

10

0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620

Longitudinal strain MNm-2

Fig-3 Lateral strain v/s longitudinal strain plot

−ϵ A Δy y 2− y 1 y 2−0 28.6 ×1 0−6

Poission ' s Ratio(ν )= = = = = =0.31
ϵH Δx x 2−x 1 x 2−0 93.7 ×1 0−6

6.3 Principal Stresses- Determined for the ‘closed ends’ condition.

Experimental principal stress calculation.

−6 −6
ε H =485.5 ×1 0 , ε A=103.2 ×1 0

E (ε H +ν ε A ) 68.2 ×1 09 (485.5× 1 0−6 +0.31 ×103.2 ×1 0−6 ) −2

Hoop stress(σ ¿¿ H )= 2
= 2
=39.4 MN m ¿
1−ν 1−0.3 1

E ( ε A + ν ε H ) 68.2 ×1 0 9 ( 103.2 ×1 0−6 + 0.31× 485.5 ×1 0−6 ) −2

Axial Stress( σ A )= 2
= 2
=19.18 MN m
1−ν 1−0.3 1

Theoretical principal stress calculation

pD 3.01 ×80 −2
Hoop stress(σ ¿¿ H )= = =40.13 MN m ¿
2t 2 ×3

pD 3.01 ×80 −2
Axial stress( σ ¿¿ A)= = =20.06 MN m ¿
2t 4×3

6.4 Factor of Safety: Determined for the ‘closed ends’ condition.

σ y =Maximum yield stress of cylinder material aluminium alloy 6063−T 6 is214 MPa=214MN
m-2

Major principal stress = Hoop stress(σ ¿¿ H )¿ = 39.4 MNm-2

Intermediate principal stress = Axial stress(σ ¿¿ A)¿ = 19.18 MNm-2

As per Tresca theory:

σ y 214
FoS= = =5.4
σ H 39.4

As per Von Mises theory:

 √ √
2 2
σ y 21 4
FoS= 2 2
= 2 2
=5.9
σ H −σ H σ A + σ A 39. 4 −39.4 ×19.18+19.1 8
6.5 Mohr’s circle of strain: Created for the ‘closed ends’ condition.

Fig-4 Mohr’s circle plot

 7. Discussion
The experimental value of Young's modulus for the cylinder material was found to be 68.2
GNm-2, while the theoretical value was reported as 69 GNm -2. To assess the accuracy of the
experimental result, the percentage error can be calculated using the following formula:

Experimental−Theoretical 68.20−69.00
% error= ×100= =−1.15 %
Theoretical 69.00

This small percentage error indicates that the experimental value is close to the theoretical
value, suggesting good agreement between the measured and expected Young's modulus for
the cylinder material.

To compare the experimental value of Poisson's ratio to the theoretical value, the percentage
error can be calculated using the formula:

Experimental−Theoretical 0.31−0.33
% error= ×100= =−6.06 %
Theoretical 0.33

This indicates a moderate difference between the experimental and theoretical values,
suggesting that there may be some discrepancy or variation in the material behaviour as
compared to the expected Poisson ratio.

To compare the experimental values for the principal stresses to the theoretical values we
have, Principal stress: Experimental value- Hoop stress = 39.4 MNm -2, Axial stress = 19.18
MNm-2. Theoretical value- Hoop stress = 40.13 MNm-2, Axial stress 20.13 MNm-2.
Percentage error for hoop stress = -1.82% & percentage error for axial stress = -4.73%. These
values represent the differences between the experimental and theoretical values for the
principal stresses, indicating a relatively small discrepancy in both cases.

As per the Tresca and von Mises theories, the Factor of Safety (FoS) values are 5.4 and 5.9,
respectively. The Factor of Safety measures how much a structure or material can endure
loads beyond what it is designed for before failure occurs. A higher FoS implies a greater
margin of safety. In this case, both the Tresca and von Mises theories provide FoS values
well above 1, which is typically considered a minimum safe threshold. A FoS of 5.4 (Tresca)
and 5.9 (von Mises) indicates a substantial level of safety, suggesting that the cylinder is not
likely to fail under the levels of pressure produced during the experiment. A structure is
considered to be more robust and less prone to failure, the higher the FoS.

To compare the recorded (experimental) readings for strain gauges 3, 4, and 5 with those
values determined from Mohr's circle of strain (theoretical), the percentage error was
calculated for each strain gauge using the formula:

Experimental−Theoretical
% error= ×100
Theoretical

191.3−190.8
Strain Gauge 3: % Error= ×100=0.26 %
190.8

297.6−294.35
Strain Gauge 4: % Error= × 100=1.10 %
294.35

384.5−385
Strain Gauge 5: % Error= ×100=0.13 %
385

These calculated percentage errors represent the differences between the recorded
experimental strain readings and the values determined from Mohr's circle of strain. The
relatively low percentage of errors suggests that the experimental and theoretical values are in
close agreement, indicating a good match between the recorded and theoretical strain values
for all three strain gauges.

8. Conclusion
In this experimental study, a thorough investigation was conducted into the stress and strain
analysis of a thin-walled aluminium cylinder subjected to internal pressure. The primary
focus was on understanding the mechanical behaviour of the cylinder through the application
of the "thin cylinder theory," considering principal stresses such as hoop stress and axial
stress.

Young's Modulus was determined using the 'open ends' condition, resulting in a value of 68.2
GMm-2. This fundamental material property provides insight into the relationship between
stress and strain under uni-axial loading. Poisson's Ratio was determined under the 'open
ends' condition, yielding a value of 0.31. This ratio helps in understanding the deformation
characteristics of the material under pressure. Hoop stress and axial stress were
experimentally calculated under the 'closed ends' condition, resulting in 39.40 MNm -2 and
19.18 MNm-2 respectively. Theoretical calculations closely aligned with experimental values,
validating the accuracy of the measurements. The factors of safety were determined using
Tresca and Von Mises theories, providing values of 5.4 and 5.9, respectively. These factors
of safety help in assessing the structural integrity of the thin cylinder under its maximum
operating pressure.

This experimental study successfully achieved its objectives, providing valuable insights into
the mechanical properties and structural behaviour of thin-walled cylinders under internal
pressure. The combination of theoretical concepts and experimental findings contributes to
the broader field of structural engineering, emphasizing the importance of such analyses in
ensuring the safety and reliability of engineering components.

References
Matweb, A. (n.d.). ASM Matweb. Retrieved from
https://asm.matweb.com/search/SpecificMaterial.asp?bassnum=MA6063T6)