Chapter 4

Load and Stress Analyis

A. Bazoune

Chapter Outline
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16
4.17

Equilibrium and Free-Body Diagram Shear Force and Bending Moments in Beams Singularity Functions (Omitted) Stress Cartesian stress Components Mohr's Circle for Plane Stress General Three-Dimensional Stress Elastic Strain Uniformly Distributed Stresses Normal Stresses for Beams in Bending Beams with Asymmetrical Sections (Omitted) Shear Stresses for Beams in Bending Torsion Stress Concentration Stress in Pressurized Cylinders Stresses in Rotating Rings (Omitted) Press and Shrink Fits

LEC-02
Equilibrium and Free-Body Diagram Shear Force and Bending Moments in Beams

ME 307 MACHINE DESIGN I

Chapter 4: Load and Stress Analysis

4.1

Equilibrium and Free-Body Diagram

Equilibrium
System: used to denote any isolated part or portion of a machine or structure. A system may consist of a particle, or several particles, a part of rigid body, an entire rigid body, or several rigid bodies. Equilibrium: A system is said to be in equilibrium if it is motionless or has a constant velocity, i.e.; zero acceleration. The phrase static equilibrium is also used to imply that the system is at rest. For equilibrium, the forces and moments acting on the system balance such that

F = Fx i + Fy j + Fz k = 0 (Vectorial Representation )
or

(4-1)

Fx = 0 Fy = 0 Fz = 0
and

(Scalar Representation )
(4-2)

M = Mx i + My j + Mz k = 0 (Vectorial Representation )
or

Mx = 0 My = 0 Mz = 0

(Scalar Representation )

Free-Body Diagram (FBD)

Free Body Diagram (FBD) is a sketch that shows a body of interest isolated from all interacting bodies. Once the body of interest is selected, the forces and moments exerted by all other bodies on the one being considered must be determined and shown in the diagram, see Figure 4.1

F2

F1

F3

F4

Figure 4-1

The isolation of a subsystem

Using FBD for force analysis serves the following important points:

Dr. A. Aziz Bazoune

LEC-02

3/10

ME 307 MACHINE DESIGN I

Chapter 4: Load and Stress Analysis

The diagram establishes the directions of reference axes, provides a place to record the dimensions of the subsystems and the magnitudes and directions of the known forces and helps in assuming the directions of unknown forces. The diagram simplifies your thinking because it provides a place to store one thought while proceeding to the next. The diagram provides a means of communicating your thoughts clearly and unambiguously to other people. Careful and complete construction of the diagram clarifies fuzzy thinking by bringing out various points that are not always apparent in the statement or in the geometry of the total problem. Thus, the diagram aids in understanding all facets of the problem. The diagram helps in recording progress in the solution and in illustrating the method used. The diagram allows others to follow your reasoning, showing all forces.

CONSTRUCTING A FREE BODY DIAGRAM (FBD)

STEP 1: STEP 2: STEP 3: Decide which body or combination of bodies is to be shown on the FBD. Prepare a drawing or sketch of the outline of this FBD. Carefully trace around the boundary of the free body and indentify all the forces exerted by contacting or attracting bodies were that were removed during the isolation process. Choose a set of coordinate axes to be used in solving the problem and indicate these directions on the FBD. Place on the diagram any dimensions required for solution of the problem.

STEP 3:

EXAMPLE 4-1
Draw a free body diagram for the beam shown in Fig. 4-2a.

Solution
Referring to Figure 4-2 (b):

Two beam.

concentrated

forces

Figure 4-2 (a)

P and P 1 2

are applied to the

The weight of the beam is represented by the force W , which has a line of action that passes through the center of gravity G of the beam.
Figure 4-2 (b)

The beam is supported at the left end with a smooth pin and bracket and at the right end with a roller. The reaction of the left support is represented by the forces The reaction of the roller is represented by the force the surface of the beam.

Ax

and

Ay .

By , which acts normal to

Dr. A. Aziz Bazoune

LEC-02

4/10

ME 307 MACHINE DESIGN I

Chapter 4: Load and Stress Analysis

EXAMPLE 4-2
A cylinder is supported on a smooth inclined surface by a two-bar frame as shown in Figure 4-3a. Assume that the cylinder has a weight W and that the two bars have negligible weight. Draw a free body diagram for a) The cylinder b) The two-bar frame c) The pin at C.

Solution
a) The FBD for the cylinder is shown in Fig. 4-3(b). The weight W of the cylinder acts through the center of gravity

Figure 4-3(a)

G . The forces N 1

and

N2

act normal to the smooth surfaces at the points of contact. b) The FBD for the two-bar frame is shown in Fig. 4-3(c). The action of the smooth pin and bracket supports at points A and C are represented by the forces

Figure 4-3(b)

Ax and Ay

and

Cx and Cy ,

respectively. Notice that the pin forces at B are internal and do not appear on the FBD shown in Fig. 43(c). c) Since bar BC is a link , the resultant

F c

of forces

Cx and Cy

must have a

line of action along the axis of the link. As a result, the FBD for pin C can be drawn as shown in Fig.4-3 d.

Figure 4-3(c)

Figure 4-3(d)

EXAMPLE 4-3 (Example 4-1 in the Textbook)

Figure 4-4(a) shows a simplified rendition of a gear reducer where the input and output shafts AB and CD are rotating at constant speed The input and output torques (torsional moments) The pitch radii of gears

i and o , respectively. are Ti = 240 lbfiin and To ,

and

respectively. The shafts are supported in the housing by bearings at A, B, C and D.

G1

and

G2

are

r1 = 0.75 in

r2 = 1.5 in ,

respectively. Draw the FBD of each member and determine the net reaction forces and moments at all points.

Dr. A. Aziz Bazoune

LEC-02

5/10

ME 307 MACHINE DESIGN I

Chapter 4: Load and Stress Analysis

Figure 4-4(a)

Gear Reducer

Figure 4-4(b) Gear Box

Figure 4-4(b) Output shaft Figure 4-4(c) Input shaft

Solution
Simplifying assumptions: 1. Gears

G1

and

G2

are spur gears with a standard pressure angle

= 20

2. The bearings are self aligning and the shafts can be considered to be simply supported. 3. The weight of each member is negligible. 4. Friction is negligible. 5. The mounting bolts at E, F, H and I are of the same size. The separate FBD of the members are shown in Figs 4-4 b-d. The force transmitted between the spur gears is not tangential but at the pressure angle . Thus,

N = F tan
Input Shaft AB

(1)

Dr. A. Aziz Bazoune

LEC-02

6/10

ME 307 MACHINE DESIGN I

Chapter 4: Load and Stress Analysis

Mx

= 0 F ( 0.75 ) 240 = 0 F = 320 lbf

(2)

and the normal force is

N = F tan = 320 tan 20 = 116.5 lbf

(3) (4) (5) (6) (7)

Fy

= 0 RAy + RBy = F = 320 lbf

Fz
Mz My

= 0 RAz + RBz = N = 116.5 lbf

= 0 RAy (2.5 ) F (1.5 ) = 0 RAy = 0.6F lbf=192 lbf = 0 RBz (1.5 ) RAz (1.0 ) = 0 RAz = 1.5RBz

Substitution of Eq. (6) into Eq. (4) gives

RBy = 128 lbf . Similarly, substitution

of Eq. (7) into Eq. (5) gives Output Shaft CD

RBz = 46.6 lbf and RAz = 69.9 lbf .

Following the same procedure,

Fy
Fz
Mz

= 0 RDy + RCy = F = 320 lbf

(8) (9) (10) (11) therefore

= 0 RDz + RCz = N = 116.5 lbf

= 0 RCy (2.5 ) RDy (1.5 ) = 0 RCy = 0.6 RDy = 0 RCz (1.0 ) RDz (1.5 ) = 0 RCz = 1.5RDz
of Eq. (10) into Eq. (8) gives

My
Substitution

RCy = 192 lbf ,

RDy = 320 192 = 128 lbf . Similarly, substitution of Eq. (11) into Eq. (9) gives RDz = 46.6 lbf , therefore RCz = 69.9 lbf .
The output moment is

To = 240 + 320 ( 0.75 ) = 480 lbfiin

Notice that in Fig.4-4(b) the net force from bearing reactions is zero whereas the net moment about the x-axis is

T = ( r1 + r2 ) Rcy + ( r1 + r2 ) RDy = ( r1 + r2 ) Rcy + RDy T = 2.25(192) + 2.25(128) = 720 lbfiin

)
7/10

Dr. A. Aziz Bazoune

LEC-02

ME 307 MACHINE DESIGN I

Chapter 4: Load and Stress Analysis

This value is the same as Ti 4(a). (Remember

+To = 240 + 480 = 720 lbfiin

as shown in Fig. 4-

Gear Box
The reaction forces

RE , RF , RH ,

and

RI

from the mounting bolts cannot be

determined from the equilibrium equations as there are too many unknowns. Only three equations are available

Fy = Fz = Mx

= 0.

In case you were

wondering about assumption 5, here is where we will use it. The gear box tends to rotate about the x-axis because of pure torsional moment of

720 lbfiin . The bolt

forces must provide an equal but opposite torsional moment. The center of rotation relative to the bolts lies at the center of the centroid of the bolt cross-sectional area. Thus if the bolt areas are equal: the center of rotation is at the center of the four bolts, a distance of bolt forces are equal

( 4 2 ) + (5 2 )

= 3.2015 in

from each bolt; the

(R

= RF = RH = RI = R ) ,

and each bolt force is

perpendicular to the line from the bolt to the center of rotation. This gives a net torque from the four bolts of

4R (3.2015 ) = 720 lbfiin .

Thus,

RE = RF = RH = RI = 56.22 lbf

4.2
F 1, F 2,

Shear Force and Bending Moments in Beams

R1
and

Figure 4-5a shows a beam supported by reactions forces and

R2

and loaded by the concentrated

F 3.

If the beam is cut at some section located at

x =x1

and the left

hand portion is removed as a free body, an internal shear force must act on the cut surface to ensure equilibrium.

and bending moment

The shear force is obtained by summing the forces on the isolated sections. The bending moment is the sum of the moments of the forces to the left of the section taken about an axis through the isolated section.

The sign conventions used for bending moment and shear force are shown in Figure 4-6.

Dr. A. Aziz Bazoune

LEC-02

8/10

ME 307 MACHINE DESIGN I

Chapter 4: Load and Stress Analysis

Cut

Figure 4-5

FBD of simply supported beam with

and

shown in positive direction

Figure 4-6

Sign conventions for bending and shear.

Shear force and bending moment are related by

V =

dM dx

(4-3)

Sometimes the bending is caused by a distributed load

q ( x ) , as shown in Figure 4-7; q ( x )

is

called the load intensity with units of force per unit length and is positive in the positive y direction. It can be shown that differentiating Eq. (4-3) results in

dV d2M = =q dx dx 2

(4-4)

Dr. A. Aziz Bazoune

LEC-02

9/10

ME 307 MACHINE DESIGN I

Chapter 4: Load and Stress Analysis

Figure 4-7 Integrating Eqs (4-3) and (4-4) result in

VB

Distributed load on beam.

dV = q dx =VB VA V x
A A

xB

(4-5)

which states that the change in shear force from A to B is equal to the area of the loading diagram between

xA

and

xB.

Similarly
MB

dM = V dx = MB MA M x
A A

xB

(4-6)

which states that the change in moment from A to B is equal to the area of the shear force diagram between

xA

and

xB.

Dr. A. Aziz Bazoune

LEC-02

10/10