Machine Elements

Dr Martina Zimmermann
Universitt Siegen
Institut fr Konstruktion
Machine Elements
02. Fundamentals of strength analysis
Universitt Siegen
Machine Elements
Concept for a strength analysis

Load
external loads
Strength
geometry
material
effective stress
load cases
strength data
theories for
combined
stress situation
strength depending on
shape or design
reduced stress
strength conditions
allowable
external loads
Steinhilper/Rper: Maschinen- und Konstruktionselemente
necessary
dimensions
necessary
material strength
given
safety
02.1
Machine Elements
Universitt Siegen
Example for a free-body diagram
External rim brake
Free-body diagram of each part of the brake

02.2
Machine Elements
Universitt Siegen
Geometry data
Moment of inertia
INA Wlzlager Schaeffler KG:

Technisches Taschenbuch
Section modulus
02.3
Machine Elements
Universitt Siegen
Geometry data
Moment of inertia
INA Wlzlager Schaeffler KG:

Technisches Taschenbuch
Section modulus
02.4
Machine Elements
Universitt Siegen
Polar moment of inertia
Beitz/
Beitz/Kttner:
Kttner:
Dubbel Taschenbuch fr den Maschinenbau
02.5
Machine Elements
Universitt Siegen
Beitz/
Beitz/Kttner:
Kttner:
02.6
Machine Elements
Universitt Siegen
Beitz/
Beitz/Kttner:
Kttner:
02.7
Universitt Siegen
Machine Elements
Moment of inertia
A1
Steiner Theorem
e.g.:
e1
e2
A2
X
YS
I x = I x + x2 A
I y = I y + y2 A
b h3
2
I1 =
+ e1 A1
12
b h3
2
I2 =
+ e2 A2
12
I xx = I1 + I 2
02.8
Universitt Siegen
Machine Elements
Moment of inertia
A1
Center of area:
e.g.:
e1
e2
Ys2
A2
YS
Ys1
Ai Ysi A1 Ys1 + A2 Ys 2
Ys =
=
A1 + A2
Ai
02.9
Universitt Siegen
Machine Elements
Section modulus
A1
Section modulus
e.g.:
b
e1
e2
A2
X
YS
I
W=
max. edge distance
I xx
Wxx =
max(Ys ; b)
02.10
Machine Elements
Universitt Siegen
Martha SchneiderSchneider-Brger:
Brger:
StahlbauStahlbau-Profile
02.11
Machine Elements
Universitt Siegen
Calculation example
The following data related to the parameter a have to be estimated:
moment of inertia and section modulus for the axis y and z
02.12
Universitt Siegen
Machine Elements
Modes of stress
Tension
Compression
Bending
Torsion
Shear
A
A
02.13
Universitt Siegen
Machine Elements
Modes of stress
Contact
(surface pressure)
Buckling
l
(exemplary case 1)
02.14
Universitt Siegen
Machine Elements
Tension
FL
FL
FL
2
FL
2
d
g
m
FG
FG
02.15
Universitt Siegen
Machine Elements
Compression
Fp
Fp
2
d
02.16
Universitt Siegen
Machine Elements
Bending
FB
FA
FB
bending stress
FA
l/2
y
d/2
F
bending moment curve
-d/2
x = l/2
Mb
02.17
Machine Elements
Universitt Siegen
Torsion
Mt
d
r
Mt
Mt
F/2
F/2
02.18
Universitt Siegen
Machine Elements
Shear
F
F
x
F
y
d/2
-d/2
true shear stress
02.19
Universitt Siegen
Machine Elements
Load cases for bending

concentrated load
distributed load
Fl
l
Mb = F l
2
3
3
F
l
F
l
F
f=
f=
l
3 E I
8 E I
double supported beam
double supported beam
Fl
Fl
Mb =
Mb =
F
=
=
4
8
F
F l3
F l3
f=
f=
l
l
48 E I
384 E I
built-in beam
F l built-in beam
Fl
F
=
=
M
M
=
=
b
b
8
12
F
F l3
F l3
f=
f=
l
l
192 E I
384 E I
cantilever beam
Mb =
cantilever beam
02.20
Universitt Siegen
Machine Elements
Example: simple supported bar

F
A
C
x
B
l
2
l
2
F
2
F
2
F
2
y
V
F
2
V = - F/2
x
V = - F/2
l
2
A
F
2
M = F/2 x
Mmax = F l/4
M = F/2 (l x )
x
x
y
02.21
Universitt Siegen
Machine Elements
Singularity+load intensity functions I

Graph of q(x)
Singularity
Concentrated
moment
Expression for q(x)
q(x) = M (x a)-2
x
a
Concentrated
force
q(x) = M (x a)-2
q
x
a
Unit step
w0
q(x) = w0 (x a)0
a
02.22
Universitt Siegen
Machine Elements
Singularity+load intensity functions II

Singularity Graph of q(x)
Expression for q(x)
Ramp
w0
q
b
a
Inverse ramp
q(x) = w0 (x a)0 w0/b (x a)1

a
Parabolic
shape
w0
q(x) = w0/b (x a)1
x
b
q(x) = (x a)2
a
x
02.23
Machine Elements
Universitt Siegen
Stress element and stress tensor
S = xy
xz
xy
y
yz
xz
yz
z
Hamrock, Fundamentals of Machine Elements
02.24
Universitt Siegen
Machine Elements
Stresses at a random plane

=
x + y
2
x y
2
= xy cos 2
cos 2 + xy sin 2
x y
2
sin 2
principal stress:
1,2 =
x + y
2
2xy +
( x y )2
4
with = 0
1,2
x y
=
2
+ y
+ 2xy with = x
02.25
Universitt Siegen
Machine Elements
Mohrs circle for plane stress
x
c = (x + y)/2
xy
0 2
xy
xy
c
2
1
y
2
02.26
Universitt Siegen
Machine Elements
Mohrs circle for plane stress
Given:
x = 100 N/mm2
y = -40 N/mm2
xy = 50 N/mm2
N
mm2
100
80
xy
60
40
20
N
mm2
-60 -40 -20

-20
20
40
60
80 100 120
-40
-60
-80
-100
02.27
Machine Elements
Universitt Siegen
Strain element and strain tensor
1
T = xy
2
1
xz
2
1
xy
2
y
1
yz
2
xz
2
1
yz
02.28
Universitt Siegen
Machine Elements
Strains at random plane

1,2 =
x + y
2
1
x y
xy +
2
2
2
1
x y
= 2 xy +
2
2
2
max
xy
2 = tan 1
x y
= (1 2 ) sin 2
1 + 2 1 2
+
cos 2
2
2
02.29
Machine Elements
Universitt Siegen
Maximum-Normal-Stress Theory
(MNST)
A part subjected by any combination of loads will fail
whenever the greatest positive principal stress exceeds the
tensile strength limit
This theory works best for fibrous brittle materials, some
glasses, and reasonable well for brittle materials (e.g. grey
cast iron)
Expected failure by a separation fracture perpendicular to
the main stress direction
Closure:
2
v = 1 = 0,5 x + y + ( x y ) + 4 2
02.30
Universitt Siegen
Machine Elements
Maximum-Shear-Stress Theory
(MSST)
A part subjected by any combination of loads will fail
whenever the maximum shear stress exceeds the tensile
strength limit
A good theory for predicting the yielding of ductile materials
or compression loading with brittle materials
Expected failure by a sliding fracture
Closure
tri-axial stress state
v = 2 max = 3 1
plane stress
v = 2 max =
2
)
+
4
x
y
2
02.31
Machine Elements
Universitt Siegen
Distortion-Energy Theory (DET)

von Mises Criterion
Valid for ductile materials with plastic deformation before
failure or dynamic loading with failure by fatigue
Greatest accuracy of all recognised theories
Closure
tri-axial stress state
v = (1 / 2 ) (1 2 ) + ( 2 3 ) + (3 1 )
2
= 2x + 2y + 2z ( x y + y z + x z ) + 3( 2xy + 2yz + 2xz )
plane stress
v = 12 + 22 1 2 = 2x + 2y x y + 3 2
02.32
Universitt Siegen
Machine Elements
Real load situations I

stress at rear car axle
load
pressure in a condenser
chamber of a reactor
stress at car wheel
torque of a driving system
of a roll stand
time
Buxbaum: Betriebsfestigkeit
02.33
Universitt Siegen
Machine Elements
Real load situations II

Bending moment at the
axle of a passenger car
load
multiple load in the gravity

center of a military airplane
pressure in a pipeline
time
multiple load in the gravity

center of a cargo transport
airplane
Component diameter, d in mm
Buxbaum: Betriebsfestigkeit
02.34
Universitt Siegen
Machine Elements

Load
external loads
Strength
geometry
material
load cases
effective stress
theories for
combined
stress situation
reduced stress
02.35
Universitt Siegen
Machine Elements
Cyclic Stress
+
02.36
Universitt Siegen
Machine Elements
Special Cases of Cyclic Stresses

+
max
max
+
max
0
min
02.37
Universitt Siegen
Machine Elements

Load
external loads
Strength
geometry
material
effective stress
load cases
strength data
theories for
combined
stress situation
reduced stress
02.38
Universitt Siegen
Machine Elements
Strength limits of different materials

in the static stress-strain diagram
l
=
l0
02.39
Universitt Siegen
Machine Elements
Whler diagram
(S-N diagram)
exemplary for steel with stress ratio R = -1
stress amplitude (lg)
low-cycle
fatigue
N < 510
5 4
high-cycle,
finite-life fatigue
N < 2106
high-cycle,
infinite-life fatigue
N > 210
2 6
theoretical process
real process
N
number of cycles to failure (lg)
02.40
Universitt Siegen
Machine Elements
Smith diagram
(mean stress diagram)
Rm
Rp0,2
Rp0,2 Rm
w
02.41
Machine Elements
Universitt Siegen
Smith diagram
Tabellenbuch: Roloff/Matek
02.42
Universitt Siegen
Machine Elements
Haigh diagram
Rm
Rp0,2
w
Rp0,2 Rm
02.43
Universitt Siegen
Machine Elements
Material
static strength
tensile
proportional
strength
strength
dynamic strength/fatigue strength

tension/compression
bending
reversed
released
reversed
released
2
in N/mm
175
240
200
340
230
300
260
420
270
340
300
470
320
370
340
520
S235JR
E 295
E 335
E 360
60-440
490-590
590-710
690-830
225
285
325
355
C 35, C 35E
C 45, C 45E
C 60, C 60E
580-730
660-00
780-930
365
410
490
300
340
380
420
480
570
330
370
410
28 Mn 6
690-830
490
380
570
38Cr2
46Cr2
34Cr4
37Cr4
41Cr4
690-830
780-930
780-930
830-980
880-1080
440
540
590
630
665
360
400
450
450
450
25CrMo4
34CrMo4
42CrMo4
32CrMo12
780-930
880-1080
980-1180
1230-1420
590
665
765
1030
36CrNiMo4
34CrNiMo6
30CrNiMo8
980-1180
1080-1270
1230-1420
50CrV4
980-1180
torsion
reversed
released
140
180
210
240
170
210
230
260
550
630
700
230
260
280
300
340
400
410
700
280
400
510
650
780
780
780
390
440
480
480
480
660
750
810
810
810
270
300
330
330
330
360
450
550
550
550
400
450
500
570
650
780
860
980
430
480
540
600
730
810
940
1040
300
330
370
420
450
550
630
730
785
885
1030
500
500
570
860
860
980
540
540
600
940
940
1040
370
370
420
630
630
730
785
500
860
540
940
370
630
02.44
Universitt Siegen
Machine Elements
Material
static strength
tensile
proportional
strength
strength
dynamic strength/fatigue strength

tension/compression
bending
reversed
released
reversed
released
2
in N/mm
240
300
260
420
C15, C 15E
590-780
355
15Cr3
16MnCr5
20MnCr5
20MoCr4
690-880
780-1080
980-1270
780-1080
440
590
685
590
280
370
460
370
400
600
700
600
330
390
500
390
15CrNi6
17CrNiMo6
880-1180
1080-1320
635
785
410
560
650
800
EN-GJL-150
EN-GJL-200
EN-GJL-300
150
200
290
40
60
80
EN-GJMW-400
390
215
*GS38
*GS45
*GS52
*GS60
370
440
510
590
EN-GJS-400-15
EN-GJS-500-7
EN-GJS-600-3
EN-GJS-700-2
400
500
600
700
torsion
reversed
released
180
210
560
670
850
670
210
270
340
270
280
430
490
430
450
600
780
1040
300
410
450
550
t=60; c=180
t=90; c=280
t=130; c=380
60
90
130
110
170
220
50
80
110
80
130
180
110
t=170; c=280
~140
~240
~150
~280
185
225
255
295
150
180
210
240
190
230
260
300
150
180
210
240
250
300
350
400
85
100
120
140
110
130
160
180
250
320
380
440
120
150
180
210
200
250
300
360
170
210
250
300
290
360
440
530
10
130
150
170
150
200
250
290
*GS: probably new name for international standard
02.45
Universitt Siegen
Machine Elements
Material
tension/compression
static
reversed
released
S235JR
S275
E 295
E 335
E 360
235
275
295
335
365
150
180
210
250
300
235
275
295
335
365
330
380
410
470
510
bending
reversed
N/mm2
170
200
240
280
330
C 15
17Cr3
16MnCr5
20MnCr5
17CrNiMo
440
510
635
735
835
330
390
430
480
550
440
510
635
735
835
610
710
890
1030
1170
370
390
440
540
610
610
670
740
920
1040
250
290
360
420
470
210
220
270
310
350
250
290
360
420
470
C22E
C 45, C 45E
C 60, C 60E
46Cr2
41Cr4
50CrMo4
30CrNiMo8
340
490
580
650
800
900
1050
220
280
325
370
410
450
510
340
490
580
630
710
760
870
490
700
800
910
1120
1260
1470
240
310
350
390
440
480
550
410
520
600
670
750
820
930
245
350
400
455
560
630
735
165
210
240
270
330
330
375
245
350
480
455
510
560
640
GS-38
GS-45
GS-52
GS-60
200
230
260
300
160
185
210
240
200
230
260
300
260
300
340
390
150
180
210
240
260
300
340
390
115
135
150
175
90
105
120
140
115
135
150
175
EN-GJS-400
EN-GJS-500
EN-GJS-600
EN-GJS-700
250
300
360
400
140
155
190
205
240
270
330
355
350
420
500
560
220
270
270
300
345
380
470
520
200
240
290
320
115
130
160
175
195
225
275
305
static
released
static
torsion
reversed
released
290
350
410
470
510
140
160
170
190
210
120
140
150
160
190
140
160
170
190
210
02.46
Universitt Siegen
Machine Elements
Safety factors
for static loading:
against fracture:
s=2 - 4 for temperatures < crystal regeneration temperature

s=1,5 - 2 for temperatures > crystal regeneration temperature
against instability:
s=3 - 5 for all temperatures
against deformation: s=1,2 - 2 for temperatures < crystal regeneration temperatures

s=1,0 1,5 for temperatures > crystal regeneration temperatures
for dynamic loading:

against fracture:
s=2 - 4 for temperatures < crystal regeneration temperature

s=1,5 - 2 for temperatures > crystal regeneration temperature
against instability:
against deformation: s=1,2 - 2 for temperatures < crystal regeneration temperatures

s=1,0 1,5 for temperatures > crystal regeneration temperatures
against fatigue:

02.47
Machine Elements
Universitt Siegen
Axial load on plate with hole
Rectangular plate with hole subjected to axial load. (a) Plate with crosssectional plane. (b) Half of plate with stress distribution.
02.48
Machine Elements
Universitt Siegen
Stress concentration factor for rectangular plate with central hole. (a) Axial
Load. [Adapted from Collins (1981).]
02.49
Machine Elements
Universitt Siegen
Stress concentration factor for rectangular plate with central hole. (b)
Bending. [Adapted from Collins (1981).]
02.50
Machine Elements
Universitt Siegen
Stress concentration factor for rectangular plate with fillet. (a) Axial Load.
[Adapted from Collins (1981).]
02.51
Machine Elements
Universitt Siegen
Stress concentration factor for rectangular plate with fillet. (b) Bending Load.
02.52
Machine Elements
Universitt Siegen
Stress concentration factor for rectangular plate with groove. (a) Axial Load.
02.53
Machine Elements
Universitt Siegen
Stress concentration factor for rectangular plate with groove. (b) Bending.
02.54
Machine Elements
Universitt Siegen
Stress concentration factor for round bar with fillet. (a) Axial load. [Adapted
from Collins (1981).]
02.55
Machine Elements
Universitt Siegen
Stress concentration factor for round bar with fillet. (b) Bending. [Adapted
02.56
Machine Elements
Universitt Siegen
Stress concentration factor for round bar with fillet. (c) Torsion. [Adapted
02.57
Machine Elements
Universitt Siegen
Stress concentration factor for round bar with groove. (a) Axial load.
02.58
Machine Elements
Universitt Siegen
Stress concentration factor for round bar with groove. (b) Bending. [Adapted
02.59
Machine Elements
Universitt Siegen
Stress concentration factor for round bar with groove. (c) Torsion.
02.60
Machine Elements
Universitt Siegen
Dynamic stress concentration factor

acc. to Thum
Material
carbon steel (S235JR...S355JR)
heat-treatable steel
spring steel
light metal
02.61
Universitt Siegen
Machine Elements
te
e
Steinhilper/Rper, Maschinen- und Konstruktionselemente
ca
s
ts
ca
st
iro
n

acc. to Siebel I
ic
nit
e
st
au
l
ee
st
tee
ral s
u
t
c
stru
)
teel
le s
i
t
c
l (du
steel
eatable
heat-tr
ss
bra
ral
du
brass
Mg-alloy
Al-alloy,
spring steel
02.62
Universitt Siegen
Machine Elements

acc. to Siebel II
Notch
Load case 0*
tension,
compression
*
2
Notch
Load case 0*
tension,
compression
4
D+d
4
D+d
4
2
+
D+d
4
1
+
D+d
torsion
2
D
2 1
+
D
bending
2
D
2 4
+
D
torsion
2
D
2 3
+
D
bending
bending
4
b
4 2
+
b
tension,
compression
bending
2
b
2 2
+
b
tension,
compression
2
d
2
d
2 2
+
d
2 1
+
d
bending
torsion
torsion
0* = related stress gradient of a notchnotch-free component

* = related stress gradient of a notched component
02.63
Machine Elements
Universitt Siegen
Example K factor for plain stress

bending
torsion
02.64
Machine Elements
Universitt Siegen
Size factor, b2
Geometry size factor
Component diameter, d in mm
02.65
Universitt Siegen
Machine Elements
Surface finish factor, b1
Surface finish factor

surface finish R = 2
m
t
rol
led
, fo
rge
d,
an
dc
as
ts
urf
ac
e
Tensile strength, Rm in N/mm2

02.66
Machine Elements
Universitt Siegen
Strength analysis for static loads

1. Calculation of stress in the critical section
, , reduced
2. In case of a notch-effect:
calculation of maxium stress
max=c
3. Define the allowable stress
allowable=Re, Rp0,2, Rm
3. Verify the given safety against failure
S=allowable / max
S=allowable / max
02.67
Machine Elements
Universitt Siegen
Strength analysis for dynamic loads

1. Calculation of maximum stress amplitude
max, max, reduced
2. Define the allowable stress
D,rel; D,rev for tension. compression or bending
D,rel; D,rev
3. Integrate the various influence factors
D,allowable =
D b1 b 2
b b
D,allowable = D 1 2
K
K
4. Verify the given safety against failure

S=D, allowable / max
02.68
Machine Elements
Universitt Siegen
Example for a strength analysis

structural steel:
S235JR
3 load cases:
a) simple static force:
F=150 kN
b) completely reversed force:
F=80 kN
b) mixed dynamic force:
F=150 kN 80 kN
02.69
Machine Elements
Universitt Siegen
Example for a strength analysis

structural steel:
S235JR ; Re = 240 N/mm2
w = 160 N/mm2
3 load cases:
a) simple static force:
F=100 kN
b) completely reversed force:
F=70 kN
b) mixed dynamic force:
F=55 kN 45 kN
02.70

Machine Elements

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Machine Elements

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Dr Martina Zimmermann

Concept for a strength analysis

02. Fundamentals of strength analysis

Example for a free-body diagram

External rim brake

Free-body diagram of each part of the brake

INA Wlzlager Schaeffler KG:

02. Fundamentals of strength analysis

INA Wlzlager Schaeffler KG:

02. Fundamentals of strength analysis

Polar moment of inertia

02. Fundamentals of strength analysis

Polar moment of inertia

02. Fundamentals of strength analysis

Polar moment of inertia

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis

true shear stress

02. Fundamentals of strength analysis

Load cases for bending

02. Fundamentals of strength analysis

Example: simple supported bar

Singularity+load intensity functions I

Expression for q(x)

02. Fundamentals of strength analysis

Singularity+load intensity functions II

Expression for q(x)

q(x) = w0 (x a)0 w0/b (x a)1

q(x) = w0/b (x a)1

Stress element and stress tensor

Hamrock, Fundamentals of Machine Elements

02. Fundamentals of strength analysis

Stresses at a random plane

Hamrock, Fundamentals of Machine Elements

02. Fundamentals of strength analysis

Mohrs circle for plane stress

Mohrs circle for plane stress

-60 -40 -20

Strain element and strain tensor

Hamrock, Fundamentals of Machine Elements

Hamrock, Fundamentals of Machine Elements

02. Fundamentals of strength analysis

Strains at random plane

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis

Distortion-Energy Theory (DET)

= 2x + 2y + 2z ( x y + y z + x z ) + 3( 2xy + 2yz + 2xz )

Real load situations I

02. Fundamentals of strength analysis

Real load situations II

multiple load in the gravity

multiple load in the gravity

02. Fundamentals of strength analysis

Concept for a strength analysis

Steinhilper/Rper: Maschinen- und Konstruktionselemente

02. Fundamentals of strength analysis

02. Fundamentals of strength analysis