Design for

Fluctuating Load
Slides by Ramkumar
Mechanical Department
Bits goa

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 Stress Concentration
While discussing we have seen no. of elementary equations (for bending,
torsion etc..) .
These equations are based on some assumption like no discontinuities in
the component, in practice it is not possible. (grooves , oil holes, keyways
are necessary)
Consider., a plate
“Stress concentration” is defined as the
localization of high stresses due to
irregularities present in the component
and abrupt changes of the cross section.
In order to consider the stress
concentration and find out localized
Stress a factor called stress
concentration factor is used

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 Kt = Highest value of actual stress near the discontinuity
Nominal stress obtained by elementary equations

Kt= бmax/ б0 = ‫ح‬max/ ‫ح‬0

t – theoretical stress concentration factor

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Design is complete disaster

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Comparison: Worst Design Vs Right Design

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

FE Analysis helps us to know the localized stresses

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Sources of Stress Concentration

Abrupt changes in geometry can give rise to stress

concentrations
–e.g. screw threads, stepped shafts and holes

•Other sources for stress discontinuities

–Contact points
–Material discontinuities, e.g. an inclusion
–Residual stresses, e.g. welding and cold
working
–Cracks!

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Evaluation of Stress Concentration

Can calculate stress concentration factors:

–Analytically using Theory of Elasticity

–Numerically using Finite Elements Methods
–Experimentally using
•Very small strain gages
•Brittle coating
•Photoelasticity
•Moiré

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Stress Concentration Chart

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Stress Concentration Chart

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Stress Concentration Chart

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Stress Concentration Chart

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Stress Concentration Chart

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 The stress concentration factors are found out by considering epoxy
models which is not completely with respect to actual material and
condition of the particular component used, so it is called as “Theoretical
stress concentration factor”.
Therefore there is difference between theoretical and actual stress
concentration of the component.
Guidelines for the designer:
• Ductile material under static load – not effected by Kt - plastic
deformation – ignore Kt for ductile material under static loading.
• Ductile material under Fluctuating load-Stress exceeds endurance limit-
use Kt
• Brittle material: Kt is used for component made of brittle material
subjected to both static and fluctuating load.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Force Flow Analogy

(a) Force Flow around Sharp Corner (b) Force Flow around Rounded Corner

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Reduction of Stress Concentration due to V-notch

(a) Original Notch (b) Multiple Notches (c) Drilled Holes (d) Removal of
Undesirable Material

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Reduction of Stress Concentration due to Abrupt Change in C/S

(a) Original Component (b) Fillet Radius (C) Undercutting (d) Addition of
Notch
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
Reduction of Stress Concentration in Shaft with Keyway

(a) Original Shaft (b) Drilled Holes (c) Fillet Radius

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Reduction of Stress Concentration in Threaded Components

(a) Original Component (b) Undercutting (c) Reduction in Shank Diameter

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Spur Gear | Stress Concentration severity

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

EX 1

Plate material grey CI FG 200 N/mm2. Thickness of the plate?

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 EX 2

Shaft is made of brittle material UTS= 300 N/mm2. FOS is 3. Determine

dimension?
Shaft bends due to applied load. Bending stress critical at fillet sec & center of
span
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
Specimen for Fatigue Test

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Rotating Beam Fatigue Testing Machine

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Notch sensitivity for various materials

Fig. 5.22 Notch Sensitivity Charts (for Reversed Bending and Reversed Axial Stresses)

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Notch sensitivity for various materials

Fig. 5.23 Notch Sensitivity Charts (for Reversed TorsionalShear Stresses)

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Surface Finish Factor

SF factor for CI
is 1

Fig. 5.24 Surface Finish Factor

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 EX 3 ( Infinite life problems)

A Plate made of steel 20C8 (Sut= 440 N/mm2) in a hot rolled and
normalized condition is shown in Fig. It is subjected to completely
reversed axial load of 30 kN. The notch sensitivity factor q can be taken
as 0.8 and the expected reliability is 90%. The size factor is 0.85. The
factor of safety is 2. Determine the plate thickness for infinite life.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 EX 4 ( Infinite life problems)

A component machined from a plate made of steel 45C8 (Sut =630

N/mm2) is shown in Fig. It is subjected to completely reversed axial
force of 50 kN. The expected reliability is 90% and the factor of safety is
2. The size factor is 0.85. Determine the plate thickness t for infinite life
, if the notch sensitivity factor is 0.8.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 EX 5 (Finite life problems)

EX 5

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 EX 6 (Cumulative damage in
fatigue)
The work cycle of a mechanical component subjected to completely
reversed bending stress consists of the following three elements:
• +- 350 N/mm2 for 85%of time
• +- 400 N/mm2 for 12%of time
• +- 500 N/mm2 for 3%of time
The material for the component is 50C4(S ut = 660 N/mm2) and the
corrected endurance limit of the component is 280 N/mm2.
Determine the life of the component.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
Component subjected to fluctuating axial or bending stress

Modified Goodman Diagram

for Axial and Bending Stresses
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EX 7 Infinite Life | Fluctuating Load

Cantilever beam (Circular C/S)

Material: 40C8 (Sult = 600 N/mm2,Syt = 380 N/mm2),
Machined

Notch Sensitivity factor at the fillet is 0.9

Expected Reliability = 90% [Kc = 0.897]

FoS = 2

Determine the diameter d of the beam at the fillet cross
section.
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956