Design Optimization (ME41613)

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Engineering Design Optimization (ME60079)

GOUTAM CHAKRABORTY
DEPARTMENT OF MECHANICAL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGY KHARAGPUR
 Lecture 7

Introduction to Design Optimization

Objectives:

After listening to this lecture you should be able to

• Define material constraints for static loading using failure theories

• Define material constraints for variable loading
 Stress at a point

𝝈𝝈𝒙𝒙𝒙𝒙 𝝈𝝈𝒙𝒙𝒙𝒙 𝝈𝝈𝒙𝒙𝒙𝒙

𝝈𝝈 = 𝝈𝝈𝒚𝒚𝒚𝒚 𝝈𝝈𝒚𝒚𝒚𝒚 𝝈𝝈𝒚𝒚𝒚𝒚
𝒚𝒚
𝝈𝝈𝒛𝒛𝒛𝒛 𝝈𝝈𝒛𝒛𝒛𝒛 𝝈𝝈𝒛𝒛𝒛𝒛
𝒙𝒙
𝝈𝝈𝒙𝒙𝒙𝒙 = 𝝈𝝈𝒚𝒚𝒚𝒚, 𝝈𝝈𝒚𝒚𝒚𝒚 = 𝝈𝝈𝒛𝒛𝒛𝒛 , 𝝈𝝈𝒙𝒙𝒙𝒙 = 𝝈𝝈𝒛𝒛𝒛𝒛
 Principal stresses
𝝈𝝈𝟑𝟑

𝝈𝝈𝟐𝟐 𝝈𝝈𝟏𝟏

𝒚𝒚 𝝈𝝈𝟏𝟏 > 𝝈𝝈𝟐𝟐 > 𝝈𝝈𝟑𝟑

𝒙𝒙
 Mohr’s circle

𝝉𝝉 𝝉𝝉

𝝈𝝈𝟏𝟏 − 𝝈𝝈𝟐𝟐
𝑹𝑹 =
𝟐𝟐

𝝈𝝈𝟑𝟑 𝝈𝝈𝟐𝟐 𝝈𝝈𝟏𝟏 𝝈𝝈 𝝈𝝈

𝝈𝝈𝟏𝟏 + 𝝈𝝈𝟐𝟐
, 𝟎𝟎
𝟐𝟐
 Maximum shear stress
𝝈𝝈𝟑𝟑 𝝈𝝈𝟑𝟑

𝝈𝝈𝟐𝟐 𝝈𝝈𝟐𝟐

𝝈𝝈𝟏𝟏 𝝈𝝈𝟏𝟏
𝜻𝜻𝟑𝟑

𝜻𝜻𝟐𝟐 𝝈𝝈𝟏𝟏 − 𝝈𝝈𝟐𝟐 𝝈𝝈𝟐𝟐 − 𝝈𝝈𝟑𝟑 𝝈𝝈𝟑𝟑 − 𝝈𝝈𝟏𝟏

𝜻𝜻𝟏𝟏 𝝉𝝉max = max , ,
𝟐𝟐 𝟐𝟐 𝟐𝟐
 Strain energy
𝝈𝝈

For (Hookean) linear solid

𝟑𝟑 𝟑𝟑
d𝑼𝑼 = 𝝈𝝈 d𝜺𝜺 𝟏𝟏 𝟏𝟏
𝑼𝑼 = � � 𝝈𝝈𝒊𝒊𝒊𝒊 𝜺𝜺𝒊𝒊𝒊𝒊 = 𝝈𝝈𝟏𝟏 𝜺𝜺𝟏𝟏 + 𝝈𝝈𝟐𝟐 𝜺𝜺𝟐𝟐 + 𝝈𝝈𝟑𝟑 𝜺𝜺𝟑𝟑
𝟐𝟐 𝟐𝟐
𝒊𝒊=𝟏𝟏 𝒋𝒋=𝟏𝟏

𝜺𝜺
For isotropic material

1
𝑼𝑼 = 𝝈𝝈1 𝝈𝝈1 − 𝝁𝝁𝝈𝝈2 − 𝝁𝝁𝝈𝝈3 + 𝝈𝝈2 𝝈𝝈2 − 𝝁𝝁𝝈𝝈3 − 𝝁𝝁𝝈𝝈1 + 𝝈𝝈3 𝝈𝝈3 − 𝝁𝝁𝝈𝝈1 − 𝝁𝝁𝝈𝝈2
2𝑬𝑬

𝟏𝟏
= 𝝈𝝈𝟐𝟐𝟏𝟏 + 𝝈𝝈𝟐𝟐𝟐𝟐 + 𝝈𝝈𝟐𝟐𝟑𝟑 − 𝟐𝟐𝝁𝝁 𝝈𝝈𝟏𝟏 𝝈𝝈𝟐𝟐 + 𝝈𝝈𝟐𝟐 𝝈𝝈𝟑𝟑 + 𝝈𝝈𝟏𝟏 𝝈𝝈𝟑𝟑
𝟐𝟐𝑬𝑬
 Distortion energy
𝟏𝟏
Average stress 𝝈𝝈𝟏𝟏 + 𝝈𝝈𝟐𝟐 + 𝝈𝝈𝟑𝟑
𝟑𝟑

Volumetric strain 𝜺𝜺𝟏𝟏 + 𝜺𝜺𝟐𝟐 + 𝜺𝜺𝟑𝟑

𝟏𝟏 𝟏𝟏
Energy change in dilation � 𝝈𝝈𝟏𝟏 + 𝝈𝝈𝟐𝟐 + 𝝈𝝈𝟑𝟑 � 𝜺𝜺𝟏𝟏 + 𝜺𝜺𝟐𝟐 + 𝜺𝜺𝟑𝟑
𝟐𝟐 𝟑𝟑

Distortion energy = Strain energy – energy in dilation

𝟏𝟏 + 𝝁𝝁 𝟐𝟐
𝑼𝑼𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅 = 𝝈𝝈𝟏𝟏 + 𝝈𝝈𝟐𝟐𝟐𝟐 + 𝝈𝝈𝟐𝟐𝟑𝟑 − 𝝈𝝈𝟏𝟏 𝝈𝝈𝟐𝟐 − 𝝈𝝈𝟐𝟐 𝝈𝝈𝟑𝟑 − 𝝈𝝈𝟏𝟏 𝝈𝝈𝟑𝟑
𝟑𝟑𝑬𝑬
𝟏𝟏 + 𝝁𝝁
= 𝝈𝝈𝟏𝟏 − 𝝈𝝈𝟐𝟐 𝟐𝟐 + 𝝈𝝈𝟐𝟐 − 𝝈𝝈𝟑𝟑 𝟐𝟐 + 𝝈𝝈𝟑𝟑 − 𝝈𝝈𝟏𝟏 𝟐𝟐
𝟔𝟔𝑬𝑬
 von Mises stress

von Mises effective stress is defined as

The uniaxial tensile stress that would

create the same distortional energy as
created by the actual combined applied
stresses.

𝟏𝟏 + 𝝁𝝁 𝟐𝟐 𝟐𝟐 𝟐𝟐
𝟏𝟏 + 𝝁𝝁 𝟐𝟐
𝑼𝑼𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅 = 𝝈𝝈𝟏𝟏 − 𝝈𝝈𝟐𝟐 + 𝝈𝝈𝟐𝟐 − 𝝈𝝈𝟑𝟑 + 𝝈𝝈𝟑𝟑 − 𝝈𝝈𝟏𝟏 = 𝝈𝝈𝑽𝑽−𝑴𝑴
𝟔𝟔𝑬𝑬 𝟑𝟑𝑬𝑬

𝝈𝝈𝟏𝟏 − 𝝈𝝈𝟐𝟐 𝟐𝟐 + 𝝈𝝈𝟐𝟐 − 𝝈𝝈𝟑𝟑 𝟐𝟐 + 𝝈𝝈𝟑𝟑 − 𝝈𝝈𝟏𝟏 𝟐𝟐

𝝈𝝈𝑽𝑽−𝑴𝑴 =
𝟐𝟐
 Octahedral shear stress

𝝈𝝈𝟏𝟏 𝝈𝝈𝟐𝟐 𝝈𝝈𝟑𝟑

𝑻𝑻𝒐𝒐𝒐𝒐𝒐𝒐 = � 𝟏𝟏 +
𝒏𝒏 � 𝟐𝟐 +
𝒏𝒏 � 𝟑𝟑
𝒏𝒏
𝟑𝟑 𝟑𝟑 𝟑𝟑

𝝈𝝈1 + 𝝈𝝈2 + 𝝈𝝈3

𝝈𝝈𝒐𝒐𝒐𝒐𝒐𝒐 =
3

𝝈𝝈12 𝝈𝝈22 𝝈𝝈23

𝝈𝝈2𝒐𝒐𝒐𝒐𝒐𝒐 + 𝝉𝝉2𝒐𝒐𝒐𝒐𝒐𝒐 = 𝑻𝑻2𝒐𝒐𝒐𝒐𝒐𝒐 = + +
3 3 3

1
𝝉𝝉2𝒐𝒐𝒐𝒐𝒐𝒐 = 𝝈𝝈1 − 𝝈𝝈2 2
+ 𝝈𝝈2 − 𝝈𝝈3 2
+ 𝝈𝝈3 − 𝝈𝝈1 2
9

Source: Mechanical design- blogger

 Von Mises stress
distribution

Picture sources: Semantic scholar, researchgate

 Failure due to static loading
Failure surface: 𝒇𝒇 𝝈𝝈𝟏𝟏 , 𝝈𝝈𝟐𝟐 , 𝝈𝝈𝟑𝟑 = 𝟎𝟎

𝒇𝒇 𝝈𝝈𝟏𝟏 , 𝝈𝝈𝟐𝟐 , 𝝈𝝈𝟑𝟑 < 𝟎𝟎 Safe zone

𝒇𝒇 𝝈𝝈𝟏𝟏 , 𝝈𝝈𝟐𝟐 , 𝝈𝝈𝟑𝟑 > 𝟎𝟎 Unsafe zone 𝝈𝝈𝟑𝟑

𝒇𝒇 𝝈𝝈𝟏𝟏 , 𝝈𝝈𝟐𝟐 , 𝝈𝝈𝟑𝟑 = 𝟎𝟎

𝝈𝝈𝟐𝟐
𝝈𝝈𝟏𝟏
 Maximum Principal Stress Theory
𝝈𝝈𝟑𝟑
𝝈𝝈𝟐𝟐

𝝈𝝈𝟏𝟏

𝝈𝝈𝟐𝟐
𝝈𝝈𝟏𝟏

max 𝝈𝝈𝟏𝟏 , 𝝈𝝈𝟐𝟐 , 𝝈𝝈𝟑𝟑 ≤ 𝝈𝝈𝒖𝒖

 Maximum Shear Stress Theory

𝝈𝝈𝟑𝟑
𝝈𝝈𝟏𝟏 = 𝝈𝝈𝟐𝟐 = 𝝈𝝈𝟑𝟑

𝝈𝝈𝟏𝟏 − 𝝈𝝈𝟐𝟐 𝝈𝝈𝟐𝟐 − 𝝈𝝈𝟑𝟑 𝝈𝝈𝟑𝟑 − 𝝈𝝈𝟏𝟏 𝝈𝝈𝒚𝒚

max , , ≤
𝟐𝟐 𝟐𝟐 𝟐𝟐 𝟐𝟐

𝝈𝝈𝟐𝟐

𝝈𝝈𝟏𝟏
 Maximum von Mises Stress Theory/
Maximum Distortion Energy Theory
𝝈𝝈𝟑𝟑
𝝈𝝈𝟏𝟏 = 𝝈𝝈𝟐𝟐 = 𝝈𝝈𝟑𝟑

𝟐𝟐 𝟐𝟐 𝟐𝟐
𝝈𝝈𝟏𝟏 − 𝝈𝝈𝟐𝟐 + 𝝈𝝈𝟐𝟐 − 𝝈𝝈𝟑𝟑 + 𝝈𝝈𝟑𝟑 − 𝝈𝝈𝟏𝟏 ≤ 𝟐𝟐𝝈𝝈𝟐𝟐𝒚𝒚

𝝈𝝈𝟐𝟐

𝝈𝝈𝟏𝟏
 3D Representation of failure surfaces

Source: aw_efendi
Comparison of von Mises Stress Theory and Maximum
Shear Stress Theory
𝝈𝝈𝟑𝟑
𝝈𝝈𝟏𝟏 = 𝝈𝝈𝟐𝟐 = 𝝈𝝈𝟑𝟑
𝝈𝝈𝟐𝟐

𝝈𝝈𝟏𝟏

𝝈𝝈𝟐𝟐

𝝈𝝈𝟏𝟏
Failure due to variable loading
𝝈𝝈𝒂𝒂 Failure loci
𝝈𝝈𝒚𝒚 Soderberg line:
Yield line 𝝈𝝈𝒎𝒎 𝝈𝝈𝒂𝒂
+ = 𝟏𝟏
𝝈𝝈𝒚𝒚 𝝈𝝈𝒆𝒆
𝝈𝝈𝒆𝒆
Constraint:
Soderberg line
𝝈𝝈𝒎𝒎 𝝈𝝈𝒂𝒂
+ ≤ 𝟏𝟏
safe 𝝈𝝈𝒚𝒚 𝝈𝝈𝒆𝒆

𝝈𝝈𝒚𝒚 𝝈𝝈𝒖𝒖 𝝈𝝈𝒎𝒎

𝝈𝝈𝒂𝒂 Failure loci
𝝈𝝈𝒚𝒚 Soderberg line:
Yield line 𝝈𝝈𝒎𝒎 𝝈𝝈𝒂𝒂
+ = 𝟏𝟏
𝝈𝝈𝒚𝒚 𝝈𝝈𝒆𝒆
𝝈𝝈𝒆𝒆 Goodman line:
Goodman line
𝝈𝝈𝒎𝒎 𝝈𝝈𝒂𝒂
+ = 𝟏𝟏
Gerber line 𝝈𝝈𝒖𝒖 𝝈𝝈𝒆𝒆
Soderberg line
Gerber line:
𝟐𝟐
𝝈𝝈𝒎𝒎 𝝈𝝈𝒂𝒂
𝝈𝝈𝒚𝒚 𝝈𝝈𝒖𝒖 𝝈𝝈𝒎𝒎 + = 𝟏𝟏
𝝈𝝈𝒖𝒖 𝝈𝝈𝒆𝒆
Thank You