CIRCULAR SHAFT EM 327: MECHANICS OF MATERIALS LABORATORY

EXPERIMENT: CIRCULAR SHAFT OBJECTIVES: Study the combined effects of torsion and flexural loading, by observing the behavior of a circular shaft loaded in torsion and bending. INTRODUCTION: In this task of the experiment, a cantilevered hollow circular shaft with a long bar attached to the end will be used to investigate the combined effects of torsion, shear, and flexure loads at different locations on the shaft. BACKGROUND: There are many examples of machine members that are subjected to combined loading. In this task the combined effects of flexure, shear, and torsion will be examined and the location of the most severe stress will be determined. It is usually necessary to calculate the stresses at more than one point to determine where the highest stresses occur. As long as the stresses remain below the proportional limit of the material the superposition method can be used to combine the stresses at any point of a loaded member. Figure 9a shows the specimen and the loading conditions. The bending stresses are found by using equation 3.1 Mc (3.1) = I Where: M is the bending moment at the location where the stress is to be determined c is the distance from the neutral axis to the point where the stress is to be determined I is the moment of inertia with respect to the centroidal axis, ro4/4-ri4/4 The cross shear stresses are given in equation 3.2.
VQ = It

2 2 Qmax = (ro ri )[ y ] 2
Where: V is the shear force Q is the first moment of the cross sectional area, see Appendix C. t is the thickness of the section where the stress is to be determined The torsional shear stress is given in equation 3.3.

Tc J

(3.3)

Where: T is the resisting torque at the point where the stress is to be determined J is the polar moment of inertia with respect to the longitudinal axis of the shaft, ro4/2 - ri4/2 Figure 9b shows the addition of two equal and opposite collinear forces of magnitude P. The result is now a couple of magnitude Pl and a force P that produces cross shear and flexural stress in the shaft as shown in figures 9c and 9d. Figure 10 shows a breakdown of the resulting stresses at points A and B (fig. 9a). The couple, Pl, produces a torsional shearing stress at all surface points on the shaft (fig 10a). The load, P, produces a bending stress that is maximum in tension at the top and maximum in compression at the bottom of the shaft (fig 10b). The load, P, also produces a cross-shear stress, equal to the longitudinal shearing stress, that is maximum on plane yz (fig 10c).

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(3.2)

CIRCULAR SHAFT EM 327: MECHANICS OF MATERIALS LABORATORY

. .

L r
A

.
z

B y

Pl
x A

xt

l (a)
z y x

P P

. .

(a)

B A x z (b)

(b) P
z y

. .

B A x

(c) x

(c) P
z y x

FIGURE 10

torsion & shear =

Tc VQ + J It

(3.4)

(d)

FIGURE 9 Each of the three stresses is a maximum at some point(s) on the plane at the wall. Therefore, one only needs to examine the plane section at the wall to determine where the maximum stress is located. Figure 11 shows the resulting stress states at points A and B. The torsional and cross shear stresses are in the same direction on the right side of the shaft and opposite on the left side. This means the maximum stress condition resulting from the combination of these stresses will be at point A. The maximum shear stress at A is thus given by the superposition of equations 3.2 and 3.3, shown in equation 3.4.

At a point on the opposite side of the shaft from A, the combined shear stress would equal the difference of the torsional and transverse shear stress, given in equation 3.5.

torsion & shear =

Tc VQ + J It

(3.5)

The bending (flexural) stress is zero at point A since it is located on the neutral axis. At point B the bending stress is maximum and given by equation 3.1. Since the bending stress and the transverse shear stress are never maximum at the same point, the transverse shear stress is zero at point B. The same conclusion can be reached by considering the magnitude of Q at point B. It is necessary to relate the strains to the stresses. There are 90 strain gage rosettes located on the test specimen at point A and point B, as well as on the bottom, opposite of B.

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CIRCULAR SHAFT EM 327: MECHANICS OF MATERIALS LABORATORY

A 90 strain gage rosette is also installed on the side at point A. Since there is no normal stress at point A the gage aligned with the axis of the shaft, shown in equation 3.10 should measure zero strain. The strains for the gages at 45 from the center gage will measure normal strains as given in equations 3.7 and 3.8.

torsion + shear A B

torsion

FIGURE 11

x = = E

My E

(3.10)

Figure 12 shows the gages mounted on the top of the shaft (point B).
y

The relationship between shear strain and shear stress at point B is given in equation 3.11.

45 45
b x a

xy

VQ xy Tc J It = = G G

(3.11)

FIGURE 12 Equation 3.6 gives the relationship between the stress and strain for the center gage, which is aligned with the longitudinal axis of the test specimen.
Mc I (3.6) = E E Equations 3.7 and 3.8 give the relationship for the gages on either side of the center.

Once the shear strain is known, the shear stress can be calculated from Hookes law, equation 3.12.

xy = xy G

(3.12)

If the normal strains, x and y are known, Hookes Law can be used to determine the normal stress, as given in equation 3.13.

x =

x =

E x + y 1 2 E y = ( y + x ) 1 2

(3.13)

a = 45 = b = 45

x + y xy + sin(2 * 45 o ) 2 2 x + y xy = + sin(2 * (45 o )) 2 2

(3.7)

For uniaxial normal stress y = -x. MATERIAL TO BE TESTED: A 2024-T4 hollow aluminum tube is used as a cantilevered shaft. A straight bar is fixed to one end. EQUIPMENT TO BE USED:

(3.8)

The relationship between the shear strain and the shear stress for point B is given by equation 3.9.

xy =

xy
G

Tc =

J G

(3.9)

Strain indicator Switch and balance unit

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CIRCULAR SHAFT EM 327: MECHANICS OF MATERIALS LABORATORY

PROCEDURE: TEST PREPARATIONS: Observe the type of strain gage rosettes and their placement on the shaft. Trace the gages to the strain indicator box. Make a sketch of the gage configurations. Measure and record the inside and outside diameters of the circular shaft, the length of the shaft, and the length(s) to the load application location. (Your instructor will provide you with the nominal location(s) to use during the experiment.) TESTING PROCEDURE: 1.) Zero the strain indicator. 2.) Apply loading condition(s) as specified by your instructor. 3.) Record the strains for each loading condition at each strain gage rosette location. 4.) Remove the load and apply additional loading condition(s) as instructed. 5.) When all testing is complete be sure to turn off the strain indicator. REQUIREMENTS: Measure and record the strains resulting from the load configuration(s) you are assigned to investigate. REPORT: 1.) Sketch the experimental set-up indicating where the strain gages are mounted as well as the important physical dimensions. 2.) Calculate the second moment of inertia, I, the polar moment of inertia, J, and the first moment of the cross-section at the neutral axis, Q. 3.) For assigned loading condition(s), use the strain readings from each of the three rosettes to calculate the applied load and compare with the actual loads applied by calculating the percent error. 4.) Calculate based on the measured strains, the shear and normal stress magnitudes at the top and side strain gage locations for both load conditions assigned. Show the stresses on stress blocks for the top and side location. 5.) Determine the theoretical stresses at the top and side gage location using the actual applied load values. Compare to the stresses obtained in the previous step. 6.) Determine the principal stresses for the top and side strain gage locations for both load conditions. 7.) Determine the most severely stressed point on the specimen for load condition 2 using the actual applied load values. 8.) Determine the maximum load that may be applied to the specimen so that the following allowable stresses are not exceeded. (16 ksi T, and 9 ksi shear) 9.) Discuss and discrepancies you found. QUESTIONS: (3.1) Where is the following stresses maximum? a. Longitudinal and transverse shear stress b. Flexural stress c. Torsional stress

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