Practice3.

Solutions

1. Given data: 𝑑𝑖 = 15 𝑐𝑚 (𝑅𝑖 = 7.5 𝑐𝑚), 𝑑𝑒 = 20 𝑐𝑚 (𝑅𝑒 = 10 𝑐𝑚), 𝐿 = 10 𝑚

a. The shear stress at a radial distance 𝑟 from the axis is:
𝑇. 𝑟
𝜏𝑥𝜃 =
𝐽
𝜋 4 4
𝑇 being the torque and 𝐽 = 2 (𝑅𝑒 − 𝑅𝑖 ) is the polar moment of area. 𝑟 varies between
𝑅𝑖 and 𝑅𝑒 . The maximum shear stress occurs when 𝑟 is maximum, so at the outer
radius 𝑟 = 𝑅𝑒 .
𝜋
The polar moment is 𝐽 = 2 (𝑅𝑒4 − 𝑅𝑖4 ) = 1.07 × 10−4 𝑚4 .
The maximum shear stress is:
𝑇. 𝑅𝑒
𝜏𝑚𝑎𝑥 =
𝐽
The allowable shear stress is the maximum stress that can be applied: 𝜏𝑎𝑙𝑙 = 𝜏𝑚𝑎𝑥
𝑇. 𝑅𝑒 𝜏𝑎𝑙𝑙 𝐽 (200 × 106 )(1.07 × 10−4 )
𝜏𝑎𝑙𝑙 = →𝑇= = → 𝑇 = 214000 𝑁. 𝑚
𝐽 𝑅𝑒 0.1
So the maximum torque is 𝑇𝑚𝑎𝑥 = 214 𝑘𝑁. 𝑚. If a higher torque is applied, the shear
stress would exceed the allowable stress.

𝑇.𝐿
b. The angle of rotation between two points is given as ∆𝜑 = 𝐺.𝐽 where 𝐿 is the distance
between the two points and 𝐺 is the shear modulus.
To find 𝐺:
𝐸 210 × 109
𝐺= = = 80.77 𝐺𝑃𝑎
2(1 + 𝜈) 2(1 + 0.3)
The angle of rotation from one end to the other:
𝑇. 𝐿 (214000) × (10)
∆𝜑 = = → ∆𝜑 = 0.25 𝑟𝑎𝑑
𝐺. 𝐽 (80.77 × 109 )(1.07 × 10−4 )

Solutions: 𝑇𝑚𝑎𝑥 = 215000 𝑁. 𝑚, ∆𝜑 = 0.25 𝑟𝑎𝑑

2. Given data: 𝑅𝑖 = 2.5 𝑐𝑚, 𝑅𝑒 = 5 𝑐𝑚, 𝐿 = 5 𝑚

𝜋
a. The polar moment is: 𝐽 = (𝑅𝑒4 − 𝑅𝑖4 ) = 9.2 × 10−6 𝑚4
2
𝐸
The shear modulus is: 𝐺 = 2(1+𝜈) = 24.43 𝐺𝑃𝑎
The angle of rotation of one end with respect to the other is:
𝑇. 𝐿 (12000) × (5)
∆𝜑 = = → 𝛥𝜑 = 0.266 𝑟𝑎𝑑
𝐺. 𝐽 (24.43 × 109 )(9.2 × 10−6 )
b. In the case of shaft torsion, under the assumption that the cross-sections remain
perpendicular to the axial direction and that the radial lines remain straight, the
stresses in a polar coordinate system (𝑟𝜃𝑥) are at a point:
𝑟
𝜎𝑥 = 𝜎𝑟 = 𝜎𝜃 = 0, 𝜏𝑥𝑟 = 𝜏𝑟𝜃 = 0, and 𝜏𝑥𝜃 = 𝑇. 𝐽 .
At the points A and B:
𝑟𝐴 = 𝑟𝐵 = 𝑅𝑒 = 5 𝑐𝑚 and 𝐽 = 9.2 × 10−6 𝑚4 ,

So:
𝑅𝑒 0.05
𝜏𝑥𝜃𝐴 = 𝜏𝑥𝜃𝐵 = 𝑇. = 12000 ≈ 65 𝑀𝑃𝑎
𝐽 9.2 × 10−6
So in (𝑟𝜃𝑥) system, the stress tensor at A and B is:
0 0 0
𝜎𝑟𝜃𝑥 = (0 0 65) 𝑀𝑃𝑎
0 65 0
The shear strain 𝜀𝑥𝜃 can be calculated using the shear modulus 𝐺.
𝜏𝑥𝜃 65 × 106
𝜀𝑥𝜃 = = = 0.0013
2𝐺 2(24.43 × 109 )
The strain tensor is then:
0 0 0
𝜀𝑟𝜃𝑥 = (0 0 0.0013)
0 0.0013 0

Note: if the stress tensor is to be calculated in a Cartesian system (𝑥 ′ 𝑦 ′ 𝑧 ′ ), then the stress
tensor at A and B would be different.
At A: 𝑥 ′ ≡ +𝑟; 𝑦 ′ ≡ +𝜃; 𝑧 ′ ≡ +𝑥 → 𝜏𝑥𝜃𝐴 = 𝜏𝑧′𝑦′𝐴 = 65 𝑀𝑃𝑎 → 𝜏𝑧′𝑦′𝐴 = 65 𝑀𝑃𝑎
0 0 0
𝐴
→ 𝜎𝑥′𝑦′𝑧′ = (0 0 65)
0 65 0
At B: 𝑥 ′ ≡ −𝜃; 𝑦 ′ ≡ +𝑟; 𝑧 ′ ≡ +𝑥 → 𝜏𝑥𝜃𝐵 = −𝜏𝑧 ′ 𝑥 ′ 𝐵 = 65 𝑀𝑃𝑎 → 𝜏𝑧 ′𝑥′𝐵 = −65 𝑀𝑃𝑎
 0 0 −65
𝐴
→ 𝜎𝑥′𝑦′𝑧′ =( 0 0 0 )
−65 0 0

0 0 0 0 0 0
Solutions: ∆𝜑 = 0.27 𝑟𝑎𝑑, 𝜎𝑟𝜃𝑥 = (0 0 65) 𝑀𝑃𝑎, 𝜀𝑟𝜃𝑥 = (0 0 0.0013)
0 65 0 0 0.0013 0

3. To draw the torque diagram, the internal torque in each portion of the shaft should be
determined (same principle as the axial force diagram). In each portion, imagine a cut and
determine the internal torque 𝑇 (the counterclockwise direction is considered to be
positive). The external torques are given as
𝑇1 = 30 𝑘𝑁. 𝑚, 𝑇2 = 15 𝑘𝑁. 𝑚 and 𝑇3 = 10 𝑘𝑁. 𝑚.
First, the free body diagram of the shaft is drawn to determine the reaction torque at the
embedment at O.
∑𝑇 = 0 → 𝑅𝑇 − 𝑇1 + 𝑇2 + 𝑇3 = 0 → 𝑅𝑇 = 𝑇1 − 𝑇2 − 𝑇3 = 30 − 15 − 10
→ 𝑅𝑇 = 5 𝑘𝑁. 𝑚
a. To determine the internal torque 𝑇:
In the portion OA:
𝑇𝑂𝐴 + 𝑅𝑇 = 0 → 𝑇𝑂𝐴 = −𝑅𝑇 → 𝑇𝑂𝐴 = −5 𝑘𝑁. 𝑚
In the portion AB:
𝑇𝐴𝐵 − 𝑇1 + 𝑅𝑇 = 0 → 𝑇𝐴𝐵 = 𝑇1 − 𝑅𝑇 = 30 − 5 → 𝑇𝐴𝐵 = 25 𝑘𝑁. 𝑚
In the portion BC:
𝑇𝐵𝐶 = 10 𝑘𝑁. 𝑚
The torque diagram can then be drawn. Or, the diagram can be drawn graphically as
shown in the figure:

To find the maximum shear stress in each portion:

 𝑅
𝜏𝑚𝑎𝑥 = 𝑇.
𝐽
𝜋𝑅 4
With 𝐽 = .
2
In the portion OA: 𝑅𝑂𝐴 = 15 𝑐𝑚, 𝐽𝑂𝐴 = 7.95 × 10−4 𝑚4 , 𝑇𝑂𝐴 = −5000 𝑁. 𝑚
−5000 × 0.15
𝜏𝑚𝑎𝑥𝑂𝐴 = = −0.94 𝑀𝑃𝑎
7.95 × 10−4
In the portion AB: 𝑅𝐴𝐵 = 12.5 𝑐𝑚, 𝐽𝐴𝐵 = 3.8 × 10−4 𝑚4 , 𝑇𝐴𝐵 = 25000 𝑁. 𝑚
25000 × 0.125
𝜏𝑚𝑎𝑥𝐴𝐵 = = 8.22 𝑀𝑃𝑎
3.8 × 10−4
In the portion AB: 𝑅𝐵𝐶 = 7.5 𝑐𝑚, 𝐽𝐵𝐶 = 4.97 × 10−5 𝑚4 , 𝑇𝐴𝐵 = 10000 𝑁. 𝑚
10000 × 0.075
𝜏𝑚𝑎𝑥𝐵𝐶 = = 15.1 𝑀𝑃𝑎
4.97 × 10−5

b. The relative rotation between A and C is:

∆𝜑𝐴𝐶 = ∆𝜑𝐴𝐵 + ∆𝜑𝐵𝐶
With:
𝐺𝑠𝑡𝑒𝑒𝑙 = 80.77 𝐺𝑃𝑎
𝑇𝐴𝐵 . 𝐿𝐴𝐵 (25000)(1.5)
∆𝜑𝐴𝐵 = = = 0.0012 𝑟𝑎𝑑
𝐺𝐴𝐵 . 𝐽𝐴𝐵 ( 80.77 × 109 )(3.8 × 10−4 )
𝑎𝑛𝑑
𝑇𝐵𝐶 . 𝐿𝐵𝐶 (10000)(1)
∆𝜑𝐵𝐶 = = = 0.0024 𝑟𝑎𝑑
𝐺𝐵𝐶 . 𝐽𝐵𝐶 ( 80.77 × 109 )(4.97 × 10−5 )
So the relative rotation between A and C is
∆𝜑𝐴𝐶 = 0.0012 + 0.0024 = 0.0036 𝑟𝑎𝑑

c. The critical section is the one that has the highest shear stress. Based on part a., the
critical section is the section BC, with 𝜏𝐵𝐶 = 15.1 𝑀𝑃𝑎.
0 0 0
In a (𝑟𝜃𝑥) reference system, the stress tensor in BC is: 𝜎 = (0 0 15.1) 𝑀𝑃𝑎
0 15.1 0
The principal stresses are the eigenvalues of the stress tensor:
−𝜎 0 0
det ( 0 −𝜎 15.1) = 0 → 𝜎(𝜎 2 − 15.12 ) = 0
0 15.1 −𝜎
→ 𝑡ℎ𝑒 𝑝𝑟𝑖𝑛𝑐𝑖𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠𝑒𝑠: 𝜎1 = 0, 𝜎2 = 15.1 𝑀𝑃𝑎, 𝜎3 = −15.1 𝑀𝑃𝑎

Solutions: 𝜏𝑚𝑎𝑥 = 15.1 𝑀𝑃𝑎, ∆𝜑𝐴𝐶 = 0.0037 𝑟𝑎𝑑, 𝜎1 = 0, 𝜎2 = 15.1, 𝜎3 = −15.1

4. The external radius is given 𝑅𝑒 = 25 𝑚𝑚.

The objective is to find the thickness 𝑡 = 𝑅𝑒 − 𝑅𝑖 , so 𝑅𝑖 should be determined.
The power to be transmitted by the shaft is 𝑃 = 100 𝑘𝑊, and its rotation frequency is
𝑓 = 20 𝐻𝑧.
 The relation between power and torque is 𝑃 = 𝑇. 𝜔 = 𝑇. (2𝜋𝑓), which gives:
𝑃 100 × 103
𝑇= = = 795.77 𝑁. 𝑚
2𝜋𝑓 2𝜋(20)
The maximum shear stress is:
𝑇. 𝑅𝑒
𝜏𝑚𝑎𝑥 =
𝐽
The maximum allowable stress is 𝜏𝑚𝑎𝑥 = 60 𝑀𝑃𝑎.
𝐽 𝑇 795.77
→ = = 6
= 13.26 × 10−6
𝑅𝑒 𝜏𝑚𝑎𝑥 60 × 10
with
𝜋 4 4
𝐽 𝜋 (𝑅𝑒4 − 𝑅𝑖4 ) 𝜋 (0.0254 − 𝑅𝑖4 )
𝐽 = (𝑅𝑒 − 𝑅𝑖 ) → = =
2 𝑅𝑒 2 𝑅𝑒 2 0.025
4 4
𝐽 (0.025 − 𝑅𝑖 ) 2
= 13.26 × 10−6 → = ( ) 13.26 × 10−6 → 𝑅𝑖 = 20.6 × 10−3 𝑚
𝑅𝑒 0.025 𝜋
So 𝑅𝑖 = 20.6 𝑚𝑚.
Finally, the required thickness is therefore:
𝑡 = 𝑅𝑒 − 𝑅𝑖 = 25 − 20.6 = 4.4 𝑚𝑚 ≈ 5 𝑚𝑚
So a thickness of around 5 𝑚𝑚 is required to keep the stress under the allowable value.

Solution: 𝑡 = 4.4 𝑚𝑚

5. The stress is in kilopound/square-inch (𝑘𝑠𝑖). The same formulas are used, but the
dimensions should be expressed in inches (𝑖𝑛.), the torque in (𝑘𝑖𝑝. 𝑖𝑛. ), and the power in
(𝑖𝑛. 𝑙𝑏/𝑠). The power can then be expressed in horsepower (ℎ𝑝) knowing that 1ℎ𝑝 =
6600 𝑖𝑛. 𝑙𝑏/𝑠.
a. The maximum stress occurs in the fillet. It can be calculated as 𝜏𝑚𝑎𝑥 = 𝐾𝜏𝑁 , with 𝐾 is the
stress concentration factor and 𝜏𝑁 is the nominal shear stress calculated in the small-
diameter shaft.
Using the diagram:
9
𝑟 (16) 𝐷 7.5
= = 0.15 & = =2
𝑑 3.75 𝑑 3.75

So based on the diagram: 𝐾 ≈ 1.33.

The nominal stress 𝜎𝑁 is calculated in the small-diameter
shaft.
𝑑
Let 𝑐 = = 1.875 𝑖𝑛 the radius of the smaller shaft. The
2
nominal stress is:
𝑇𝑐
𝜎𝑁 =
𝐽
 And the maximum stress in the shaft is:
𝑇𝑐 𝜏𝑚𝑎𝑥 𝐽
𝜏𝑚𝑎𝑥 = 𝐾𝜎𝑁 = 𝐾 →𝑇=
𝐽 𝐾𝑐
The polar moment of the smaller shaft is
𝜋𝑐 4 𝐽 𝜋𝑐 3
𝐽= → = = 10.35 𝑖𝑛3
2 𝑐 2
The maximum shear stress is given as the allowable stress 𝜏𝑚𝑎𝑥 = 8 𝑘𝑠𝑖
𝜏𝑚𝑎𝑥 𝐽 (8)(10.35)
𝑇= = = 62.3 𝑘𝑖𝑝. 𝑖𝑛
𝐾𝑐 (1.33)
The frequency is given:
900
𝑓 = 900 𝑟𝑝𝑚 = 𝐻𝑧 → 𝑓 = 15 𝐻𝑧
60
𝑃 = 𝑇(2𝜋𝑓) = 62.3 × 2𝜋 × 15 → 𝑃 = 5.87 𝑘𝑖𝑛. 𝑙𝑏/𝑠 = 5.87 × 103 𝑖𝑛. 𝑙𝑏/𝑠
In horsepower:
5.87 × 103
𝑃= → 𝑃 ≈ 890 ℎ𝑝.
6600

15
b. If 𝑟 = 16 𝑖𝑛, then 𝐾 = 1.2 (diagram). Doing the same calculations as a., the torque is:
𝑇𝑏 = 69 𝑘𝑖𝑝. 𝑖𝑛
And the resulting power is:
𝑙𝑏
𝑃𝑏 = 2𝜋𝑓 𝑇𝑏 = 6.5 × 106 𝑖𝑛. → 𝑃𝑏 = 985 ℎ𝑝
𝑠
The change in power when the fillet radius is increased is therefore:
𝑃𝑏 − 𝑃𝑎
× 100 = 11%
𝑃𝑎
So increasing the fillet radius would allow the shaft to transmit more power.

Solutions: 𝑃𝑎 = 890 ℎ𝑝, 𝑃𝑏 = 985 ℎ𝑝, percent change = 11%.