MACHINE DESIGN - An Integrated Approach, 4th Ed.
Example 5-1-1
EXAMPLE 5-1
Failure of Ductile Materials Under Static Loading
Problem: Determine the safety factors for the bracket rod shown in Figure 5-9 based on both the
distortion-energy theory and the maximum shear theory and compare them.
Given: Yield strength S y 47000 psi Rod length L 6 in
Arm length a 8 in Rod diameter d 1.5 in
Load F 1000 lbf
Assumptions: The load is static and the assembly is at room temperature. Consider shear due to transverse
loading as well as other stresses.
Solution: See Figures 5-9 and 4-33 and Mathcad file EX0501. Also see Example 4-10 for a more
complete explanation of the stress analysis for this problem.
1. The rod is loaded in both bending (as a cantilever beam) and in torsion. The largest tensile bending stress
will be in the top outer fiber at point A. The largest torsional shear stress will be all around the outer
circumference of the rod. (See Example 4-10 for more detail.) First take a differential element at point A
where both of these stresses combine as shown in Figure 4-33b. Find the normal bending stress and
torsional shear stress on point A using equations 4.11b and 4.23b, respectively.
Bending moment
at point A M F L M 6000 lbf in
Distance to outer fiber c 0.5 d c 0.75 in
4
π d 4
Moment of inertia I I 0.249 in
64
3
Torque carried by rod T F a T 8 10 lbf in
4
Polar moment of inertia J 2 I J 0.497 in
M c
Normal bending stress σx σx 18.11 ksi (a)
I
Tc
Torsional shear stress τxz τxz 12.07 ksi (b)
J
2. Find the maximum shear stress and principal stresses that result from this combination of applied stresses at
point A using equations 4.6.
Normal stress in σz 0 psi
z-direction
2
σx σz 2
Maximum shear stress τmax τxz
2
4
τmax 1.509 10 psi
σx σz
Principal stresses σ1 τmax σ1 24.14 ksi
2
σ2 0 psi (c)
σx σz
σ3 τmax σ3 6.04 ksi
2
3. Find the von Mises effective stress from the principal stresses using equation 5.7a with 2 = 0.
EX0501.xmcd
MACHINE DESIGN - An Integrated Approach, 4th Ed. Example 5-1-2
2 2
σ' σ1 σ1 σ3 σ3 σ' 27.66 ksi (d)
4. The safety factor using the distortion-energy theory can now be found using equation 5.8a.
Sy
N N 1.70 (e)
σ'
5. The safety factor using the maximum shear-stress theory can now be found using equation 5.10.
0.5 S y
N N 1.56 (f)
τmax
6. Comparing these two results shows the more conservative nature of the maximum shear-stress theory, which
gives a slightly lower safety factor.
7. Since the rod is a short beam, we need to check the shear due to transverse loading at point B on the neutral
axis. The maximum transverse shear stress at the neutral axis of a round rod was given in equation 4.15c.
Shear load at B V F V 1000 lbf
2
π d 2
Cross-section area A A 1.767 in
4
Shear stress at the 4 V
neutral axis τbending τbending 754.5 psi (g)
3 A
Point B is in pure shear. The total shear stress at point B is the algebraic sum of the transverse shear stress
and the torsional shear stress, which both act on the same planes of the differential element in this case, in
the same direction as shown in Figure 4-33c.
τmax τxz τbending τmax 12.8 ksi (h)
8. The safety factor for point B using the distortion-energy theory for pure shear (Eq. 5.9b) is
0.577 S y
N N 2.11 (i)
τmax
and for the maximum shear-stress theory (Eq. 5.10) is
0.5 S y
N N 1.83 (j)
τmax
Again, the latter is more conservative.
EX0501.xmcd
