EMD homework solutions#2 Due 2/10 3-5, 4-8, 4-25, 5-6, 5-71 3-5 Using the specications described,

the following application requirement table (Table 1

based on Tables 3.1 and 3.2 in book) could be lled in. Material data for these evaluation Table 1: Material-Specic Application Requirements and Corresponding Performance Indices. Application Requirement Evaluation Index 1. Strength/volume ratio Ulitmate or yield strength 2. Stiness Modulus of elasticity 3. Ductility Percent elongation in 2 inches 4. Ability to store energy elastically Energy/unit volume at yield 5. Ability to dissipate energy plastically Energy/unit volume at rupture 6. Resistance to chemically reactive environment Dimensional loss in environment 7. Cost constraints Cost/unit weight; also machinability

indices may be found in Tables 3.3, 3.9, 3.10, 3.11, 3.12, 3.14, 3.18, and 3.19. Making a short list of candidate materials from each of these tables, we obtain Table 2. Surveying the lists in Table 2, we see that no material is common to all requirements. However, except for corrosion resistance and ductility, ultra-high strength steel shows high ratings, and carbon steel also has good ratings. Corrosion-resistant platings could be used for either. Therefore, it is recommended that plated ultra-high strength steel be selected.

4-8
(a) Here, it is asking only for the shear stress due to torsion. Since this shaft presumably is operating at a constant angular velocity, the torques resulting from the loads applied to the two elements need to balance. We can compute the resulting torque on the larger element: T = (1200 N 400 N)(0.12 m) = 96 N-m The smaller element then generates an equal and opposite torque, thus: FH (0.06 m) = 96 N-m FH = 1600 N

So there is a constant torque of 96 N-m applied to the shaft between the two elements. This

Table 2: Candidate materials by evaluation index. Application Requirement 1. High strength (Table 3.3) 2. High stiness (Table 3.9) 3. High ductility (Table 3.10) 4. High resilience (Table 3.11) 5. High toughness (Table 3.12) 6. Corrosion resistance (Table 3.14) 7. Low cost (Table 3.18) 8. Good machinability (Table 3.19) Candidate materials ultra-high strength steel, stainless steel (age-hardened), high carbon steel, graphite epoxy composite tungsten carbide, titanium carbide, molybdenum, steel phosphor bronze, inconel, stainless steel, copper, silver, gold, aluminum, steel ultra-high strength steel, titanium, aluminum, magnesium, steel inconel, stainless steel, phosphor bronze, ultra-high stength steel platinum, gold, graphite, titanium gray cast iron, low carbon steel, ultra-high strength steel, zinc alloy Magnesium alloy, aluminum alloy, free machining steel, low carbon steel, medium carbon steel, ultra-high strength steel

generates a shear stress that is maximum on the shaft surface and is equal to = TD Ta 16T (16)(96 N-m) = = 7.64 MPa = 24 = 3 3 D J D (0 . 04 m ) 32

(b) To nd the maximum tensile bending stress, we need to determine the maximum bending moment. Since there are forces in each of the 2 transverse directions, we need to consider the resulting moments in each plane. If we let the x axis be aligned with the shaft, and then let the y axis be the vertical axis and the z axis be the horizontal axis in the gure on the right in Fig. P4.8, then we have the following 2 free body diagrams in each plane (see Fig. 1). From force and moment equilibrium in each plane, it is straight-forward to determine RAy = 417.3 N, RBy = 197.3 N, RAz = 1386.7 N, and RBz = 1813.3 N. The shear and moment diagrams can then be constructed and are shown in Fig. 2. It is clear that the maximum magnitude of the bending moment is at C since this is where the bending moment is largest in magnitude in each plane. Thus, the overall maximum bending moment is Mmax = (277.34)2 + (83.46)2 = 289.6 N-m The maximum tensile stress, which will occur on the surface of the shaft at axial position 2

y A 0.2m RAy

800 N C 0.28m D 0.12m 580 N RBy B

z x A 0.2m RAz 1600 N C 0.28m D 0.12m 1600 N RBz B x

Vy (N) Ay
800 CN 0.2

382.7

Figure 1: 4-8 Free body diagrams. Vz 1386.7

(N) D 0.48 B 0.6
x

x (m)
A

zA

0.2
C 0.2m

C -213.3
0.28m

D 0.48
D B

B 0.6
x

x (m)

A -417.3 C 0.2m 0.28m

-197.3 B D
0.12m 580 N RBy

0.12m -1813.3 1600 N RBz 217.60

Mz (N-m)

RAy

23.70 C 0.2
A C -83.46 0.2 -417.3 382.7

MyRAz (N-m) x (m)

VzA 1386.7 (N) A

277.34 1600 N

A Vy (N)

D 0.48
D 0.48

B 0.6
B 0.6

C 0.2
C -213.3

D 0.48
D 0.48

B 0.6
B 0.6

x (m)

x (m)

0.2

x (m)

-197.3

-1813.3 Mz (N-m) A C 0.2 My (N-m) B 0.6 x (m) A 277.34 217.60 C 0.2 D 0.48 B 0.6 x (m)

23.70 D 0.48

-83.46

Figure 2: 4-8 Shear and moment diagrams.

w = 5m

x 5m RA RB MB

Figure 3: 4-25 Free body diagram. C , is then MD Mc 32M (32)(289.6 N-m) = 24 = = = 46.1 MPa = 3 I D D (0.04 m)3 64

4-25
A free body diagram is shown in Fig. 3. We have only two, non-trivial, equilibrium equations Fy = 0 and Mz = 0 (assuming y is downward and z is into the plane) and three unknown reactions RA , RB , and MB , thus, the reactions cannot be solved just from the equilibrium equations, and this problem is statically indeterminate. We have one more supporting force or moment than necessary to prevent the shaft from moving. Using the singularity function handout, I can write an equation for the downward deection v EI w d2 v = RA x x 2 2 dx 2

where I dont need to use the singularity function brackets because both terms kick in right at the start of the beam (x = 0). Integrating twice, EI dv RA 2 = x dx 2 RA 3 EIv = x 6 w 3 x + C1 6 w 4 x + C1 x + C2 24

Note, after integrating twice, I now have 3 unknowns, RA and the two constants of integration C1 and C2 . I can solve for these 3 unknowns using the boundary conditions on the deections dv and slope v (0) = 0, v (L) = 0, and dx (L) = 0, where L = 5 m. Using these boundary

conditions in the above equations, yields: EIv (0) = C2 = 0 RA 3 w 4 L L + C1 L = 0 EIv (L) = 6 24 dv RA 2 w 3 EI (L) = L L + C1 = 0 dx 2 6 3 1 RA = wL = 9375 N , C1 = wL3 8 48 So the deection and slope equations for the beam are then w 3Lx3 + 2x4 + L3 x 48EI dv w 9Lx2 + 8x3 + L3 (x) = dx 48EI v (x) = The maximum deection is when the slope is zero and 0 < x < L. For the slope to be zero, the following must be zero: 9Lx2 + 8x3 + L3 = 0 and the only solution to the above equation on the interval of interest is x = 0.4216L = 2.11 m. Now, we can use the deection equation v (x) to nd the deection at this location. Since the shaft is steel, we can assume (Table 3.9) E = 207 GPa. vmax = 5000 N/m 3(5 m)(2.11 m)3 + 2(2.11 m)4 + (5 m)3 (2.11 m) (48)(207 109 N/m2 ) 64 (0.12 m)4

= 8.03 103 m = 8.03 mm Note, this problem can also be solved using superposition by adding the solutions in Table 4.1 for cases 10 and 11.

5-6
We see that the shaft is subjected to a combination of torsion and bending. The torsion creates a shear stress that is maximum on the surface of the shaft and will be the same everywhere on the shaft surface, which is = Td Ta 16T (16)(500, 000 N-mm) = 24 = = = 39.79 MPa 3 J d d (40 mm)3 32

The bending moment is due to the transverse loads. From symmetry, the reactions at A and B are just RA = 5, 000 N and RB = 5, 000 N. The shear and moment diagrams are shown in 5

Vz (N) 0.15 -5000

5000

0.30

x (m)

My (N-m) x (m)

-750

Figure 4: 5-6 Shear and moment diagrams. Fig. 4. So the maximum bending moment is 750 N-m or 750,000 N-mm, and occurs at the middle of the shaft (x = 150 mm). Thus, the maximum tensile bending stress will be at the middle of the shaft (x = 150 mm) on the bottom surface (z = 20 mm), and is x = My d My c 32(750, 000 N-mm) 32My = = 119.37 MPa = 2 = 3 4 I d (40 mm)3 d 64

The critical location is where this maximum bending stress acts (x = 150 mm, y = 0 mm, z = 20 mm), because the shear stress due to the torsion is the same everywhere on the shaft surface. A stress element at this critical location is shown in Fig. 5, where xy = = 39.79 MPa and x = 119.37 MPa. Note that we only need to consider 2D because it is a free surface, thus the normal and shear stresses on the face are zero, i.e. z = 0, xz = 0, and yz = 0. The principal stresses can be determined using the Mohrs circle diagram, shown in Fig. 6. The principal stresses are then

xy
x x

x xy

Figure 5: 5-6 Stress element at critical location.

2 3
R

Figure 6: 5-6 Mohrs circle diagram for critical stress element.

R = 1 2 3

(119.37/2)2 + (39.79)2 = 71.732 MPa 119.37 = + R = 59.685 + 71.732 = 131.42 MPa 2 = 0 119.37 R = 59.685 71.732 = 12.05 MPa = 2

and the maximum shear stress is max = 71.73 MPa.

5-71 Using Hookes law:

x

z x

1 6000 = 2.0 104 x = 6 E 30 10 (0.3)6000 = 6.0 105 = x = E 30 106 (0.3)6000 = x = = 6.0 105 6 E 30 10 = (2.0 0.6 0.6) 104 = 8.0 105 =