Chapter 6

Failure Prediction for Static Loading

Section 6.2
6.1 Given that the stress concentration factor is 2.81 for a machine element made of steel with a modulus
of elasticity of 207 GPa, nd the stress concentration factor for an identical machine element made of
aluminum instead of steel. The modulus of elasticity for aluminum is 69 GPa.
Solution: Since the elastic stress concentration is entirely determined from the geometry of the ma-
chine element, the stress concentration factor will remain the same. Therefore, K
c
= 2.81.
6.2 A at part with constant thickness b is loaded in tension as shown in Fig. 6.3(a). The height changes
from 50 to 100 mm with a radius r = 10 mm. Find how much higher a load can be transmitted through
the bar if the height increases from 50 to 87 mm and the radius decreases from 10 to 4 mm. Ans. 42%
higher load.
Notes: To answer this question, one must compare the stress concentration factors for the two cases.
The stress concentration factors are obtained from Figure 6.3(a).
Solution: Referring to the sketch in Figure 6.3(a), in the rst case, H = 100 mm, h = 50 mm and
r = 10 mm for the rst case. Therefore, H/h = 100 mm/50 mm = 2 and r/h = 10 mm/50 mm =
0.2. From Figure 6.3(a), K
c
for this case is 1.8. For the second case, H/h = 100/87 = 1.15 and
r/h = 4 mm/87 mm = 0.046. Therefore, From Figure 6.3(a), K
c
is around 2.8. The load that can be
transmitted depends on the maximum stress. Therefore, for the rst case:
S
y
= K
c
P
bh
= 1.8
P
1
b(0.050 m)
P
1
=
S
y
b(0.050 m)
1.8
= 0.02778S
y
b
For the second case:
S
y
= K
c
P
bh
P
2
=
S
y
b(0.087 m)
2.2
= 0.03954S
y
b
The ratio of the two forces is:
P
2
P
1
=
0.03954S
y
b
0.02778S
y
b
= 1.42
6.3 A at steel plate axially loaded as shown in sketch a has two holes for electric cables. The holes are
situated beside each other and each has a diameter d. To make it possible to draw more cables, the
two holes are replaced with one hole having twice the diameter 2d, as shown in sketch b. Assume that
the ratio of diameter to width is d/b = 0.2 for the two-hole plate. Which plate will fail rst?
117
118 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
d
d
b
(a)
2d b
(b)
Sketches a and b, for Problem 6.3
Notes: The exact hole locations have not been specied, so some variation may occur with assumed
dimensions. Also, the two-hole case does not correspond to a particular chart in Fig 6.1 through 6.6.
However, it is possible to obtain a reasonable solution from the existing data. For a critical application,
more advanced approaches, such as nite element analysis, would be necessary. See also Prob. 6.6.
Solution: It will be assumed that the top and bottom halves of the plate are symmetric about the
centerline, and that the holes are placed in the center of each half of the plate. The locations where
the largest stress could occur are A and B in the sketch.
Considering the top half of the problem leads to:
d
Here the diameter to width ratio is 0.4, so K
c
is around 2.2 from Fig. 6.2 (a). Note that this is true
for point A but not point B in the gure above.
d/2
Because of St. Venants Principal, we must be concerned about the stress concentrations interacting
between the two holes. For B, take a section through the hole diameters to yield:
Here H = b/2, h = b/2 d, r/h = (d/2)/(b/2 d) = 0.1b/(0.5b 0.2b) = 0.33. Therefore, K
c
is just
under 2.0 from Fig. 6.4(a). Therefore, the larger stress concentration is K
c
= 2.2 and point A is more
important than point B. For the single hole, Figure 6.2 (a) gives a stress concentration of K
c
= 2.2
(d/b = 0.4). Therefore, either design is expected to fail at the same stress.
6.4 A 5 mm thick 100 mm wide AISI 1020 steel rectangular plate has a central elliptical hole 6 mm in
length transverse to the applied stress and 2 mm in diameter along the stress. Determine the applied
load that causes yielding at the edge of the hole.
Notes: This is a straightforward problem that requires Eq. (6.2) to obtain the solution.
Solution: Note that the width is much larger than the elliptical hole width, so Eq. (6.2) can be
applied. Note that the dimensions in Eq. (6.2) are half-widths, so we need to use b = 3 mm and a = 1
mm. Equation (6.2) gives
K
c
= 1 +
2a
b
= 1 +
2(1)
3
= 1.667
119
From the inside front cover for AISI 1020 steel, S
y
= 295 MPa. Therefore,

max
= S
y
= K
c

ave
= K
c
P
bh
P =
S
y
bh
K
c
=
(295 MPa)(0.094 m)(0.005 m)
1.667
= 83, 170 N = 83.17 kN
6.5 A round bar has a llet with r/d = 0.15 and D/d = 1.5. The bar transmits both bending moment and
torque. A new construction is considered to make the shaft stier and stronger by making it equally
thick on each side of the llet or groove. Determine whether that is a good idea.
Notes: Figures 6.5 and 6.6 are used to obtain the solution.
Solution: For r/d = 0.15 and D/d = 1.5, the stress concentrations for bending is just over 1.5 for
bending (from Fig. 6.5 (b)) and about 1.25 for torsion (from Fig. 6.5(c)). If instead of a llet the
bar became a groove, with the same root diameter, then the stress concentrations are obtained from
Fig. 6.6 (b) and (c). The new stress concentration factors are around 1.65 for bending and 1.325 for
torsion. Since the stress concentration factors are higher for the proposed redesign, it is not a good
idea.
6.6 A 10-inch wide plate loaded in tension contains a 2 inch long, 1/2 inch wide slot. Estimate the stress
concentration by:
(a) Approximating the slot as an ellipse that is inscribed within the slot.
(b) Obtaining the stress concentration at the edge of the slot by taking a section through the slot and
approximating the geometry as a rectangular plate with a groove.
Notes: Neither of these is an accurate capture of the stress concentration geometry. Students should
be encouraged to conduct a literature search to obtain the stress concentration for this case or to
conduct a nite element analysis to obtain the factor.
Solution:
(a) If we assume the slot is an ellipse, and we take the member to be innitely wide, we can write
from Eq. (6.2),
K
c
= 1 +
2(0.25)
1
= 1.5
(b) The geometry can be approximated as in Fig. 6.4a, with H = 5 in., h = 4 in., r = 0.5 in. Thus,
H/h = 1.25 and r/h = 0.125, so that K
c
= 2.5.
Note that part a) assumes a very large width exists, which is not the case here. Also in part b), the
area under consideration must be reduced, while it is not reduced in part a), so that the results are
actually slightly closer.
6.7 A machine has three circular shafts, each with llets giving stress concentrations. The ratio of llet
radius to shaft diameter is 0.1 for all three shafts. One of the shafts transmits a tensile force, one
transmits a bending torque, and one transmits torsion. Because they are stressed exactly to the stress
limit (n
s
= 1), a design change is proposed doubling the notch radii to get a safety factor greater than
1. How large will the safety factors be for the three shafts if the diameter ratio is 2 (D/d = 2)? Ans.
n
s,tension
= 1.21, n
s,bending
= 1.19, n
s,torsion
= 1.17.
Notes: Figure 6.5 is used to solve this problem.
120 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
Solution: For the shaft under tension, Fig 6.5a is used to obtain the stress concentration factors. For
D/d = 2 and r/d = 0.1, K
c
= 2.0, and corresponds to the original case. If r is doubled, then r/d = 0.2
and K
c
= 1.65. Since the original design was fully stressed, the new safety factor is
n
s
=
2
1.65
= 1.21
For the shaft under bending, Fig. 6.5b is used to obtain the stress concentration factors. For D/d = 2
and r/d = 0.1, K
c
= 1.7, and corresponds to the original case. If r is doubled, then r/d = 0.2 and
K
c
= 1.43. Since the original design was fully stressed, the new safety factor is
n
s
=
1.7
1.43
= 1.19
For the shaft under torsion, Fig. 6.5(c) is used to obtain the stress concentration factors. For D/d = 2
and r/d = 0.1, K
c
= 1.43, and corresponds to the original case. If r is doubled, then r/d = 0.2 and
K
c
= 1.22. Since the original design was fully stressed, the new safety factor is
n
s
=
1.43
1.33
= 1.17
Therefore, the lowest safety factor is n
s
= 1.17 and corresponds to the torsion-loaded shaft.
6.8 The shaft shown in sketch c is subjected to tensile, torsional, and bending loads. Determine the
principal stresses at the location of stress concentration. Ans.
1
= 52.99 MPa,
2
= 0,
3
= -12.27
MPa.
150 mm
120 mm
D = 45 mm
d = 30 mm
r = 3 mm
100 N-m
1000 N
500 N
Sketch c, for Problem 6.8
Notes: This problem can be easily solved through the principal of superposition. The stress concen-
tration factors are obtained from Figures 6.5 (a) and (b).
Solution: The rod will see normal stresses due to axial loads and bending, and a shear stress due to
torsion. Note that the shear stress due to shear is zero at the extreme bers where the stresses are
largest. The critical location is at the bottom where the bending and axial stresses are both tensile.
Assign the x-axis to the rod axis. The normal stress is given by:

c
= K
c1
P
A
+K
c2
Mc
I
= (1.9)
1000 N

4
(0.03 m)
2
+ (1.65)
(500 N)(0.120 m)(0.015 m)

64
(0.030 m)
4
= 40.0 MPa
where the stress concentration factors of 1.9 and 1.65 are obtained from Figure 6.5 (a) and (b). The
shear stress is
= K
c
Tc
J
= (1.4)
(100 Nm)(0.015 m)

32
(0.030 m)
4
= 26.45 MPa
121
Equation (2.16) gives the principal stresses.

1
,
2
=

x
+
y
2

2
xy
+
_

y
2
_
2
=
40.0 MPa
2

(26.45 MPa)
2
+
_
40.0 MPa
2
_
2
or
1
= 53.0 MPa and
2
=-12.7 MPa. Note that the shear stress is very small compared to the normal
stress; we could have taken
x
as a principal direction.
6.9 A steel plate with dimensions shown in sketch d is subjected to 150-kN tensile force and 300-N-m
bending moment. The plate is made of AISI 1080 steel and is kept at 20

C. A hole is to be punched
in the center of the plate. What is the maximum diameter of the hole for a safety factor of 1.5? Ans.
d = 120 mm.
d
M
M
P
235 mm
5 mm
1000 mm
Sketch d, for Problem 6.9
Notes: Equation (3.16) gives the allowable stress in bending. The normal stress is the sum of the
bending stress and the axial normal stress, and is equated to the allowable stress. This gives an
equation in terms of the hole diameter and the stress concentration factors in tension and bending
which can be solved iteratively.
Solution: From the inside front cover, AISI steel has a yield strength of S
y
= 380 MPa. Therefore,
the allowable stress is given by Eq. (3.16) as:

all
= 0.6S
y
= 0.6(380 MPa) = 228 MPa
However, since the safety factor is 1.5, the allowable stress for this problem is 228 MPa/1.5= 152 MPa.
The stress associated with axial tension is (see Fig. 6.2a):

a
=
K
ca
P
(b d)h
=
K
ca
(150 kN)
(0.235 md)(0.025 m)
=
6 MN/m
0.235 md
K
ca
The stress associated with bending is (see Fig. 6.2b):

b
=
6K
cb
M
(b d)h
2
=
6K
cb
(300 Nm)
(0.235 md)(0.025 m)
2
=
2.88 MN/m
0.235 md
K
cb
Therefore, the maximum stress is:

max
=
a
+
b
=
(6 MN/m)K
ca
+ (2.88 MN/m)K
cb
0.235 md
This should be equated to the maximum allowable stress, of
max
= 152 MPa. Note that K
ca
and K
cb
are functions of only d, since the other variables needed for their denition are xed. Therefore, this
equation can be iteratively solved. Note that we can re-write the equation as:
(6 MN/m)K
ca
+ (2.88 MN/m)K
cb
0.235 md
= 152 MPa
122 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
d = 0.235
(6 MN/m)K
ca
+ (2.88 MN/m)K
cb
152 MPa
Assume d = 100 mm, so that d/b = (100 mm)/(235 mm) = 0.426, and d/h = 100/25 = 4. From Fig.
6.2 (a), K
ca
= 2.2 and From Fig. 6.2 (b), K
cb
= 1.46. Therefore, this equation would predict
d = 0.235 m
(6 MN/m)(2.2) + (2.88 MN/m)(1.46)
152 MPa
= 0.120 m
Therefore, the initial value was too small. If we now use d = 0.120 m = 120 mm, then d/h = 120/25 =
4.8 and d/b = 120/235 = 0.511. This gives K
ca
= 2.16 and K
cb
= 1.4. Therefore,
d = 0.235 m
(6 MN/m)(2.16) + (2.88 MN/m)(1.4)
152 MPa
= 0.123 m
This is close to the assumed value, and closer agreement between assumed and calculated values is
dicult because of the resolution of Figs. 6.2a and 6.2b.
Section 6.3
6.10 A Plexiglas plate with dimensions 1 m 1 m 10 mm is loaded by a nominal tensile stress of 55 MPa
in one direction. The plate contains a small crack perpendicular to the load direction. At this stress
level a safety factor of 2 against crack propagation is obtained. Find how much larger the crack can
get before it grows catastrophically. Ans, a
2
= 4a
1
.
Notes: Equation (6.4) is used to solve this problem.
Solution: For the rst case, Eq. (6.4) gives:
K
ci
2
= Y
nom

a
1
K
ci
= 2Y
nom

a
1
For the second case, the safety factor would be unity so that:
K
ci
= Y
nom

a
2
Substituting for K
ci
:
Y
nom

a
2
= 2Y
nom

a
1
a
2
= 2
2
a
1
= 4a
1
Therefore, the crack can be 300% larger before catastrophic failure occurs.
6.11 A pressure container is made of AISI 4340 steel. The wall thickness is such that the tensile stress in
the material is 1100 MPa. The dimensionless geometry correction factor Y = 1 for the given geometry.
Find how big the largest crack can be without failure if the steel is tempered
(a) At 260

C Ans. 1.31 mm.

(b) At 425

C Ans. 4.00 mm.

Notes: The material properties as a function of temper temperature is obtained from Table 6.1.
Equation 6.4 is used to solve the problem.
Solution: The nominal stress is given as
nom
= 1100 MPa, and Y = 1. The critical crack length is
derived from Eq. (6.4):
K
ci
= Y
nom

a a =
1

_
K
ci
Y
nom
_
2
Note that a is one-half the crack length.
123
(a) From Table 6.1, at a temper of 260

C, the fracture toughness is 50 MPa-m

1/2
. Therefore,
a =
1

_
50 MPa

m
(1)(1100 MPa)
_
2
= 6.577 10
4
m = 0.6577 mm
Note that a is one-half the crack length, so that the critical crack length is 1.31 mm.
(b) At a temper of 425

C, K
ci
= 87.4 MPa

m. Therefore,
a =
1

_
87.4 MPa

m
(1)(1100 MPa)
_
2
= 0.002009 10
4
m = 2.009 mm
The critical crack length is 4.00 mm.
6.12 Two tensile test rods are made of AISI 4340 steel tempered at 260

C and aluminum alloy 2024-T351.

The dimensionless geometry correction factor Y = 1. Find how high a stress each rod can sustain if
there is a crack of 2-mm half-length in each of them. Ans. AISI 4340: = 631 MPa.
Notes: The fracture toughness for these materials is obtained from Table 6.1 on page 232. The
nominal stress that can be sustained is then given by Eq. (6.4).
Solution: From Table 6.1 on page 232, K
ci
for AISI 4340 is 50.0 MPa-m
1/2
. For Al 2024-T351, K
ci
is 36 MPa-m
1/2
. Therefore, the stress in the steel is given by Eq. (6.4) as:
K
ci
= Y
nom

a
nom
=
K
ci
Y

a
=
50.0 MPa
(1)
_
(0.002)
= 631 MPa
For the Al 2024-T351,
K
ci
= Y
nom

a
nom
=
K
ci
Y

a
=
36.0 MPa
(1)
_
(0.002)
= 454 MPa
6.13 A plate made of titanium alloy Ti-6Al-4V has the dimensionless correction factor Y = 1. How large
can the largest crack in the material be if it still should be possible to plastically deform the plate in
tension? Ans. 1.488 mm.
Notes: To plastically deform the plate, the nominal stress must exceed the yield strength of the
material. Therefore, Eq. (6.4) solves the problem.
Solution: From Table 6.1 on page 232, the fracture toughness for Ti-6Al-4V varies from 44-66 MPa-
m
1/2
. Also, the yield strength is 910 MPa. To plastically deform the material,
nom
> S
y
, or, from
Eq. (6.4),
K
ci
= Y
nom

a
nom
=
K
ci
Y

a
S
y
Solving for a,
K
ci
Y

a
S
y
a =
1

_
K
ci
Y S
y
_
2
=
1

_
K
ci
(1)(910 MPa)
_
2
Since K
ci
has a value between 44-66 MPa-m
1/2
, then a has a range of a 0.7441.67 mm. Therefore,
if the largest crack is below 0.744 mm in half-length (1.488 mm in length), then the nominal stress will
be larger than the yield strength.
6.14 A Plexiglas model of a gear has a 1-mm half-length crack formed in its llet curve (where the tensile
stress is maximum). The model is loaded until the crack starts to propagate. Y = 1.5. How much
higher a load can a gear made of AISI 4340 steel tempered to 425

C carry with the same crack and

the same geometry? Ans.
steel
/
plexiglass
= 87.4
124 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
Notes: Equation (6.4) is used to solve the problem with data from Table 6.1. This solution makes
sure that the steel does not plastically deform before catastrophic crack propagation occurs.
Solution: From Table 6.1 on page 232, the fracture toughnesses for plexiglass and steel are 1.0 and
87.4 MPa-m
1/2
, respectively. For a gear, the bending stress is directly proportional to the applied load,
so for a constant crack size a and correction factor Y the load possible is directly proportional to K
ci
.
Therefore, K
ci
for steel is 87.4 times larger than for plexiglass, so it may be possible to support a load
87.4 times larger.
However, it is possible that the steel will plastically deform at a lower stress than that needed to
propogate the crack. With a = 1 mm = 0.001 m, Eq. (6.4) predicts the nominal stress level as:
K
ci
= Y
nom

a
nom
=
K
ci
Y

a
=
87.4 MPa

m
(1.5)
_
(0.001 m)
= 1040 MPa
Table 6.1 gives the yield strength for AISI 4340 tempered to 425

C as 1420 MPa. Therefore, the

nominal stress level needed for crack propagation is not sucient to cause plastic deformation, and a
load 87.4 times larger than for plexiglass can be carried.
6.15 A pressure vessel made of aluminum alloy 2024-T351 is manufactured for a safety factor of 2.5 guarding
against yielding. The material contains cracks through the wall thickness with a crack half-length less
than 3 mm. Y = 1. Find the safety factor when considering crack propagation.
Notes: The safety factor guarding against crack propagation is obtained from the ratio of the fracture
toughness of the material to the stress intensity factor calculated by Eq. (6.4).
Solution: From Table 6.1 on page 232, S
y
= 325 MPa and K
ci
= 36 MPa-m
1/2
. The safety factor
guarding against yielding is 2.5, therefore the nominal stress is
nom
= 130 MPa. The stress intensity
factor is therefore calculated from Equation (6.4) as
K
i
= Y
nom

a = (1)(130 MPa)
_
(0.003 m) = 12.62 MPa

m
The safety factor against crack propagation is therefore
n
s
=
K
ci
K
i
=
36 MPa

m
12.62 MPa

m
= 2.85
Since the safety factor for yielding is lower than the safety factor guarding against crack propagation,
the safety factor for the pressure vessel is still 2.5.
6.16 The clamping screws holding the top lid of a nuclear reactor are made of AISI 4340 steel tempered
at 260

C. They are stressed to a maximum level of 1250 MPa during a pressurization test before
starting the reactor. Find the safety factor guarding against yielding and the safety factor guarding
against crack propagation if the initial cracks in the material have Y = 1 and a = 1 mm. Also, do the
calculations for the same material but tempered to 425

C. Ans. AISI 4340 tempered at 260

C: n
s
=
0.714.
Notes: This problem is similar to the previous problem. Equation (6.4) is used to solve this problem.
Solution:
(a) AISI 4340 Tempered at 260

C
From Table 6.1 on page 232, S
y
= 1640 MPa and K
ci
= 50 MPa-m
1/2
. The safety factor against
yielding is therefore
n
s
=
S
y

=
1640 MPa
1250 MPa
= 1.31
125
From Equation (6.4), the stress intensity factor is
K
i
= Y
nom

a = (1)(1250 MPa)
_
(0.001 m) = 70.06 MPa

m
The safety factor guarding against crack propagation is therefore
n
s
=
K
ci
K
i
=
50 MPa

m
70.06 MPa

m
= 0.714
Since the safety factor is less than 1, the bolts will fail.
(b) AISI 4340 Tempered at 435

C From Table 6.1 on page 232, S

y
= 1420 MPa and K
ci
= 87.4
MPa-m
1/2
. Using the same equations, the safety factor against yielding is n
s
= 1.14, and the
safety factor against crack propagation is n
s
= 1.25. Therefore, the bolts will not crack.
6.17 A glass tube used in a pressure vessel is made of aluminum oxide (sapphire) to make it possible to
apply 30-MPa pressure and still have a safety factor of 2 guarding against fracture. For a soda-lime
glass of the same geometry only 7.5-MPa pressure can be allowed if a safety factor of 2 is maintained.
Find the size of the cracks the glass tube can tolerate at 7.5-MPa pressure and a safety factor of 2. Y
= 1 for both tubes. Ans. Sapphire: 2a < 75.2 m, Glass: 2a < 65.6 m.
Notes: Material properties are obtained from Table A.3. As is shown in Chapter 9, the stress is
proportional to the pressure. Equation (6.4) is used to solve this problem.
Solution: From Table A.3 on page 901, the fracture strength of soda-lime glass is 69 MPa. The
stresses in the tube are directly proportional to the pressure, so the fracture strength of the aluminum
oxide tube is:
S
fa
p
a
=
S
fs
p
s
S
fs
=
S
fs
p
a
p
s
=
(69 MPa)(30 MPa)
7.5 MPa
= 276 MPa
Note that this is on the low end of the fracture strength values given in Table A.3 for aluminum oxide
(Al
2
O
3
).
For a safety factor of 2, the applied stress is 276/2=138 MPa. From Table 6.1 on page 232, using a
low value of fracture toughness for Al
2
O
3
, use K
cia
= 3.0 MPa-m
1/2
. From Eq. (6.4),
K
i
=
K
ci
2
= Y
nom

a
a =
1

_
K
ci
2Y
nom
_
2
=
1

_
3.0 MPa

m
2(1)(138 MPa)
_
2
= 3.76 10
5
m = 37.6 m
For the soda lime glass, the lowest value of fracture toughness is K
ci
= 0.7 MPa-m
1/2
. The applied
stress is
nom
= 69 MPa/2 = 34.5 MPa. The stress intensity factor equation is
K
i
=
K
ci
2
= Y
nom

a
a =
1

_
K
ci
2Y
nom
_
2
=
1

_
0.7 MPa

m
2(1)(34.5 MPa)
_
2
= 3.28 10
5
m = 32.8 m
Therefore, the largest crack in the aluminum oxide must be less than 2a or 75.2 m, while for soda
lime glass the largest crack must be smaller than 65.6 m.
6.18 A stress optic model used for demonstrating the stress concentrations at the ends of a crack is made
of polymethylmethacrylate. An articially made crack 100 mm long is perpendicular to the loading
126 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
direction. Y = 1. Calculate the highest tensile stress that can be applied to the model without
propagating the crack. Ans.
nom
= 1.78 MPa.
Notes: Material properties are obtained from Table 6.1 and Table A-4. Equation (6.4) is used to solve
this problem.
Solution: From Table 6.1 on page 232, the critical stress intensity factor for polymethylmethacrylate
is K
ci
= 1.0 MPa-m
1/2
. From Equation (6.4) the stress when the crack propagates catastrophically is:
K
ci
= Y
nom

a
nom
=
K
ci
Y

a
=
1.0 MPa

m
(1)
_
(0.1 m)
= 1.78 MPa
From Table A-4 on page 902, the ultimate strength is between 48 and 76 MPa. Therefore, the crack
will propagate at a stress far lower than the ultimate strength of the material.
6.19 A passengerless airplane requires wings that are lightweight and the prevention of cracks more than 2
mm long. The dimensionless geometry correction factor Y is usually 2.15 for a safety factor of 2.
(a) What is the appropriate alloy for this application? Ans. Either Aluminum 2024-T351 or Alloy
steel 4340 tempered at 425

C.
(b) If Y is increased to 3.5, what kind of alloy from Table 6.1 should be used? Ans. Al 2020-T351.
Notes: This problem solution is restricted to the materials in Table 6.1. Equation (6.4) is needed to
obtain the solution.
Solution:
(a) From Eq. (6.4),
K
ci
= Y
nom

a
a is one-half the crack length, so a is set equal to 1 mm or 0.001 m for this case. Recognizing the
safety factor is 2, we assign
nom
= S
y
/2. Therefore, Eq. (6.4) yields
K
ci
= Y
S
y
2

a
K
ci
S
y
=
Y
2

a = 2.15
1
2
_
(0.001 m) = 0.060
Note from Table 6.1:
Material S
y
K
ci
K
ci
/S
y
Al 2024-T351 325 36 0.110
Al 2024-T651 505 29 0.057
Steel 4340 Tempered at 260

C 1640 50 0.0305
Steel 4340 Tempered at 425

C 1420 87.4 0.0615

Ti-6Al-4V 910 44-66 0.048-0.0725
From these calculations, either Al 2024-T351 or Steel 4340 tempered at 425

C would be suitable.
Ti-6Al-4V may be acceptable depending on the quality of the material.
(b) If Y = 3.5, then from Eq. (6.4),
K
ci
S
y
=
Y
2

a = 3.5
1
2
_
(0.001 m) = 0.098
For this condition, only Al 2024-T351 would be suitable.
Section 6.6
127
6.20 The anchoring of the cables carrying a suspension bridge are made of cylindrical AISI 1080 steel bars
210 mm in diameter. The force transmitted from the cable to the steel bar is 3.5 MN. Calculate the
safety factor range guarding against yielding based on the allowable stressed from Eq. (3.13). Ans.
1.69 < n
s
< 2.25
Notes: The material property is obtained from the inside front cover. Equation (3.13) gives a range
for allowable stresses in tension.
Solution: From the inside front cover, the yield strength for AISI 1080 is S
y
= 380 MPa. The stress
in the steel bar is
=
P
A
=
3.5 MN

4
(0.21 m)
2
= 101 MPa
Since the safety factor is n
s
=
all
/, Eq. (3.13) gives
0.45S
y

all
0.60S
y
0.45S
y

n
s

0.60S
y

0.45(380 MPa)
101 MPa
n
s

0.60(380 MPa)
101 MPa
Therefore the safety factor is in the range of 1.69 n
s
2.25.
6.21 The arm of a crane has two steel plates connected with a rivet that transfers the force in pure shear.
The rivet is made of AISI 1040 steel and has a circular cross section with a diameter of 25 mm. The
load on the rivet is 20 kN. Calculate the safety factor. Ans. n
s
= 3.44
Notes: Equation (3.14) gives the allowable stress in shear.
Solution: The yield strength of AISI 1040 steel is obtained from the inside front cover as S
y
= 350
MPa. From Eq. (3.14),

all
= 0.4S
y
= 0.4(350 MPa) = 140 MPa
The shear stress on the rivet is
=
P
A
=
20 kN
_

4
(0.025 m)
2
_ = 40.74 MPa
Therefore, the safety factor is:
n
s
=

all

=
140 MPa
40.74 MPa
= 3.44
Section 6.7
6.22 A machine element is loaded so that the principal normal stresses at the critical location for a biaxial
stress state are
1
= 20 ksi and
2
= -15 ksi. The material is ductile with a yield strength of 60 ksi.
Find the safety factor according to
(a) The maximum-shear-stress theory (MSST) Ans. n
s
= 1.714
(b) The distortion-energy theory (DET) Ans. n
s
= 1.97
Notes: Equation (6.6) is used to obtain the safety factor for the MSST. Equation (6.11) gives the
safety factor for the DET after the von Mises stress is calculated from Eq. (6.9). If the stress is biaxial,
then one principal stress is zero.
128 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
Solution: First of all, since the stress state is biaxial, then one normal stress is zero. Therefore,
the three principle stresses are properly referred to as
1
= 20 ksi,
2
= 0 and
3
= 15 ksi, since

1

2

3
. For the maximum shear stress theory, Eq. (6.6) gives the safety factor as:

3
=
S
y
n
s
n
s
=
S
y

3
=
60 ksi
(20 ksi + 15 ksi)
= 1.714
The von Mises stress is obtained from Eq. (6.9) as:

e
=
1

2
_
(
2

1
)
2
+ (
3

1
)
2
+ (
3

2
)
2
_
1/2
=
1

2
_
(20 ksi)
2
+ (35 ksi)
2
+ (15 ksi)
2

1/2
or
e
= 30.4 ksi. Therefore, the safety factor is, from Eq. (6.11),

e
=
S
y
n
s
n
s
=
S
y

e
=
60 ksi
30.4 ksi
= 1.97
6.23 A bolt is tightened, subjecting its shank to a tensile stress of 80 ksi and a torsional shear stress of 50
ksi at a critical point. All of the other stresses are zero. Find the safety factor at the critical point by
the DET and the MSST. The material is high-carbon steel (AISI 1080). Will the bolt fail because of
the static loading? Ans. n
s,DET
= 0.47, n
s,MSST
= 0.43.
Notes: Equations (2.16), (6.6), (6.10), and (6.11) are used to solve this problem.
Solution: From the inside front cover, the yield stress for AISI 1080 steel is 55 ksi. Directions are
arbitrary; lets refer to the tensile stress as
x
= 80 ksi and the shear stress as
xy
= 50 ksi. Since all
other stresses are zero, Eq. (2.16) gives the principal stresses as

1
,
2
=

x
+
y
2

2
xy
+
_

y
2
_
2
=
80 ksi
2

(50 ksi)
2
+
_
80 ksi
2
_
2
or
1
= 104 ksi,
2
= 24 ksi. Note that the other stresses are zero, so the principal stress out of the
plane of the normal and shear stresses is zero. Putting the stresses in the proper order (
1

2

3
),
we assign them the values
1
= 104 ksi,
2
= 0 ksi,
3
= 24 ksi. From Eq. (6.6),

3
=
S
y
n
s
n
s
=
S
y

3
=
55 ksi
104 ksi (24 ksi)
= 0.43
which is the safety factor for the maximum shear stress theory. Equation (6.9) gives

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(104 ksi 0)
2
+ (104 ksi + 24 ksi)
2
+ (0 + 24 ksi)
2

1/2
= 118 ksi
From Eq. (6.11),

e
=
S
y
n
s
n
s
=
S
y

e
=
55 ksi
118 ksi
= 0.47
Since the safety factor is less than one for both cases, both cases predict failure.
6.24 A torque is applied to a piece of chalk used in a classroom until the chalk cracks. Using the maximum-
normal-stress theory (MNST) and assuming the tensile strength of the chalk to be small relative to its
compressive strength, determine the angle of the cross section at which the chalk cracks. Ans. 45

.
129
Notes: Given the loading condition, the angle of the largest tensile stress is obtained from Eq. (2.15).
Based on the MNST, failure will occur at this angle.
Solution: For pure torque, the stress state is
xy
= and
x
=
y
= 0. The angle of the largest
tensile stress,

, is given by Eq. (2.15) as:

tan2

=
2
xy

y
=
2
xy
0
=
Therefore,

= 45

. The chalk will crack along a 45

angle from its circumference.

6.25 A cantilevered bar 500 mm long with square cross section has 25-mm sides. Three perpendicular forces
are applied to its free end, a 1000 N force is applied in the x direction, a 100 N force is applied in the
y direction, and an equivalent force of 100 N is applied in the z direction. Calculate the equivalent
stress at the clamped end of the bar by using the DET when the sides of the square cross section are
parallel with the y and z directions.
Notes: The stresses are largest at the corners, where the total stress is the sum of two bending stresses
and the axial stress. The eective stress is obtained from Eq. (6.9).
Solution: The moment of inertia for the cross section is:
I =
bh
3
12
=
a
4
12
=
(0.025 m)
4
12
= 3.255 10
8
m
4
The cross sectional area is A = a
2
= (0.025 m)
2
= 6.25 10
4
m
2
. Since the bar is cantilevered,
the loading is a combined situation of two bending moments and one axial load. The perpendicular
moments are M
1
= M
2
= Fl = (100 N)(0.5 m) = 50 Nm. The axial load is 1000 N. Therefore, the
maximum stress occurs at a corner of the cross section, and is the sum of the stresses due to the three
loads. Therefore,

x
=
M
1
c
I
+
M
2
c
I
+
P
A
= 2
(50 Nm)(0.0125 m)
3.255 10
8
m
4
+
1000 N
6.25 10
4
m
2
= 40.00 MPa
There is no stress in the y or z directions. Also, at the outside edge of the bar, the shear stress is zero
(see page 169). Therefore,
1
= 40.00 MPa,
2
=
3
= 0. From Eq. (6.9), the von Mises stress is

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(40 MPa)
2
+ (40 MPa)
2
+ (0)
2

1/2
This is evaluated as
e
= 40 MPa.
6.26 A shaft transmitting torque from the gearbox to the rear axle of a truck is unbalanced, so that a
centrifugal load of 500 N acts at the middle of the 3-m-long shaft. The AISI 1040 tubular steel shaft
has an outer diameter of 70 mm and an inner diameter of 58 mm. Simultaneously, the shaft transmits
a torque of 6000 N-m. Use the DET to determine the safety factor guarding against yielding. Ans. n
s
= 1.196.
Notes: The moment must be determined, which then allows for calculation of the bending stress. The
torque results in a shear stress; this combined stress state is then transformed to obtain the principal
stresses. Equations (6.9) and (6.11) are then used to solve the problem.
Solution: From the inside front cover, the yield strength of AISI 1040 steel is S
y
= 350 MPa. The
moment of inertia for the shaft is:
I =

64
_
d
4
o
d
4
i
_
=

64
_
(0.070 m)
4
(0.058 m)
4

= 6.23 10
7
m
4
130 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
Similarly, J = 1.246 10
6
m
4
. For a simply supported shaft, the maximum moment occurs at the
center of the shaft and has the value M = Pl/4 = (500 N)(3 m)/4 = 375 Nm. Therefore, the bending
stress is obtained from Eq. (4.48) as:

x
=
Mc
I
=
(375 Nm)(0.035 m)
6.23 10
7
m
4
= 21.07 MPa
The shear stress due to the torque is given by Eq. (4.34) as:

xy
=
Tc
J
=
(6000 Nm)(0.035 m)
1.246 10
6
m
4
= 168.5 MPa
Also,
y
=
z
=
zx
=
yz
= 0. Therefore, from Eq. (2.16),

1
,
2
=

x
+
y
2

2
xy
+
_

y
2
_
2
=
21.07 MPa
2

(168.5 MPa)
2
+
_
21.07 MPa
2
_
2
Therefore,
1
= 179.4 MPa,
2
= 0, and
3
= 158.3 MPa. Note that the principal stresses have been
renumbered so that
1

2

3
. Equation (6.9) gives the eective stress as

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(179.4 MPa 0)
2
+ (179.4 MPa + 158.3 MPa)
2
+ (158.3 MPa)
2

1/2
= 292.6 MPa
From Equation (6.11),

e
=
S
y
n
s
n
s
=
S
y

e
=
350 MPa
292.6 MPa
= 1.196
6.27 The right-angle-cantilevered bracket used in Problem 5.30, sketch w, has a concentrated force of 1000
N and a torque of 300 N-m. Calculate the safety factor. Use the DET and neglect transverse shear.
Assume that the bracket is made of AISI 1040 steel and use the following values: a = 0.5 m, b = 0.3
m, d = 0.035 m, E = 205 GPa, and = 0.3. Ans. n
s
=1.76.
Notes: The stresses must be determined using the approach described in Chapter 4. From the stress
state, the principal stresses are determined. Equation (6.6) gives the safety factor for the Maximum
Shear Stress Theory, and Eqs. (6.9) and (6.11) give the safety factor for the Distortion-Energy Theory.
Solution: From the inside front cover, S
y
= 350 MPa for AISI 1040 steel. The moment of inertia of
the bracket cross section is:
I =

64
d
4
=

64
(0.035 m)
4
= 7.366 10
8
m
4
Similarly, J = 1.4732 10
7
m
4
. The maximum stress for the bracket occurs at the wall (x = a). The
loading is a bending moment and a torque. The moment is due to the applied torque T and the load
P, and is
M = Pa +T = (1000 N)(0.5 m) + 300 Nm = 800 Nm
Therefore, the bending stress is obtained from Eq. (4.48) as:

x
=
Mc
I
=
(800 Nm)(0.0175 m)
7.366 10
8
m
4
= 190 MPa
At the wall, there is a torque of T = Pb = (1000 N)(0.3 m) = 300 Nm. The shear stress due to the
torque is given by Eq. (4.34) as:

xy
=
Tc
J
=
(300 Nm)(0.0175 m)
1.4732 10
7
m
4
= 35.6 MPa
131
Also,
y
=
z
=
zx
=
yz
= 0. Therefore, from Eq. (2.16),

1
,
2
=

x
+
y
2

2
xy
+
_

y
2
_
2
=
190 MPa
2

(35.6 MPa)
2
+
_
190 MPa
2
_
2
Therefore,
1
= 196 MPa,
2
= 0, and
3
= 6.45 MPa. Note that the principal stresses have been
renumbered so that
1

2

3
. From Eq. (6.6), the safety factor for MSST is:

3
=
S
y
n
s
n
s
=
S
y

3
=
350 MPa
196 MPa + 6.45 MPa
= 1.73
Equation (6.9) gives the eective stress as

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(196 MPa 0)
2
+ (196 MPa + 6.45 MPa)
2
+ (6.45 MPa)
2

1/2
= 199 MPa
From Equation (6.11), the safety factor for DET is:

e
=
S
y
n
s
n
s
=
S
y

e
=
350 MPa
199 MPa
= 1.76
6.28 A 100-mm-diameter shaft is subjected to a 10 kN-m steady bending moment, an 8 kN-m steady torque,
and a 150-kN axial force. The yield strength of the shaft material is 600 MPa. Use the MSST and the
DET to determine the safety factors for the various types of loading. Ans. n
s
= 4.28.
Notes: This is similar to problems 6.28 and 6.29, but now a stress due to the axial force must be
included. From the stress state, the principal stresses are determined. Equation (6.6) gives the safety
factor for the Maximum Shear Stress Theory, and Eqs. (6.9) and (6.11) give the safety factor for the
Distortion-Energy Theory.
Solution: The moment of inertia of the shaft cross section is:
I =

64
d
4
=

64
(0.10 m)
4
= 4.909 10
6
m
4
Similarly, J = 9.817 10
6
m
4
. The area of the cross section is d
2
/4 = 0.00785 m
2
. The bending
stress is obtained from Eq. (4.48) as:

x
=
Mc
I
=
(10 kNm)(0.05 m)
4.909 10
6
m
4
= 101.8 MPa
The normal stress due to the axial load is

x
=
P
A
=
150 kN
0.00785 m
2
= 19.10 MPa
Therefore, the maximum normal stress is
x
= 101.8 MPa+19.10 MPa = 120.9 MPa. The shear stress
due to the torque is given by Eq. (4.34) as:

xy
=
Tc
J
=
(8 kNm)(0.05 m)
9.817 10
6
m
4
= 40.7 MPa
Also,
y
=
z
=
zx
=
yz
= 0. Therefore, from Eq. (2.16),

1
,
2
=

x
+
y
2

2
xy
+
_

y
2
_
2
=
120.9 MPa
2

(40.7 MPa)
2
+
_
120.9 MPa
2
_
2
132 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
Therefore,
1
= 133.3 MPa,
2
= 0, and
3
= 12.42 MPa. Note that the principal stresses have been
renumbered so that
1

2

3
. From Eq. (6.6), the safety factor for MSST is:

3
=
S
y
n
s
n
s
=
S
y

3
=
600 MPa
133.3 MPa + 12.42 MPa
= 4.12
Equation (6.9) gives the eective stress as

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(133.3 MPa 0)
2
+ (133.3 MPa + 12.42 MPa)
2
+ (12.42 MPa)
2

1/2
= 140 MPa
From Eq. (6.11), the safety factor for DET is:

e
=
S
y
n
s
n
s
=
S
y

e
=
600 MPa
140 MPa
= 4.28
6.29 Use the MSST and the DET to determine the safety factor for 2024 aluminum alloys for each of the
following stress states:
(a)
x
= 10 MPa,
y
= -60 MPa Ans. n
s,MSST
= 4.64.
(b)
x
=
y
=
xy
= -30 MPa Ans. n
s,DET
= 5.42.
(c)
x
=
y
= 20 MPa, and
xy
= 10 MPa Ans. n
s,MSST
= 7.27.
(d)
x
= 2
y
= -70 MPa, and
xy
= 40 MPa Ans. n
s,DET
= 3.53.
Notes: This problem does not require determination of the stresses as in Problems 6.28 through 6.30,
but uses the same approach. From the stress state, the principal stresses are determined. Equation
(6.6) gives the safety factor for the Maximum Shear Stress Theory, and Equations (6.9) and (6.11) give
the safety factor for the Distortion-Energy Theory
Solution: From Table 6.1, the yield strength for 2024-T351 is S
y
= 325 MPa.
(a) For
x
= 10 MPa,
y
= 60 MPa, note that there are no shear stresses. Therefore, we can
directly write the principal stresses as
1
= 10 MPa,
2
= 0 MPa and
3
= 60 MPa. Note that
the principal stresses have been renumbered so that
1

2

3
. From Eq. (6.6), the safety
factor for MSST is:

3
=
S
y
n
s
n
s
=
S
y

3
=
325 MPa
10 MPa + 60 MPa
= 4.64
Equation (6.9) gives the eective stress as

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(10 MPa 0)
2
+ (10 MPa + 60 MPa)
2
+ (60 MPa)
2

1/2
= 65.57 MPa
From Eq. (6.11), the safety factor for DET is:

e
=
S
y
n
s
n
s
=
S
y

e
=
325 MPa
65.57 MPa
= 4.96
133
(b) For
x
=
y
=
xy
= 30 MPa, Eq. (2.16) gives

1
,
2
=

x
+
y
2

2
xy
+
_

y
2
_
2
=
30 MPa 30 MPa
2

_
(30 MPa)
2
+ (0)
2
Therefore,
1
= 0 MPa,
2
= 0 MPa and
3
= 60 MPa. Note that the principal stresses have
been renumbered so that
1

2

3
. From Eq. (6.6), the safety factor for MSST is:

3
=
S
y
n
s
n
s
=
S
y

3
=
325 MPa
0 MPa + 60 MPa
= 5.42
Equation (6.9) gives the eective stress as

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(0 MPa)
2
+ (60 MPa)
2
+ (60 MPa)
2

1/2
= 60 MPa
From Equation (6.11), the safety factor for DET is:

e
=
S
y
n
s
n
s
=
S
y

e
=
325 MPa
60 MPa
= 5.42
(c) For
x
=
y
= 20 MPa and
xy
= 10 MPa, Eq. (2.16) gives

1
,
2
=

x
+
y
2

2
xy
+
_

y
2
_
2
=
20 MPa 20 MPa
2

_
(10 MPa)
2
+ (20 MPa + 20 MPa)
2
Therefore,
1
= 22.36 MPa,
2
= 0 MPa and
3
= 22.36 MPa. Note that the principal stresses
have been renumbered so that
1

2

3
. From Eq. (6.6), the safety factor for MSST is:

3
=
S
y
n
s
n
s
=
S
y

3
=
325 MPa
22.36 MPa + 22.36 MPa
= 7.27
Equation (6.9) gives the eective stress as

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(22.36 MPa 0)
2
+ (22.36 MPa + 22.36 MPa)
2
+ (22.36 MPa)
2

1/2
= 38.73 MPa
From Equation (6.11), the safety factor for DET is:

e
=
S
y
n
s
n
s
=
S
y

e
=
325 MPa
38.73 MPa
= 8.39
(d) For
x
= 2
y
= 70 MPa, and
xy
= 40 MPa, Eq. (2.16) gives

1
,
2
=

x
+
y
2

2
xy
+
_

y
2
_
2
=
70 MPa 35 MPa
2

_
(40 MPa)
2
+ (70 MPa + 35 MPa)
2
134 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
Therefore,
1
= 0 MPa,
2
= 8.84 MPa and
3
= 96.16 MPa. Note that the principal stresses
have been renumbered so that
1

2

3
. From Eq. (6.6), the safety factor for MSST is:

3
=
S
y
n
s
n
s
=
S
y

3
=
325 MPa
0 MPa + 96.16 MPa
= 3.38
Equation (6.9) gives the eective stress as

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(8.84 MPa)
2
+ (96.16 MPa)
2
+ (8.84 MPa + 96.16 MPa)
2

1/2
= 92.06 MPa
From Equation (6.11), the safety factor for DET is:

e
=
S
y
n
s
n
s
=
S
y

e
=
325 MPa
92.06 MPa
= 3.53
6.30 Four dierent stress elements, each made of the same material, are loaded as shown in sketches e, f,
g, and h. Use the MSST and the DET to determine which element is the most critical. Ans. Sketch e
is most critical.
21 MPa
21 MPa
7.5 MPa
28.5 MPa
30 MPa
30 MPa
10 MPa
30 MPa
(e) (f)
(g) (h)
Sketches e, f, g, and h, for Problem 6.30
Notes: Equations (2.16), (6.6), (6.10), and (6.11) are used to solve this problem.
Solution:
(e)
1
= 21 MPa,
2
= 0,
3
= 21 MPa. Therefore, from Eq. 6.6:
1

3
= 42 MPa. Also, from
Eq. 6.9,

e
=
1

2
_
(
1

2
)
2
+ (
2

3
)
2
+ (
3

1
)
2

1/2
= 36 MPa
(f)
1
= 28.5 MPa,
2
= 0,
3
= 7.5 MPa. Thus,
1

3
= 36 MPa. Also,

e
=
1

2
_
(
1

2
)
2
+ (
2

3
)
2
+ (
3

1
)
2

1/2
= 33 MPa
135
(g)
1
= 30 MPa,
2
= 30 MPa,
3
= 0. Thus,
1

3
= 30 MPa. Also
e
= 30 MPa.
(h)
x
= 30 MPa,
y
= 0,
xy
= 10 MPa. Therefore, from Equation (2.16),
1
= 33 MPa,
2
= 0,

3
= 3.02 MPa. Therefore,
1

3
= 36.02 MPa,
e
= 31.6 MPa.
This shows that the stress state in (e) is the largest.
6.31 The rod shown in sketch i is made of AISI 1040 steel and has two 90

bends. Use the MSST and the

DET to determine the minimum rod diameter for a safety factor of 2 at the most critical section.
300 mm
750 mm
y
y
x
z
z
x
50 mm
1500 N
100 N
800 N
Sketches i, for Problem 6.31
Notes: Recognizing that the critical section is at the wall, the component stresses can be expressed
as functions of the rod diameter. Applying MSST or DET gives an expression that can be solved for
d.
Solution: The yield strength for AISI 1040 is obtained from the inside front cover as 350 MPa. The
critical section is at the wall; the rod is slender so transverse shear eects will be ignored. The 800 N
load causes a torque equal to T
1
= 800 N(0.75 m)=600 Nm, and bending moment M
x1
= 800 N(0.3 m)
= 240 Nm. The 100 N load causes axial normal stress, a bending moment M
z1
= 100 N(0.75m)=75
Nm and a bending moment M
x2
= 100 N(0.05m)=5 Nm, which is in the opposite direction as M
x1
.
The 1500 N load causes torque equal to T
2
= 1500 N(0.05m)=75 Nm (in the opposite direction as
T
1
) and a bending moment M
z2
= 1500 N(0.3 m)= 450 Nm, which is in the opposite direction as M
z1
.
Therefore, the bar sees the following: M
x
= M
x1
M
x2
= 235 Nm, M
z
= 450 Nm-75 Nm= 375 Nm,
and T = T
1
T
2
= 600 Nm-75 Nm= 525 Nm. Therefore, the moment at the wall is
M =
_
M
2
x
+M
2
z
=
_
(235 Nm)
2
+ (375 Nm)
2
= 442.5 Nm
The normal stress is therefore
=
Mc
I
+
P
A
=
100 N

4
d
2
+
(442.5 Nm)(d/2)

64
d
4
=
127.3 N
d
2
+
4507 Nm
d
3
=
(127.3 N)d + 4507 Nm
d
3
The shear stress is:
=
Tc
J
=
(525 Nm)(d/2)

32
d
4
=
2674 Nm
d
3
136 CHAPTER 6. FAILURE PREDICTION FOR STATIC LOADING
Equation (2.16) gives

1
,
2
=

x
+
y
2

2
xy
+
_

y
2
_
2
=
1
d
3
_
[(63.65 N)d + 2253.5 Nm]
_
(2674 Nm)
2
+ [(63.65 N)d + 2253.5 Nm]
2
_
It can be shown that unless d is in the thousands of meters, that one of these stresses will be positive,
and the other negative. Therefore, for MSST, Eq. (6.6) is:

3
=
S
y
n
s
=
350 MPa
2
= 175 MPa
Substituting for the stresses and solving yields d = 0.0341 m. Therefore, a 35 mm diameter cross-section
is a good design designation. For DET, Equations (6.9) and (6.11) give:

e
=
1

2
_
(
1

2
)
2
+ (
1

3
)
2
+ (
2

3
)
2

1/2
=
1

2
_
(
1
)
2
+ (
1

3
)
2
+ (
3
)
2

1/2
= 175 MPa
This is solved numerically as d = 0.0287 m. Therefore, a 35 mm diameter cross section is still accept-
able.
6.32 The shaft shown in sketch j is made of AISI 1020 steel. Determine the most critical section by using
the MSST and the DET. Dimensions of the various diameters shown in sketch j are d = 30 mm, D =
45 mm, and d
2
= 40 mm.
40 mm
40 mm
40 mm
D
d
r = 6 mm
r = 9 mm
T = 50 N-m
10 kN
1 kN
d
2
Sketches j, for Problem 6.32
Notes: This problem requires the incorporation of stress concentration eects into the component
stresses before determining the principal stresses.
Solution:
(a) Fillet. First, considering the location of stress concentration 80 mm from the wall:
J =

32
d
4
=

32
(0.040 m)
4
= 7.95 10
8
m
4
I =
J
2
= 3.98 10
8
m
4
A = d
2
/4 = 7.07 10
4
m
2
Also, from statics, V = 1 kN, M = 40 Nm, N = 10 kN, T = 50 Nm. The bottom location
is critical, since the bending and tensile stresses are additive at this location. Also, there is no
shear stress due to shear at the extreme location. The stress concentration due to bending is
obtained from Fig. 6.5(b) as 1.4, while for tension it is K
c
= 1.55 from Fig. 6.5(a). The stress
concentration for torsion is K
c
= 1.2 from Fig. 6.5(c). Therefore,
1
= 458 MPa and
2
= 28
MPa.
137
(b) Groove For the location 40 mm from the wall, N = 10 kN, M = 80 Nm T = 50 Nm,
K
c
(bending) = 1.45, K
c
(tension) = 1.5, K
c
(torsion) = 1.2 (all from Fig. 6.6). Therefore,

1
= 31.2 MPa and
2
= 0.76.
This means that the critical location is 80 mm from the wall, as the stresses are higher.