MOS - CEP 1 Fahad
MOS - CEP 1 Fahad
MOS - CEP 1 Fahad
ME314
MECHANICS OF SOLIDS
Dated 28/12/2022
Contents
Problem Statement:.................................................................................................................................2
Design Limitations and Requirements: ....................................................................................................2
Assumption: .............................................................................................................................................3
Procedure: ...............................................................................................................................................3
Calculation: ..............................................................................................................................................3
Reaction forces on the Beam:..............................................................................................................3
Moment on the beam:.........................................................................................................................4
Equation for Shear force: .....................................................................................................................5
Equation for Bending Moment: ...........................................................................................................5
Equation for Deflection (θ): .................................................................................................................6
Equation for Displacement (y): ............................................................................................................7
First Moment of Inertia of point P: ......................................................................................................7
Second Moment of Inertia 𝑰𝒙𝒙: ..........................................................................................................8
Equation for Bending stress (𝝈): ..........................................................................................................8
Equation for Shear Stress (𝝉): ..............................................................................................................8
Equation for Torsional Stresses: ..........................................................................................................9
Equation for Total Shear stresses: .......................................................................................................9
Equation for Principal Stresses: ...........................................................................................................9
Equation for Maximum Shear stress: ................................................................................................10
Calculating Factor of Safety: ..............................................................................................................10
FINITE ELEMENT ANALYSIS (FEA): ..........................................................................................................11
Procedure: .........................................................................................................................................11
CAD Modelling: ..................................................................................................................................11
Geometry: ..........................................................................................................................................12
Conclusion:.............................................................................................................................................21
1
Problem Statement:
A Cantilever beam is to be designed, as shown in Figure 1, which is under torsion and non-uniform
distributed loading. The data provided is as follows:
• The beam is fixed on one end by solid surface and the other end is free to move.
• Total length of the beam is 3 m.
• Torsional load of 500 Nm is applied at the free end (at x=3m).
• Distributed load (𝑤𝑜 ) of 1 kN/m is applied over its top surface. The load is distributed as
follows:
➢ At x = 0 m, F = 0 N/m.
➢ At x = 3 m, F = 1 kN/m.
• Reaction Forces
• Cross-sectional dimensions
• Maximum stress value and location by distortion energy theory
• Maximum displacement value and location
• Factor of safety
• Strength to weight ratio
• Manufacturing drawing
• Finite Element Analysis (FEA).
2
➢ Elastic Modulus: 69 GPa
• Maximum Strength to weight ratio (𝑋):
𝑈𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑆𝑡𝑟𝑒𝑛𝑔ℎ𝑡
𝑋= (1)
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑇ℎ𝑒 𝑏𝑒𝑎𝑚
Assumption:
Some assumptions are made to simplify the analysis of beam to design. It is follows:
Procedure:
The problem-solving strategy adopted for the analysis can be put as follows:
Calculation:
Reaction forces on the Beam:
Let 𝑹𝑨 is the reaction force acting on the beam at the fixed end A, W is the weight of the beam and
𝒘𝒐 is the distributed load acting on the beam in the downward direction. Applying the condition of
3
Figure 2 Free body diagram of the beam
equilibrium on the beam to find the reaction force 𝑹𝑨 . The free body diagram of the beam is shown
in the figure. In the free body diagram, the distributed load (𝒘𝒐 ) is shown as the concentrated
𝒘𝒐 𝒍
equivalent load ( ) at appropriate distance from the fixed end A.
𝟐
∑𝐹𝑦 = 0
𝑤𝑜 𝑙
𝑅𝐴 − 𝑊 − =0
2
Solve the equation for 𝑅𝐴 :
𝑤𝑜 𝑙
𝑅𝐴 = 𝑊𝑚 + (2)
2
Put 𝑤𝑜 = 1000 𝑁/𝑚 and 𝑙 = 3 𝑚 in equation (2), we get;
𝑅𝐴 = 𝑊𝑚 + 1500 (𝑖)
∑𝑀𝑧 = 0
𝑙 𝑤𝑜 𝑙 2𝑙
𝑀𝐴 − 𝑊 ( ) − ( )=0
2 2 3
Simplify the equation and solve for 𝑀𝐴 , we get;
𝑊𝑙 𝑤𝑜 𝑙2
𝑀𝐴 = + (3)
2 3
Put 𝑤𝑜 = 1000 𝑁/𝑚 and 𝑙 = 3 𝑚 in equation (3), we get;
4
Equation for Shear force:
Using the method of sections and equilibrium conditions with the sign conventions, we will find the
equation for shear forces. The free body diagram of a section of the given beam is shown in the
figure (2).
𝑾𝒙 𝒘𝒐 𝒙𝟐
In the free body diagram, represent the weight of the beam per unit length, represent the
𝒍 𝟐𝒍
distributed load on the section and V represent the shear force.
Now applying the condition of equilibrium, the sum of all forces acting on the beam in the direction
of y- axis is zero. i.e
∑𝐹𝑦 = 0
𝑊 𝑤𝑜 𝑥 2
𝑅𝐴 − .𝑥 − −𝑉 =0
𝑙 2𝑙
𝑊𝑥 𝑤𝑜 𝑥 2
𝑉 = 𝑅𝐴 − −
𝑙 2𝑙
𝑤𝑜 𝑙
Substitute 𝑅𝐴 = 𝑊 + in the above equation:
2
𝑤𝑜 𝑙 𝑊𝑥 𝑤𝑜 𝑥 2
𝑉 = (𝑊 + )− −
2 𝑙 2𝑙
Simplifying the equation, we get;
𝑤𝑜 𝑙 𝑊𝑥 𝑤𝑜 𝑥 2
𝑉=𝑊+ − − (4)
2 𝑙 2𝑙
Equation for Bending Moment:
Let M is the bending moment acting on the beam. Using the method of sections and equilibrium
conditions with the sign conventions, we will find the equation for bending moment.
Applying the condition for equilibrium on the beam, the sum of all moment acting on the beam
about z-axis is zero. i.e.
∑𝑀𝑧 = 0
From the free body diagram shown in the figure(2),
𝑤𝑜 𝑥 2 𝑥 𝑊𝑥 𝑥
𝑀𝐴 + 𝑀 − 𝑅𝐴 . 𝑥 + . + . =0
2𝑙 3 𝑙 2
5
𝑤𝑜 𝑥 3 𝑊𝑥 2
𝑀 = 𝑅𝐴 . 𝑥 − 𝑀𝐴 − −
6𝑙 2𝑙
𝑤𝑜 𝑙 𝑊𝑙 𝑤𝑜 𝑙2
Substitute 𝑅𝐴 = 𝑊 + and 𝑀𝐴 = + into the equation:
2 2 3
𝑤𝑜 𝑙 𝑊𝑙 𝑤𝑜 𝑙2 𝑤𝑜 𝑥 3 𝑊𝑥 2
𝑀 = (𝑊 + )𝑥 − ( + )− −
2 2 3 6𝑙 2𝑙
𝑤𝑜 𝑙𝑥 𝑊𝑙 𝑤𝑜 𝑙2 𝑤𝑜 𝑥 3 𝑊𝑥 2
𝑀(𝑥) = 𝑊𝑥 + − − − − (5)
2 2 3 6𝑙 2𝑙
Equation for Deflection (θ):
The formula for displacement and deflection is given by;
𝑑2 𝑦
𝐸𝐼 = 𝑀(𝑥) (6)
𝑑𝑥 2
Substituting equation (5) in equation (6):
𝑑2 𝑦 𝑊𝑙 𝑤𝑜 𝑙2 𝑤𝑜 𝑙𝑥 𝑊𝑥 2 𝑤𝑜 𝑥 3
𝐸𝐼 2 = − − + 𝑊𝑥 + − −
𝑑𝑥 2 3 2 2𝑙 6𝑙
𝑑𝑦 𝑊𝑙𝑥 𝑤𝑜 𝑙2 𝑥 𝑊𝑥 2 𝑤𝑜 𝑙𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑥 4
𝐸𝐼 = − − + + − − + 𝐶1 (𝑎)
𝑑𝑥 2 3 2 4 6𝑙 24𝑙
𝑑𝑦
Since 𝑑𝑥 = θ, substitute it in equation (a) and solve for θ:
1 𝑊𝑙𝑥 𝑤𝑜 𝑙2 𝑥 𝑊𝑥 2 𝑤𝑜 𝑙𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑥 4
θ= (− − + + − − + 𝐶1 ) (𝑏)
𝐸𝐼 2 3 2 4 6𝑙 24𝑙
Using the boundary condition for cantilever beam, find the value of constant 𝐶1 .
At x=0, the value of θ=0. Substitute these values in equation (b), we get;
𝐶1 = 0
By putting the value of 𝐶1 in equation (b), the deflection equation of the given beam become as;
1 𝑊𝑙𝑥 𝑤𝑜 𝑙2 𝑥 𝑊𝑥 2 𝑤𝑜 𝑙𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑥 4
θ= (− − + + − − ) (7)
𝐸𝐼 2 3 2 4 6𝑙 24𝑙
6
Equation for Displacement (y):
In order to find the equation for the displace of the beam after deformation in the direction of y-
axis, integrate the equation (a) with respect to dx, we get:
𝑊𝑙𝑥 2 𝑤𝑜 𝑙2 𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑙𝑥 3 𝑊𝑥 4 𝑤𝑜 𝑥 5
𝐸𝐼y = (− − + + − − + 𝐶2 )
4 6 6 12 24𝑙 120𝑙
1 𝑊𝑙𝑥 2 𝑤𝑜 𝑙2 𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑙𝑥 3 𝑊𝑥 4 𝑤𝑜 𝑥 5
y= (− − + + − − + 𝐶2 ) (𝑐)
𝐸𝐼 4 6 6 12 24𝑙 120𝑙
Now using the boundary conditions for cantilever beam to find the value of constant 𝐶2 .
At x=3, the value of y=. Substitute these values in equation (), we get;
𝐶2 = 0
By putting the value of 𝐶2 in equation (c), the displacement equation of the given beam become as;
1 𝑊𝑙𝑥 2 𝑤𝑜 𝑙2 𝑥 2 𝑊𝑥 3 𝑤𝑜 𝑙𝑥 3 𝑊𝑥 4 𝑤𝑜 𝑥 5
y= (− − + + − − ) (8)
𝐸𝐼 4 6 6 12 24𝑙 120𝑙
𝑄 = 𝐴 × 𝑦̅
𝑎𝑡 𝑎
To find the value of 𝑸 at point P, Substitute 𝐴 = and 𝑦̅ = 2 in the above equation:
2
𝑎𝑡 𝑎
𝑄= ×
2 2
𝑎2 𝑡
𝑄= (9)
4
7
Second Moment of Inertia 𝑰𝒙𝒙 :
The moment of inertia of a square cross section about the 𝑥-axis is given by:
1
𝐼𝑥𝑥 = 𝑏ℎ3
12
To find the second moment of the cross section having thickness (𝑡) and length (𝑙), subtract the
moment of inertia of the inner square from the outer square:
1 1
𝐼𝑥𝑥 = ( 𝑎. 𝑎 3 ) − ( (𝑎 − 2𝑡)(𝑎 − 2𝑡)3 )
12 12
1 4 1
𝐼𝑥𝑥 = ( 𝑎 ) − ( (𝑎 − 2𝑡)4 )
12 12
1 4 1 4
𝐼𝑥𝑥 = ( 𝑎 )− (𝑎 − 8𝑎 3 𝑡 + 24𝑎 2 𝑡 2 − 32𝑎𝑡 3 + 16𝑡 4 )
12 12
By simplify the above equation, we get;
2 3 7 4
𝐼𝑥𝑥 = 𝑎 𝑡 − 2𝑎 2 𝑡 2 + 𝑎𝑡 3 − 𝑡 4
3 3 3
1
𝐼𝑥𝑥 = (2𝑎 3 𝑡 − 6𝑡 2 + 7𝑎𝑡 3 − 4𝑡 4 ) (10)
3
8
𝑎2 𝑡
𝜏1 = 4 𝑉
1
(2𝑎 3 𝑡 − 6𝑡 2 + 7𝑎𝑡 3 − 4𝑡 4 )𝑡
3
3𝑎 2 𝑡𝑉
𝜏1 =
4(2𝑎 3 𝑡 − 6𝑡 2 + 7𝑎𝑡 3 − 4𝑡 4 )𝑡
3𝑎 2 𝑉
𝜏1 = (12)
(8𝑎 3 𝑡 − 24𝑡 2 + 28𝑎𝑡 3 − 16𝑡 4 )
Where,
T= Applied Torque
As the mean perimeter of the hollow square cross section have thickness 𝑡 is (𝑎 − 𝑡)2 , then the
torsional stresses became as;
𝑇
𝜏2 =
2𝑡(𝑎 − 𝑡)2
T
𝜏2 = (13)
2a2 t − 8at 2 + 8t 3
Equation for Total Shear stresses:
There are two shear stresses in the beam, i.e one shear stress (𝜏1 ) is due to the distributed load and
the second shear stress (𝜏2 ) is due to the applied torque (T). The net shear stresses in the beam is
given by.
𝜏 = 𝜏1 + 𝜏2
3𝑎 2𝑉 T
Substitute 𝜏1 = (8𝑎3 and 𝜏2 = in the equation to get equation for
𝑡−24𝑡 2+28𝑎𝑡 3 −16𝑡 4) 2a2t−8at2+8t3
total shear stresses:
3𝑎 2 𝑉 T
𝜏= + (14)
(8𝑎 3 𝑡 − 24𝑡 2 + 28𝑎𝑡 3 − 16𝑡 4 ) 2a2 t − 8at 2 + 8t 3
9
Substitute equation (11) and equation (14) in equation (d), we get;
3𝑀. 𝑎
𝜎1,2 = ( )
2(4𝑎 3 𝑡 − 12𝑡 2 + 14𝑎𝑡 3 − 8𝑡 4 )
2 2
3𝑀. 𝑎 3𝑎 2 𝑉 T
±√ ( 3 2 3 4 ) + ( + 2 )
2(4𝑎 𝑡 − 12𝑡 + 14𝑎𝑡 − 8𝑡 ) (8𝑎 𝑡 − 24𝑡 + 28𝑎𝑡 − 16𝑡 ) 2a t − 8at 2 + 8t 3
3 2 3 4
𝜎𝑥𝑥 − 𝜎𝑥𝑥 2
𝜏𝑚𝑎𝑥 = √( ) + 𝜏𝑥𝑦 2
2
Substitute equation (11) and equation (14) in above equation, we get;
2 2
3𝑀.𝑎 3𝑎2𝑉 T
𝜏𝑚𝑎𝑥 =√(2(4𝑎3𝑡−12𝑡 2+14𝑎𝑡 3 −8𝑡 4) ) + ((8𝑎3𝑡−24𝑡 2+28𝑎𝑡 3 −16𝑡 4) + 2a2t−8at2+8t3) (15)
The following beam is selected based upon the design requirements as discussed in Section 2.
10
Property Value
Thickness 0.001 m
Volume 0.00159 𝑚3
Weight 42.11433 N
Procedure:
The procedure used for modelling and simulation is discussed in this section.
CAD Modelling:
11
Geometry:
TABLE 2 Model (B4) > Geometry Imports
Object Name Geometry Imports
State Solved
Model (B4) > Geometry Imports > Geometry Import (B3)
Object Name Geometry Import (B3)
State Solved
Definition
Source C:\Users\izhar\Documents\Fahad Cep Mos\Part2.STEP
Type Step
Basic Geometry Options
Solid Bodies Yes
Surface Bodies Yes
Line Bodies No
Parameters Independent
Parameter Key ANS;DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves Updated File No
Use Instances Yes
Smart CAD Update Yes
Compare Parts On Update No
Analysis Type 3-D
Mixed Import Resolution None
Import Facet Quality Source
Clean Bodies On Import No
Stitch Surfaces On Import None
Decompose Disjoint Geometry Yes
Enclosure and Symmetry Processing Yes
Geometry
TABLE 4
Model (B4) > Geometry
Object Name Geometry
State Fully Defined
Definition
Source C:\Users\izhar\Documents\Fahad Cep Mos\Part2.STEP
Type Step
Length Unit Meters
Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 3. m
12
Length Y 0.1335 m
Length Z 0.1335 m
Properties
Volume 1.59e-003 m³
Mass 4.4043 kg
Scale Factor Value 1.
Statistics
Bodies 1
Active Bodies 1
Nodes 3360
Elements 1656
Mesh Metric None
Update Options
Assign Default Material No
Basic Geometry Options
Solid Bodies Yes
Surface Bodies Yes
Line Bodies No
Parameters Independent
Parameter Key ANS;DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves Updated File No
Use Instances Yes
Smart CAD Update Yes
Compare Parts On Update No
Analysis Type 3-D
Mixed Import Resolution None
Import Facet Quality Source
Clean Bodies On Import No
Stitch Surfaces On Import None
Decompose Disjoint Geometry Yes
Enclosure and Symmetry Processing Yes
TABLE 5 Model
(B4) > Geometry > Parts
Object Name Part2-FreeParts|Boss-Extrude1
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
13
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Treatment None
Material
Assignment Aluminum Alloy
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 3. m
Length Y 0.1335 m
Length Z 0.1335 m
Properties
Volume 1.59e-003 m³
Mass 4.4043 kg
Centroid X 1.5 m
Centroid Y -2.273e-017 m
Centroid Z 0. m
Moment of Inertia Ip1 2.5776e-002 kg·m²
Moment of Inertia Ip2 3.3161 kg·m²
Moment of Inertia Ip3 3.3161 kg·m²
Statistics
Nodes 3360
Elements 1656
Mesh Metric None
TABLE 6 Model (B4) > Materials
Object Name Materials
State Fully Defined
Statistics
Materials 1
Material Assignments 0
TABLE 7
Model (B4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Coordinate System Program Controlled
APDL Name
Suppressed No
Origin
Origin X 0. m 1.5 m
Origin Y 0. m 6.675e-002 m
Origin Z 0. m
14
Define By Geometry Selection
Geometry Defined
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ] [ 0. 0. -1. ]
Z Axis Data [ 0. 0. 1. ] [ 0. 1. 0. ]
Principal Axis
Axis X
Define By Global X Axis
Orientation About Principal Axis
Axis Z
Define By Global Y Axis
Transformations
Base Configuration Absolute
Transformed Configuration [ 1.5 6.675e-002 0. ]
Mesh
TABLE 8
Model (B4) > Mesh
Object Name Mesh
State Solved
Display
Display Style Use Geometry Setting
Defaults
Physics Preference Mechanical
Element Order Program Controlled
Element Size Default
Sizing
Use Adaptive Sizing Yes
Resolution Default (2)
Mesh Defeaturing Yes
Defeature Size Default
Transition Fast
Span Angle Center Coarse
Initial Size Seed Assembly
Bounding Box Diagonal 3.0059 m
Average Surface Area 0.31811 m²
Minimum Edge Length 0.1315 m
Quality
Check Mesh Quality Yes, Errors
Error Limits Aggressive Mechanical
Target Element Quality Default (5.e-002)
Smoothing Medium
Mesh Metric None
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
15
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Straight Sided Elements No
Rigid Body Behavior Dimensionally Reduced
Triangle Surface Mesher Program Controlled
Topology Checking Yes
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Statistics
Nodes 3360
Elements 1656
TABLE 9 Model (B4) > Mesh > Mesh Controls
Object Name Patch Conforming Method Body Sizing
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Body
Definition
Suppressed No
Method Tetrahedrons
Algorithm Patch Conforming
Element Order Use Global Setting
Type Element Size
Element Size 9.e-002 m
Advanced
Defeature Size Default
Behavior Soft
16
Magnitude Tabular Data
Coordinate System Global Coordinate System
X Component -500. N·m (ramped)
Y Component 0. N·m (ramped)
Z Component 0. N·m (ramped)
Behavior Deformable
Tabular Data
Independent Variable X
Coordinate System Global Coordinate System
Graph Controls
X-Axis X
Advanced
Pinball Region All
TABLE 18 Model (B4) > Static Structural (B5) > Solution (B6) > Normal Stress
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1. -1.4806e+008 1.4199e+008 310.37
17
Maximum Shear Stress
TABLE 19 Model (B4) > Static Structural (B5) > Solution (B6) > Maximum Shear Stress
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1. 4.5898e+006 6.8572e+007 2.5002e+007
18
FIGURE 8 Model (B4) > Static Structural (B5) > Solution (B6) > Stress Intensity
TABLE 20
Model (B4) > Static Structural (B5) > Solution (B6) > Stress Intensity
Time [s] Minimum [Pa] Maximum [Pa] Average [Pa]
1. 9.1797e+006 1.3714e+008 5.0003e+007
19
Model (B4) > Static Structural (B5) > Solution (B6) > Stress Tool > Safety Factor
Time [s] Minimum Maximum Average
1. 2.0416 15. 7.5292
20
Figure 5 Bending moment diagram
Conclusion:
A hollow square cantilever beam was to be designed with multiple design constraints as discussed in
the above sections. After analysing the beam with multiple cross section dimensions, following
parameters are selected which could provide a strength to weight ratio of 7360914.919 Pa/N and a
factor of safety (n) 2.006943942.
21
The results obtained from FEA analysis and manual calculations are approximately same with
relative error calculated as follows,
• The error in the normal stress can be due to the factor that the load was applied in
ANSYS in terms of pressure and the torsional stress calculated manually may not be
accurate as there is no correct form of formula available.
22