9.1 INTRODUCTION [LO1]

Stresses given by relatively simple equations in the strength of materials for structures or machine members are based on the assumed continuity of the elastic medium. However, the presence of discontinuity destroys the assumed regularity of stress distribution in a member and a sudden increase in stresses occurs in the neighborhood of the discontinuity. In developing machines, it is impossible to avoid abrupt changes in cross-sections, holes, notches, shoulders, etc. Abrupt changes in cross-section also occur at the roots of gear teeth and threads of bolts. Some examples are shown in Figure 9.1.

Any such discontinuity acts as a stress raiser. Ideally, discontinuity in materials such as non-metallic inclusions in metals, casting defects, residual stresses from welding may also act as stress raisers. In this chapter, however, we shall consider only the geometric discontinuity that arises from design considerations of structures or machine parts.

Many theoretical methods and experimental techniques have been developed to determine stress concentrations in different structural and mechanical systems. In order to understand the concept, we shall begin with a plate with a centrally located hole. The plate is subjected to uniformly distributed tensile loading at the ends, as shown in Figure 9.2.

1.1 INTRODUCTION [LO1]

Mechanics is one of the oldest physical sciences, dating back to the times of Aristotle and Archimedes. The subject deals with force, displacement, and motion. The concepts of mechanics have been used to solve many mechanical and structural engineering problems through the ages. Because of its intriguing nature, many great scientists including Sir Isaac Newton and Albert Einstein delved into it for solving intricate problems in their own fields.

Engineering mechanics and mechanics of materials developed over centuries with a few experiment-based postulates and assumptions, particularly to solve engineering problems in designing machines and structural parts. Problems are many and varied. However, in most cases, the requirement is to ensure sufficient strength, stiffness, and stability of the components, and eventually those of the whole machine or structure. In order to do this, we first analyze the forces and stresses at different points in a member, and then select materials of known strength and deformation behavior, to withstand the stress distribution with tolerable deformation and stability limits. The methodology has now developed to the extent of coding that takes into account the whole field stress, strain, deformation behaviors, and material characteristics to predict the probability of failure of a component at the weakest point. Inputs from the theory of elasticity and plasticity, mathematical and computational techniques, material science, and many other branches of science are needed to develop such sophisticated coding.

The theory of elasticity too developed but as an applied mathematics topic, and engineers took very little notice of it until recently, when critical analyses of components in high-speed machinery, vehicles, aerospace technology, and many other applications became necessary. The types of problems considered in both the elementary strength of material and the theory of elasticity are similar, but the approaches are different. The strength of the materials approach is generally simple. Here the emphasis is on finding practical solutions to a problem with simplifying assumptions.

4.1 CONSTITUTIVE EQUATIONS [LO1]

So far, we have discussed the strain and stress analysis in detail. In this chapter, we shall link the stress and strain by considering the material properties in order to completely describe the elastic, plastic, elasto-plastic, visco-elastic, or other such deformation characteristics of solids. These are known as constitutive equations, or in simpler terms the stress–strain relations. There are endless varieties of materials and loading conditions, and therefore development of a general form of constitutive equation may be challenging. Here we mainly consider linear elastic solids along with their mechanical properties and deformation behavior.

Fundamental relation between stress and strain was first given by Robert Hooke in 1676 in the most simplified manner as, “Force varies as the stretch”. This implies a load–deflection relation that was later interpreted as a stress–strain relation. Following this, we can write P = kδ, where P is the force, δ is the stretch or elongation, and k is the spring constant. This can also be written for linear elastic materials as σ = E∈, where σ is the stress, ∈ is the strain, and E is the modulus of elasticity. For nonlinear elasticity, we may write in a simplistic manner σ = E∈n, where n ≠ 1.

Hooke's Law based on this fundamental relation is given as the stress–strain relation, and in its most general form, stresses are functions of all the strain components as shown in equation (4.1.1).

7.1 INTRODUCTION [LO1]

The problems of stresses and deformations in disks rotating at high speeds are important in the design of both gas and steam turbines, generators and many such rotating machinery in industry. As discussed in earlier chapters, this is another example of axisymmetric problems in polar coordinates. Although the theoretical treatment of a flat disk is simpler, in many industrial applications, disks are tapered. They are usually thicker near the hub, and their theoretical analysis is slightly more involved. We shall first take up the analysis for flat disks.

In the case of rotating disks with centrifugal force as body force, the equation of equilibrium reduces to as in equation (6.1.3).

Combining this with displacement equations, we have, as in equation (6.1.5), a general equation for determining the stress distribution in axisymmetric problems. This is given as

This is a nonhomogeneous differential equation. The associated homogeneous equation (complementary equation) is

The solution of this equation is Lame's equation as discussed in Chapter 6, equation (6.2.3), and taking into consideration the particular solution, the solution to equation (7.1.2) turns out to be

We may also determine the radial displacement from equation (6.2.11), and this is given as

We may therefore write the stresses and displacement for the rotating disk under one bracket as

With these introductory basic equations, we shall now set out to discuss the stress distribution and displacement in rotating disks.

6.1 INTRODUCTION [LO1]

In earlier chapters, we have discussed axisymmetric problems in two-dimensional (2D) polar coordinate systems. Thick cylinders fall into this class of problems. Cylindrical pressure vessels, hydraulic cylinders, gun-barrels, and pipes carrying fluids at high pressure develop radial and tangential stresses (circumferential). Longitudinal stresses can also be developed if the ends are closed. Therefore, ideally, this is a triaxial stress system as shown in Figure 6.1.

• (a) Circumferential or hoop stress (σθ)

• (b) Longitudinal stress (σz)

• (c) Radial stress (σr)

If the wall thickness of a hollow cylinder is less than about 10% of its radius, it may be treated as a thin cylinder. Cylinders with higher wall thickness are considered to be thick cylinders. Before analyzing the stress in a thick cylinder, we should briefly consider the stress state in thin cylinders, where radial stress is small compared to the other stresses, and this can be neglected. Stress variation across the thin wall is also negligible. Analysis of thin-walled pressure vessels may therefore be carried out on the basis of biaxial stress system. Since the presence of shear stress at the cut section would lead to incompatible distortion, the longitudinal and circumferential stresses in this case are both principal stresses. We now take another section of the cut section as shown in Figure 6.2 (a) to consider the equilibrium of the section, and this is shown in Figure 6.2 (b).

The section is acted upon by internal pressure p and the circumferential stress developed at the cut section is σθ. Force on an infinitesimal small area subtended by angle dθ at θ inclination from the horizontal axis is pridθ.

5.1 INTRODUCTION [LO1]

In any three-dimensional (3D) elasticity problem, there are 15 unknown parameters: 6 stress components, 6 strain components, and 3 displacements. There are 15 related equations: 3 equations of equilibrium, 6 compatibility equations, and 6 constitutive equations. Solutions to a particular elasticity problem require evaluation of these 15 unknown parameters using 15 equations, satisfying all the boundary conditions. As discussed in the earlier chapters, there may be displacement or stress, or mixed boundary conditions. In many cases, solutions to 3D problems are not easy analytically. Even numerical solutions may be difficult.

There are mainly three methods of simplification of solution techniques:

• (a) If the boundary conditions are in terms of stresses, stress function approach may be made as discussed in the earlier chapter. This makes the solution simpler.

• (b) Assumptions of plane stress and plane strain reduce 3D problems to two-dimensional (2D) ones and this also makes the solution simpler.

• (c) Use of St. Venant's principle and superposition principle also makes the solution of elasticity problems simpler.

An introduction to stress function approach has been discussed in Chapter 4. We therefore start our discussion on plane stress and plane strain approaches.

5.2 PLANE STRESS AND PLANE STRAIN PROBLEMS [LO2]

The idealizations of both plane stress and plane strain states are suitable for certain classes of problems that are made to reduce the complexity of solutions. We shall consider the plane stress state first.