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Section A: Long Answer Questions

Attempt all questions.

5 questions
1long10 marks

A rigid composite member is made of a steel rod of cross-sectional area 600 mm2600\ \text{mm}^2 placed concentrically inside a copper tube of cross-sectional area 1000 mm21000\ \text{mm}^2. The assembly is 400 mm400\ \text{mm} long and the two ends are rigidly connected by end plates so that they deform together.

(a) An axial compressive load of 90 kN90\ \text{kN} is applied to the assembly through the end plates. Determine the stress in the steel and in the copper and the shortening of the assembly.

(b) Subsequently (load removed), the temperature of the whole assembly is raised by 50C50^{\circ}\text{C}. Determine the stresses set up in the steel and copper due to this temperature rise.

Take Es=200 GPaE_s = 200\ \text{GPa}, Ec=100 GPaE_c = 100\ \text{GPa}, αs=12×106/C\alpha_s = 12 \times 10^{-6}/^{\circ}\text{C}, αc=18×106/C\alpha_c = 18 \times 10^{-6}/^{\circ}\text{C}.

Given: As=600 mm2A_s = 600\ \text{mm}^2, Ac=1000 mm2A_c = 1000\ \text{mm}^2, L=400 mmL = 400\ \text{mm}, Es=200 GPaE_s = 200\ \text{GPa}, Ec=100 GPaE_c = 100\ \text{GPa}.

Part (a): Axial load 90 kN

For a composite bar with ends rigidly connected, both materials share the same strain (compatibility) and the loads add up (equilibrium).

Compatibility (equal strain):

εs=εc    σsEs=σcEc    σs=σcEsEc=2σc\varepsilon_s = \varepsilon_c \;\Rightarrow\; \frac{\sigma_s}{E_s} = \frac{\sigma_c}{E_c} \;\Rightarrow\; \sigma_s = \sigma_c\frac{E_s}{E_c} = 2\sigma_c

Equilibrium:

P=σsAs+σcAcP = \sigma_s A_s + \sigma_c A_c 90,000=(2σc)(600)+σc(1000)=1200σc+1000σc=2200σc90{,}000 = (2\sigma_c)(600) + \sigma_c(1000) = 1200\sigma_c + 1000\sigma_c = 2200\,\sigma_c σc=90,0002200=40.91 N/mm2\sigma_c = \frac{90{,}000}{2200} = 40.91\ \text{N/mm}^2 σs=2σc=81.82 N/mm2\sigma_s = 2\sigma_c = 81.82\ \text{N/mm}^2

Both are compressive.

Shortening:

δ=εsL=σsEsL=81.82200,000×400=0.1636 mm\delta = \varepsilon_s L = \frac{\sigma_s}{E_s}L = \frac{81.82}{200{,}000}\times 400 = 0.1636\ \text{mm}
  • Steel stress = 81.82 N/mm² (compressive)
  • Copper stress = 40.91 N/mm² (compressive)
  • Shortening = 0.164 mm

Check: σsAs+σcAc=81.82(600)+40.91(1000)=49,092+40,91090,000 N\sigma_s A_s + \sigma_c A_c = 81.82(600)+40.91(1000)=49{,}092+40{,}910 \approx 90{,}000\ \text{N}

Part (b): Temperature rise of 50 °C (no external load)

Copper has the higher α\alpha, so it tends to expand more; the steel restrains it. The result: copper is put in compression, steel in tension, with the internal forces self-balancing.

Equilibrium of internal forces (no external load):

σsAs=σcAcσs(600)=σc(1000)σs=1.6667σc\sigma_s A_s = \sigma_c A_c \quad\Rightarrow\quad \sigma_s (600) = \sigma_c (1000) \Rightarrow \sigma_s = 1.6667\,\sigma_c

Compatibility (free expansions differ; final lengths equal):

αcΔTσcEc=αsΔT+σsEs\alpha_c\,\Delta T - \frac{\sigma_c}{E_c} = \alpha_s\,\Delta T + \frac{\sigma_s}{E_s}

(copper expansion reduced by its compressive strain equals steel expansion increased by its tensile strain)

(αcαs)ΔT=σsEs+σcEc(\alpha_c-\alpha_s)\Delta T = \frac{\sigma_s}{E_s} + \frac{\sigma_c}{E_c} (1812)×106×50=1.6667σc200,000+σc100,000(18-12)\times10^{-6}\times 50 = \frac{1.6667\,\sigma_c}{200{,}000} + \frac{\sigma_c}{100{,}000} 300×106=σc(8.333×106+10×106)=σc(18.333×106)300\times10^{-6} = \sigma_c\left(8.333\times10^{-6} + 10\times10^{-6}\right) = \sigma_c(18.333\times10^{-6}) σc=300×10618.333×106=16.36 N/mm2 (compressive)\sigma_c = \frac{300\times10^{-6}}{18.333\times10^{-6}} = 16.36\ \text{N/mm}^2\ \text{(compressive)} σs=1.6667×16.36=27.27 N/mm2 (tensile)\sigma_s = 1.6667\times16.36 = 27.27\ \text{N/mm}^2\ \text{(tensile)}
  • Steel stress (thermal) = 27.27 N/mm² (tensile)
  • Copper stress (thermal) = 16.36 N/mm² (compressive)

Check equilibrium: 27.27×600=16,362 N27.27\times600 = 16{,}362\ \text{N} and 16.36×1000=16,360 N16.36\times1000 = 16{,}360\ \text{N}

composite-barsthermal-stresselastic-constants
2long10 marks

A beam ABCDABCD of length 8 m8\ \text{m} is simply supported at BB and CC. The overhang AB=2 mAB = 2\ \text{m} (left) and CD=1 mCD = 1\ \text{m} (right); span BC=5 mBC = 5\ \text{m}. The beam carries:

  • a point load of 20 kN20\ \text{kN} at the free end AA,
  • a uniformly distributed load (UDL) of 10 kN/m10\ \text{kN/m} over the span BCBC (5 m5\ \text{m}),
  • a point load of 15 kN15\ \text{kN} at the free end DD.

Draw the shear force diagram (SFD) and bending moment diagram (BMD). Locate the point of maximum bending moment in the span and the points of contraflexure.

Layout (distance from AA): A=0A=0, B=2 mB=2\ \text{m}, C=7 mC=7\ \text{m}, D=8 mD=8\ \text{m}.

Loads: 20 kN20\ \text{kN}\downarrow at AA; UDL 10 kN/m10\ \text{kN/m} over BCBC (total =10×5=50 kN= 10\times5 = 50\ \text{kN} acting at midspan, x=4.5 mx=4.5\ \text{m}); 15 kN15\ \text{kN}\downarrow at DD.

Reactions

Take moments about BB (x=2x=2). Let RB,RCR_B, R_C upward.

MB=0:  20(2)+50(2.5)+15(6)RC(5)=0\sum M_B = 0:\; -20(2) + 50(2.5) + 15(6) - R_C(5) = 0 40+125+90=5RC175=5RCRC=35 kN-40 + 125 + 90 = 5R_C \Rightarrow 175 = 5R_C \Rightarrow R_C = 35\ \text{kN} Fy=0:  RB+RC=20+50+15=85RB=50 kN\sum F_y=0:\; R_B + R_C = 20 + 50 + 15 = 85 \Rightarrow R_B = 50\ \text{kN}

Shear Force (from left, downward loads negative)

  • Just right of AA: V=20 kNV = -20\ \text{kN} (constant to BB).
  • Just left of BB: V=20V = -20.
  • Just right of BB: V=20+50=+30 kNV = -20 + 50 = +30\ \text{kN}.
  • Across BCBC shear drops linearly by UDL: at CC^-: V=3010(5)=3050=20 kNV = 30 - 10(5) = 30-50 = -20\ \text{kN}.
  • Just right of CC: V=20+35=+15 kNV = -20 + 35 = +15\ \text{kN}.
  • At DD^-: V=+15V = +15; the 15 kN15\ \text{kN} load brings it to 00. ✓

Zero shear in span: measuring xx' from BB, V=3010x=0x=3 mV = 30 - 10x' = 0 \Rightarrow x' = 3\ \text{m} (i.e. x=5 mx = 5\ \text{m} from AA). Max span BM here.

Bending Moments (sagging +)

  • MA=0M_A = 0.
  • MB=20(2)=40 kN\cdotpmM_B = -20(2) = -40\ \text{kN·m} (hogging).
  • MD=0M_D = 0; MC=15(1)=15 kN\cdotpmM_C = -15(1) = -15\ \text{kN·m} (hogging) (from right side).
  • Max span moment at x=3 mx'=3\ \text{m} from BB:
M=RB(3)20(2+3)10322M = R_B(3) - 20(2+3) - 10\cdot\frac{3^2}{2} M=50(3)20(5)45=15010045=+5 kN\cdotpm (sagging)M = 50(3) - 20(5) - 45 = 150 - 100 - 45 = +5\ \text{kN·m (sagging)}

Points of contraflexure (M = 0 in span BCBC)

With xx' from BB: M(x)=50x20(2+x)5x2=5x2+30x40M(x') = 50x' - 20(2+x') - 5x'^2 = -5x'^2 + 30x' - 40. Set =0=0: 5x230x+40=0x26x+8=0(x2)(x4)=05x'^2 - 30x' + 40 = 0 \Rightarrow x'^2 - 6x' + 8 = 0 \Rightarrow (x'-2)(x'-4)=0.

x=2 m and 4 m from B  (x=4 m and 6 m from A)x' = 2\ \text{m and } 4\ \text{m from } B \;(x = 4\ \text{m and } 6\ \text{m from } A)

Diagrams (schematic)

SFD (kN):
  A      B          (zero @3m)        C        D
 -20 --- -20 | +30 \____ 0 ____ -20 | +15 \ 0
            (jump +50)              (jump +35)

BMD (kN·m):
   0 .... -40 (B, hog) /  +5 (x'=3) \  -15 (C, hog) .. 0
        contraflex @ x'=2 and x'=4

Summary: RB=50 kNR_B = 50\ \text{kN}, RC=35 kNR_C = 35\ \text{kN}; max sagging =+5 kN\cdotpm= +5\ \text{kN·m} at 5 m5\ \text{m} from AA; max hogging =40 kN\cdotpm= -40\ \text{kN·m} at BB; contraflexure at 4 m4\ \text{m} and 6 m6\ \text{m} from AA.

shear-force-diagrambending-moment-diagramoverhanging-beam
3long8 marks

A simply supported beam of span 4 m4\ \text{m} carries a central point load of 48 kN48\ \text{kN}. Its cross-section is a symmetrical I-section with the following dimensions: top and bottom flanges each 150 mm×20 mm150\ \text{mm} \times 20\ \text{mm}, and web 200 mm200\ \text{mm} deep ×10 mm\times 10\ \text{mm} thick (overall depth =240 mm= 240\ \text{mm}).

(a) Determine the maximum bending stress in the section. (b) Determine the maximum shear stress and the shear stress at the flange–web junction. Sketch the shear-stress distribution.

Maximum bending moment and shear force:

Mmax=WL4=48×44=48 kN\cdotpm;Vmax=W2=24 kNM_{max} = \frac{WL}{4} = \frac{48\times4}{4} = 48\ \text{kN·m}; \qquad V_{max} = \frac{W}{2} = 24\ \text{kN}

Section properties (about neutral axis = centroid, by symmetry at mid-depth)

Overall depth D=240 mmD = 240\ \text{mm}, ymax=120 mmy_{max} = 120\ \text{mm}.

I=10×200312web+2[150×20312flange own+150×20×1102transfer]I = \underbrace{\frac{10\times200^3}{12}}_{\text{web}} + 2\Big[\underbrace{\frac{150\times20^3}{12}}_{\text{flange own}} + \underbrace{150\times20\times110^2}_{\text{transfer}}\Big]

Web: 10×200312=10×8×10612=6.667×106 mm4\dfrac{10\times200^3}{12} = \dfrac{10\times8\times10^6}{12} = 6.667\times10^6\ \text{mm}^4

Flange own: 150×800012=0.1×106 mm4\dfrac{150\times8000}{12} = 0.1\times10^6\ \text{mm}^4 each.

Flange transfer: distance from NA to flange centroid =100+10=110 mm= 100 + 10 = 110\ \text{mm}; 150×20×1102=3000×12,100=36.3×106 mm4150\times20\times110^2 = 3000\times12{,}100 = 36.3\times10^6\ \text{mm}^4 each.

I=6.667×106+2(0.1×106+36.3×106)=6.667×106+72.8×106=79.467×106 mm4I = 6.667\times10^6 + 2(0.1\times10^6 + 36.3\times10^6) = 6.667\times10^6 + 72.8\times10^6 = 79.467\times10^6\ \text{mm}^4

(a) Maximum bending stress

σmax=MymaxI=48×106×12079.467×106=5.76×10979.467×106=72.5 N/mm2\sigma_{max} = \frac{M\,y_{max}}{I} = \frac{48\times10^6 \times 120}{79.467\times10^6} = \frac{5.76\times10^9}{79.467\times10^6} = 72.5\ \text{N/mm}^2

Maximum bending stress = 72.5 N/mm² (tension at bottom, compression at top).

(b) Shear stress: τ=VAyˉIb\tau = \dfrac{V\,A\bar{y}}{I\,b}

Maximum shear at neutral axis (web width b=10 mmb = 10\ \text{mm}). First moment of area above NA:

  • Flange: Ayˉ=(150×20)×110=3000×110=330,000 mm3A\bar y = (150\times20)\times110 = 3000\times110 = 330{,}000\ \text{mm}^3
  • Half web (above NA): (100×10)×50=1000×50=50,000 mm3(100\times10)\times50 = 1000\times50 = 50{,}000\ \text{mm}^3
  • Total QNA=380,000 mm3Q_{NA} = 380{,}000\ \text{mm}^3
τmax=24×103×380,00079.467×106×10=9.12×109794.67×106=11.48 N/mm2\tau_{max} = \frac{24\times10^3 \times 380{,}000}{79.467\times10^6 \times 10} = \frac{9.12\times10^9}{794.67\times10^6} = 11.48\ \text{N/mm}^2

At flange–web junction, Q=Q = flange only =330,000 mm3= 330{,}000\ \text{mm}^3.

  • Using web width b=10 mmb = 10\ \text{mm}:
τ=24×103×330,00079.467×106×10=7.92×109794.67×106=9.97 N/mm2\tau = \frac{24\times10^3 \times 330{,}000}{79.467\times10^6 \times 10} = \frac{7.92\times10^9}{794.67\times10^6} = 9.97\ \text{N/mm}^2
  • Using flange width b=150 mmb = 150\ \text{mm} (just inside flange):
τ=24×103×330,00079.467×106×150=0.66 N/mm2\tau = \frac{24\times10^3 \times 330{,}000}{79.467\times10^6 \times 150} = 0.66\ \text{N/mm}^2

So there is a sudden jump at the junction from 0.660.66 (flange side) to 9.97 N/mm29.97\ \text{N/mm}^2 (web side).

Shear-stress distribution (sketch)

 top flange:  small parabola, 0 -> 0.66 N/mm^2
 junction:    JUMP 0.66 -> 9.97 N/mm^2
 web:         parabola 9.97 -> 11.48 (NA, max) -> 9.97
 junction:    JUMP 9.97 -> 0.66
 bottom flg:  0.66 -> 0

Results: τmax=11.48 N/mm2\tau_{max} = 11.48\ \text{N/mm}^2 at NA; τ\tau at junction =9.97 N/mm2= 9.97\ \text{N/mm}^2 (web) and 0.66 N/mm20.66\ \text{N/mm}^2 (flange).

bending-stressshear-stress-distributionflexure
4long8 marks

At a point in a strained material the stresses on two mutually perpendicular planes are σx=80 N/mm2\sigma_x = 80\ \text{N/mm}^2 (tensile) and σy=40 N/mm2\sigma_y = -40\ \text{N/mm}^2 (compressive), together with a shear stress of τxy=30 N/mm2\tau_{xy} = 30\ \text{N/mm}^2.

(a) Determine analytically the magnitude and direction of the principal stresses and the maximum shear stress. (b) Verify the principal stresses and the maximum shear stress using Mohr's circle (describe the construction and read off values).

Given: σx=80\sigma_x = 80, σy=40\sigma_y = -40, τxy=30 N/mm2\tau_{xy} = 30\ \text{N/mm}^2.

(a) Analytical solution

Principal stresses:

σ1,2=σx+σy2±(σxσy2)2+τxy2\sigma_{1,2} = \frac{\sigma_x+\sigma_y}{2} \pm \sqrt{\left(\frac{\sigma_x-\sigma_y}{2}\right)^2 + \tau_{xy}^2} σx+σy2=80402=20 N/mm2\frac{\sigma_x+\sigma_y}{2} = \frac{80-40}{2} = 20\ \text{N/mm}^2 σxσy2=80(40)2=60 N/mm2\frac{\sigma_x-\sigma_y}{2} = \frac{80-(-40)}{2} = 60\ \text{N/mm}^2 R=602+302=3600+900=4500=67.08 N/mm2R = \sqrt{60^2 + 30^2} = \sqrt{3600 + 900} = \sqrt{4500} = 67.08\ \text{N/mm}^2 σ1=20+67.08=87.08 N/mm2  (tensile)\sigma_1 = 20 + 67.08 = 87.08\ \text{N/mm}^2 \;(\text{tensile}) σ2=2067.08=47.08 N/mm2  (compressive)\sigma_2 = 20 - 67.08 = -47.08\ \text{N/mm}^2 \;(\text{compressive})

Orientation of principal planes:

tan2θp=2τxyσxσy=2(30)80(40)=60120=0.5\tan 2\theta_p = \frac{2\tau_{xy}}{\sigma_x-\sigma_y} = \frac{2(30)}{80-(-40)} = \frac{60}{120} = 0.5 2θp=26.57θp=13.28  (and 103.28)2\theta_p = 26.57^{\circ} \Rightarrow \theta_p = 13.28^{\circ} \;(\text{and } 103.28^{\circ})

The plane of σ1\sigma_1 is at θp=13.28\theta_p = 13.28^{\circ} (measured anticlockwise from the plane on which σx\sigma_x acts).

Maximum shear stress:

τmax=R=67.08 N/mm2\tau_{max} = R = 67.08\ \text{N/mm}^2

occurring on planes at 4545^{\circ} to the principal planes, i.e. at θ=13.28+45=58.28\theta = 13.28^{\circ}+45^{\circ} = 58.28^{\circ}.

(b) Mohr's circle construction

  1. Plot horizontal axis σ\sigma, vertical axis τ\tau (to scale, e.g. 1 cm=10 N/mm21\ \text{cm} = 10\ \text{N/mm}^2).
  2. Point X=(σx,+τxy)=(80,30)X = (\sigma_x, +\tau_{xy}) = (80, 30); point Y=(σy,τxy)=(40,30)Y = (\sigma_y, -\tau_{xy}) = (-40, -30).
  3. Join XYXY; it crosses the σ\sigma-axis at the centre C=(80402,0)=(20,0)C = \left(\frac{80-40}{2}, 0\right) = (20, 0).
  4. Radius R=R = distance CX=(8020)2+302=3600+900=67.08 N/mm2CX = \sqrt{(80-20)^2 + 30^2} = \sqrt{3600+900} = 67.08\ \text{N/mm}^2.
  5. Circle cuts σ\sigma-axis at σ1=20+67.08=87.08\sigma_1 = 20+67.08 = 87.08 and σ2=2067.08=47.08\sigma_2 = 20-67.08 = -47.08.
  6. Top of circle gives τmax=R=67.08 N/mm2\tau_{max} = R = 67.08\ \text{N/mm}^2.
  7. Angle XCBXCB (to σ1\sigma_1) =arctan3060=26.57=2θp= \arctan\frac{30}{60} = 26.57^{\circ} = 2\theta_p, so θp=13.28\theta_p = 13.28^{\circ} on the element.
        tau
         |        X(80,30)
         |       /
  -------C(20,0)------- sigma
  s2=-47 | \ /        s1=87
         | Y(-40,-30)
   tau_max = 67.08 at top of circle

Values read from Mohr's circle agree with analysis:

  • σ1=87.08 N/mm2\sigma_1 = 87.08\ \text{N/mm}^2, σ2=47.08 N/mm2\sigma_2 = -47.08\ \text{N/mm}^2
  • τmax=67.08 N/mm2\tau_{max} = 67.08\ \text{N/mm}^2, θp=13.28\theta_p = 13.28^{\circ}
principal-stressesmohr-circleplane-stress
5long8 marks

A solid circular shaft is required to transmit 150 kW150\ \text{kW} at 200 rpm200\ \text{rpm}. The permissible shear stress is 80 N/mm280\ \text{N/mm}^2 and the twist must not exceed 11^{\circ} in a length of 3 m3\ \text{m}. Take G=80 GPaG = 80\ \text{GPa}.

(a) Determine the minimum diameter of the shaft. (b) If the solid shaft is replaced by a hollow shaft of the same material with internal diameter =0.6×= 0.6 \times external diameter and designed for the same maximum shear stress and the same torque, find the external diameter and the percentage saving in weight.

Torque to be transmitted

T=60P2πN=60×150×1032π×200=9,000,0001256.64=7161 N\cdotpm=7.161×106 N\cdotpmmT = \frac{60\,P}{2\pi N} = \frac{60\times150\times10^3}{2\pi\times200} = \frac{9{,}000{,}000}{1256.64} = 7161\ \text{N·m} = 7.161\times10^6\ \text{N·mm}

(a) Solid shaft

Strength criterion (τ80\tau \le 80): T=π16τd3T = \dfrac{\pi}{16}\tau d^3

d3=16Tπτ=16×7.161×106π×80=114.58×106251.33=455,900 mm3d^3 = \frac{16T}{\pi\tau} = \frac{16\times7.161\times10^6}{\pi\times80} = \frac{114.58\times10^6}{251.33} = 455{,}900\ \text{mm}^3 d=76.95 mmd = 76.95\ \text{mm}

Stiffness criterion (θ=1=0.01745 rad\theta = 1^{\circ} = 0.01745\ \text{rad} over L=3000 mmL = 3000\ \text{mm}): TJ=GθL\dfrac{T}{J} = \dfrac{G\theta}{L}, with J=π32d4J = \dfrac{\pi}{32}d^4.

J=TLGθ=7.161×106×300080,000×0.01745=21.483×1091396=15.39×106 mm4J = \frac{T L}{G\theta} = \frac{7.161\times10^6 \times 3000}{80{,}000\times0.01745} = \frac{21.483\times10^9}{1396} = 15.39\times10^6\ \text{mm}^4 d4=32Jπ=32×15.39×106π=156.7×106d=111.9 mmd^4 = \frac{32 J}{\pi} = \frac{32\times15.39\times10^6}{\pi} = 156.7\times10^6 \Rightarrow d = 111.9\ \text{mm}

The stiffness criterion governs (larger). Adopt d112 mmd \approx 112\ \text{mm}.

(b) Hollow shaft (same torque, same τ=80\tau = 80 strength design)

Let external =D= D, internal di=0.6Dd_i = 0.6D, so k=0.6k = 0.6.

T=π16τD4di4D=π16τD3(1k4)T = \frac{\pi}{16}\tau\,\frac{D^4 - d_i^4}{D} = \frac{\pi}{16}\tau D^3 (1-k^4) 1k4=10.64=10.1296=0.87041-k^4 = 1 - 0.6^4 = 1 - 0.1296 = 0.8704 D3=16Tπτ(1k4)=455,9000.8704=523,780 mm3D^3 = \frac{16T}{\pi\tau(1-k^4)} = \frac{455{,}900}{0.8704} = 523{,}780\ \text{mm}^3 D=80.6 mm,di=0.6×80.6=48.4 mmD = 80.6\ \text{mm}, \quad d_i = 0.6\times80.6 = 48.4\ \text{mm}

(Comparison for weight saving is made on the strength-designed shafts of equal τ\tau.)

Weight (∝ cross-sectional area, same material and length):

  • Solid (strength): As=π4d2=π4(76.95)2=4650 mm2A_s = \dfrac{\pi}{4}d^2 = \dfrac{\pi}{4}(76.95)^2 = 4650\ \text{mm}^2
  • Hollow: Ah=π4(D2di2)=π4(80.6248.42)=π4(64962343)=π4(4153)=3262 mm2A_h = \dfrac{\pi}{4}(D^2 - d_i^2) = \dfrac{\pi}{4}(80.6^2 - 48.4^2) = \dfrac{\pi}{4}(6496 - 2343) = \dfrac{\pi}{4}(4153) = 3262\ \text{mm}^2
% saving=AsAhAs×100=465032624650×100=29.8%\%\text{ saving} = \frac{A_s - A_h}{A_s}\times100 = \frac{4650 - 3262}{4650}\times100 = 29.8\%

Results: Solid shaft diameter governed by stiffness 112 mm\approx \mathbf{112\ mm}; hollow shaft (strength design) D=80.6 mmD = 80.6\ \text{mm}, di=48.4 mmd_i = 48.4\ \text{mm}, giving a weight saving of about 30% over the strength-designed solid shaft.

torsionshaftspower-transmission
B

Section B: Short Answer Questions

Attempt all questions.

6 questions
6short6 marks

A steel bar of length 1.5 m1.5\ \text{m} has three segments: AB (500 mm500\ \text{mm}, area 400 mm2400\ \text{mm}^2), BC (500 mm500\ \text{mm}, area 800 mm2800\ \text{mm}^2), CD (500 mm500\ \text{mm}, area 200 mm2200\ \text{mm}^2). It is subjected to an axial tensile pull of 40 kN40\ \text{kN}. Taking E=200 GPaE = 200\ \text{GPa}, determine the stress in each segment and the total elongation of the bar.

The axial force in every segment =P=40 kN=40,000 N= P = 40\ \text{kN} = 40{,}000\ \text{N} (series bar).

Stresses (σ=P/A\sigma = P/A)

σAB=40,000400=100 N/mm2\sigma_{AB} = \frac{40{,}000}{400} = 100\ \text{N/mm}^2 σBC=40,000800=50 N/mm2\sigma_{BC} = \frac{40{,}000}{800} = 50\ \text{N/mm}^2 σCD=40,000200=200 N/mm2\sigma_{CD} = \frac{40{,}000}{200} = 200\ \text{N/mm}^2

Total elongation   δ=PLAE\;\delta = \sum \dfrac{PL}{AE}

δ=PE(LABAAB+LBCABC+LCDACD)\delta = \frac{P}{E}\left(\frac{L_{AB}}{A_{AB}}+\frac{L_{BC}}{A_{BC}}+\frac{L_{CD}}{A_{CD}}\right) =40,000200,000(500400+500800+500200)= \frac{40{,}000}{200{,}000}\left(\frac{500}{400}+\frac{500}{800}+\frac{500}{200}\right) =0.2(1.25+0.625+2.5)=0.2×4.375=0.875 mm= 0.2\,(1.25 + 0.625 + 2.5) = 0.2\times 4.375 = 0.875\ \text{mm}

Results: σAB=100\sigma_{AB}=100, σBC=50\sigma_{BC}=50, σCD=200 N/mm2\sigma_{CD}=200\ \text{N/mm}^2; total elongation =0.875 mm= 0.875\ \text{mm}.

simple-stress-strainelastic-constantsdeformation
7short6 marks

(a) Derive the relation between the modulus of elasticity EE, the modulus of rigidity GG and Poisson's ratio μ\mu: E=2G(1+μ)E = 2G(1+\mu) — state the basis clearly. (b) For a material E=200 GPaE = 200\ \text{GPa} and G=80 GPaG = 80\ \text{GPa}. Compute Poisson's ratio μ\mu and the bulk modulus KK.

(a) Relation E=2G(1+μ)E = 2G(1+\mu) (outline)

Consider an element under pure shear stress τ\tau. Pure shear is equivalent to direct stresses +τ+\tau (tensile) and τ-\tau (compressive) acting on planes at 4545^{\circ}.

The linear strain along the 4545^{\circ} tensile diagonal due to these two direct stresses:

ε45=τEμ(τ)E=τE(1+μ)\varepsilon_{45} = \frac{\tau}{E} - \mu\frac{(-\tau)}{E} = \frac{\tau}{E}(1+\mu)

The shear strain ϕ=τ/G\phi = \tau/G produces a diagonal strain of ϕ/2=τ/(2G)\phi/2 = \tau/(2G). Equating the two expressions for the diagonal strain:

τ2G=τE(1+μ)    E=2G(1+μ)\frac{\tau}{2G} = \frac{\tau}{E}(1+\mu) \;\Rightarrow\; \boxed{E = 2G(1+\mu)}

(b) Numerical values

E=2G(1+μ)1+μ=E2G=2002×80=200160=1.25E = 2G(1+\mu) \Rightarrow 1+\mu = \frac{E}{2G} = \frac{200}{2\times80} = \frac{200}{160} = 1.25 μ=0.25\mu = 0.25

Bulk modulus from E=3K(12μ)E = 3K(1-2\mu):

K=E3(12μ)=2003(10.5)=2001.5=133.33 GPaK = \frac{E}{3(1-2\mu)} = \frac{200}{3(1-0.5)} = \frac{200}{1.5} = 133.33\ \text{GPa}

Results: μ=0.25\mu = 0.25, K=133.33 GPaK = 133.33\ \text{GPa}.

elastic-constantsrelation-E-G-Kpoisson-ratio
8short6 marks

A thin cylindrical shell 1.2 m1.2\ \text{m} internal diameter and 8 m8\ \text{m} long is subjected to an internal pressure of 2 N/mm22\ \text{N/mm}^2. The plate thickness is 12 mm12\ \text{mm}. Determine (a) the hoop (circumferential) stress and longitudinal stress, and (b) the change in diameter and change in length. Take E=200 GPaE = 200\ \text{GPa}, μ=0.3\mu = 0.3.

Given: d=1200 mmd = 1200\ \text{mm}, L=8000 mmL = 8000\ \text{mm}, p=2 N/mm2p = 2\ \text{N/mm}^2, t=12 mmt = 12\ \text{mm}.

(a) Stresses

Hoop (circumferential) stress:

σh=pd2t=2×12002×12=240024=100 N/mm2\sigma_h = \frac{p d}{2t} = \frac{2\times1200}{2\times12} = \frac{2400}{24} = 100\ \text{N/mm}^2

Longitudinal stress:

σl=pd4t=2×12004×12=50 N/mm2\sigma_l = \frac{p d}{4t} = \frac{2\times1200}{4\times12} = 50\ \text{N/mm}^2

(b) Deformations

Circumferential (hoop) strain:

εh=1E(σhμσl)=1200,000(1000.3×50)=85200,000=4.25×104\varepsilon_h = \frac{1}{E}(\sigma_h - \mu\sigma_l) = \frac{1}{200{,}000}(100 - 0.3\times50) = \frac{85}{200{,}000} = 4.25\times10^{-4} Δd=εhd=4.25×104×1200=0.51 mm\Delta d = \varepsilon_h \cdot d = 4.25\times10^{-4}\times1200 = 0.51\ \text{mm}

Longitudinal strain:

εl=1E(σlμσh)=1200,000(500.3×100)=20200,000=1.0×104\varepsilon_l = \frac{1}{E}(\sigma_l - \mu\sigma_h) = \frac{1}{200{,}000}(50 - 0.3\times100) = \frac{20}{200{,}000} = 1.0\times10^{-4} ΔL=εlL=1.0×104×8000=0.80 mm\Delta L = \varepsilon_l \cdot L = 1.0\times10^{-4}\times8000 = 0.80\ \text{mm}

Results: σh=100 N/mm2\sigma_h = 100\ \text{N/mm}^2, σl=50 N/mm2\sigma_l = 50\ \text{N/mm}^2; Δd=0.51 mm\Delta d = 0.51\ \text{mm}, ΔL=0.80 mm\Delta L = 0.80\ \text{mm}.

thin-cylindershoop-stresspressure-vessel
9short6 marks

A hollow cast-iron column has external diameter 200 mm200\ \text{mm} and internal diameter 160 mm160\ \text{mm}, and is 4 m4\ \text{m} long with both ends fixed. (a) Determine the Euler crippling load. Take E=100 GPaE = 100\ \text{GPa}. (b) Determine the Rankine crippling load taking σc=550 N/mm2\sigma_c = 550\ \text{N/mm}^2 and Rankine constant a=1/1600a = 1/1600.

Section properties: D=200 mmD = 200\ \text{mm}, d=160 mmd = 160\ \text{mm}.

A=π4(D2d2)=π4(20021602)=π4(40,00025,600)=π4(14,400)=11,310 mm2A = \frac{\pi}{4}(D^2 - d^2) = \frac{\pi}{4}(200^2 - 160^2) = \frac{\pi}{4}(40{,}000 - 25{,}600) = \frac{\pi}{4}(14{,}400) = 11{,}310\ \text{mm}^2 I=π64(D4d4)=π64(20041604)=π64(1.6×1090.6554×109)I = \frac{\pi}{64}(D^4 - d^4) = \frac{\pi}{64}(200^4 - 160^4) = \frac{\pi}{64}(1.6\times10^9 - 0.6554\times10^9) I=π64(0.9446×109)=46.37×106 mm4I = \frac{\pi}{64}(0.9446\times10^9) = 46.37\times10^6\ \text{mm}^4

Both ends fixed: effective length Le=L/2=4000/2=2000 mmL_e = L/2 = 4000/2 = 2000\ \text{mm}.

(a) Euler crippling load

PE=π2EILe2=π2×100,000×46.37×10620002P_E = \frac{\pi^2 E I}{L_e^2} = \frac{\pi^2 \times 100{,}000 \times 46.37\times10^6}{2000^2} =9.8696×100,000×46.37×1064×106=45.77×10124×106=11.44×106 N= \frac{9.8696 \times 100{,}000 \times 46.37\times10^6}{4\times10^6} = \frac{45.77\times10^{12}}{4\times10^6} = 11.44\times10^6\ \text{N} PE=11,443 kN11.44 MN\boxed{P_E = 11{,}443\ \text{kN} \approx 11.44\ \text{MN}}

(b) Rankine crippling load

Radius of gyration: k2=I/A=46.37×10611,310=4100 mm2k^2 = I/A = \dfrac{46.37\times10^6}{11{,}310} = 4100\ \text{mm}^2.

PR=σcA1+a(Lek)2=σcA1+aLe2k2P_R = \frac{\sigma_c\,A}{1 + a\left(\dfrac{L_e}{k}\right)^2} = \frac{\sigma_c A}{1 + a\,\dfrac{L_e^2}{k^2}} Le2k2=200024100=4×1064100=975.6\frac{L_e^2}{k^2} = \frac{2000^2}{4100} = \frac{4\times10^6}{4100} = 975.6 1+aLe2k2=1+975.61600=1+0.6098=1.60981 + a\frac{L_e^2}{k^2} = 1 + \frac{975.6}{1600} = 1 + 0.6098 = 1.6098 PR=550×11,3101.6098=6.2205×1061.6098=3.864×106 NP_R = \frac{550\times11{,}310}{1.6098} = \frac{6.2205\times10^6}{1.6098} = 3.864\times10^6\ \text{N} PR=3864 kN3.86 MN\boxed{P_R = 3864\ \text{kN} \approx 3.86\ \text{MN}}

Rankine load is much lower (and more realistic for this stocky column) than the Euler load.

columnseuler-bucklingrankine-formula
10short3 marks

A steel rod 30 mm30\ \text{mm} in diameter and 2 m2\ \text{m} long is subjected to a gradually applied axial tensile load of 60 kN60\ \text{kN}. Compute the strain energy stored in the rod. Take E=200 GPaE = 200\ \text{GPa}.

Cross-sectional area:

A=π4d2=π4(30)2=706.86 mm2A = \frac{\pi}{4}d^2 = \frac{\pi}{4}(30)^2 = 706.86\ \text{mm}^2

Direct stress:

σ=PA=60,000706.86=84.88 N/mm2\sigma = \frac{P}{A} = \frac{60{,}000}{706.86} = 84.88\ \text{N/mm}^2

Strain energy (gradually applied load):

U=σ22E×V,V=AL=706.86×2000=1.4137×106 mm3U = \frac{\sigma^2}{2E}\times V, \qquad V = A\,L = 706.86\times2000 = 1.4137\times10^6\ \text{mm}^3 U=(84.88)22×200,000×1.4137×106=7204.6400,000×1.4137×106U = \frac{(84.88)^2}{2\times200{,}000}\times 1.4137\times10^6 = \frac{7204.6}{400{,}000}\times1.4137\times10^6 U=0.018012×1.4137×106=25,460 N\cdotpmm=25.46 N\cdotpm (J)U = 0.018012\times1.4137\times10^6 = 25{,}460\ \text{N·mm} = 25.46\ \text{N·m (J)}

Check via U=12PδU = \tfrac12 P\delta: δ=PLAE=60,000×2000706.86×200,000=0.8488 mm\delta = \dfrac{PL}{AE} = \dfrac{60{,}000\times2000}{706.86\times200{,}000} = 0.8488\ \text{mm}; U=12×60,000×0.8488=25,464 N\cdotpmmU = \tfrac12\times60{,}000\times0.8488 = 25{,}464\ \text{N·mm}

Strain energy stored =25.46 J= 25.46\ \text{J}.

strain-energyresilienceaxial-loading
11short3 marks

A simply supported timber beam of rectangular cross-section 150 mm150\ \text{mm} wide and 300 mm300\ \text{mm} deep spans 4 m4\ \text{m} and carries a uniformly distributed load ww over the whole span. If the permissible bending stress is 8 N/mm28\ \text{N/mm}^2, determine the maximum safe value of ww (kN/m).

Section modulus (rectangular):

Z=bd26=150×30026=150×90,0006=2.25×106 mm3Z = \frac{b d^2}{6} = \frac{150\times300^2}{6} = \frac{150\times90{,}000}{6} = 2.25\times10^6\ \text{mm}^3

Moment of resistance:

M=σZ=8×2.25×106=18×106 N\cdotpmm=18 kN\cdotpmM = \sigma\,Z = 8\times2.25\times10^6 = 18\times10^6\ \text{N·mm} = 18\ \text{kN·m}

Maximum bending moment for UDL on simple span:

Mmax=wL28=w×428=2w  (kN\cdotpm, with w in kN/m)M_{max} = \frac{wL^2}{8} = \frac{w\times4^2}{8} = 2w \ \ (\text{kN·m, with } w \text{ in kN/m})

Set Mmax=MM_{max} = M:

2w=18w=9 kN/m2w = 18 \Rightarrow w = 9\ \text{kN/m}

Maximum safe UDL w=9 kN/mw = 9\ \text{kN/m} (inclusive of self-weight).

bending-stresssection-modulusflexure

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