Solid Mechanics Cep Report
Solid Mechanics Cep Report
COMPLEX ENGINEERING
PROBLEM
Ayesha AU-22001
Syeda Hamna Asad AU-22009
Hashir Ali AU-22022
Abdul Hadi Khan AU-22035
Muhammad Saifullah Khan AU-22301
Batch: [2022]
Course Code: [ME-302]
Data
Engine Max. Power: 40 + A kW
Engine Max. RPM: 3500 + B rpm
Allowable shear Stress: 42 + C MPa
Outer Dia. of Shaft: 4.2 cm = 0.042 m
Bending Moment: 100 + D N-m
Axial load: 1 kN
c: 0.021m
A = Sum of last two digits of roll numbers of all three members
A = 01 + 09 + 22 + 35 + 01
A = 68
B = Sum of last three digits of roll numbers of three members
B = 001 + 009 + 022 + 035 + 301
B = 368
C = sum of last digit of roll numbers of three members
C=1+9+2+5+1
C = 18
D = Sum of last two digits of roll numbers of three members
D = 01 + 09 + 22 + 35 + 01
D = 68
So, the final data would be;
Engine Max. Power: 108 kW
Engine Max. RPM: 2868 rpm
Allowable shear Stress: 60 MPa
Outer Dia. of Shaft: 4.2 cm = 0.042 m
Bending Moment: 168 N-m
Axial load: 1 kN
c: 0.021m
Calculations
1. Inner Diameter:
2𝜋𝑁𝑇
𝑃=
60
𝑃 × 60
𝑇=
2𝜋𝑁
108 × 60
𝑇=
2𝜋(3868)
𝑇 = 0.28 𝑘𝑁. 𝑚
𝑇𝑐
𝜏=
𝐽
𝑇𝑐
𝐽=
𝜏
280 × 0.021
𝐽=
60 × 106
𝐽 = 9.8 × 10−8 𝑚4
𝜋
𝐽= (𝐷𝑜 4 − 𝐷𝑖 4 )
32
𝐽 × 32
− 𝐷𝑜 4 = −𝐷𝑖 4
𝜋
9.8 × 10−8 × 32
− (0.042)4 = −𝐷𝑖 4
𝜋
𝑫𝒊 = 𝟎. 𝟎𝟑𝟖 𝒎
2. Area
𝜋
𝐴= (𝐷𝑜 2 − 𝐷𝑖 2 )
4
𝜋
𝐴= ((0.042)2 − (0.038)2 )
4
𝑨 = 𝟐. 𝟓𝟏 × 𝟏𝟎−𝟒 𝒎𝟐
3. Axial Stress
𝑃
𝜎𝑎 =
𝐴
108 × 103
σa =
2.51 × 10−4
𝝈𝒂 = 𝟒𝟐𝟗. 𝟕𝟔 𝑴𝑷𝒂
4. Bending Stress
𝑀𝑐
𝜎𝑏 =
𝐼
𝜋
𝐼= (𝐷𝑜 4 − 𝐷𝑖 4 )
64
𝜋
𝐼= ((0.042)4 − (0.038)4 )
64
𝐼 = 5.038 × 10−8 𝑚4
168 × 0.021
𝜎𝑏 =
5.038 × 10−8
𝝈𝒃 = 𝟕𝟎. 𝟎𝟐 𝑴𝑷𝒂
𝜏𝑎𝑙𝑙𝑜𝑤 = 𝝉𝒙𝒚 = 𝟔𝟎 𝑴𝑷𝒂
𝝈𝒚 = 𝟎 𝑴𝑷𝒂
𝜎𝑥 = σa + 𝜎𝑏
𝜎𝑥 = 429.76 + 70.02
𝝈𝒙 = 𝟒𝟗𝟗. 𝟕𝟖 𝑴𝑷𝒂
𝜎𝑥 − 𝜎𝑦 𝜎𝑥 − 𝜎𝑦 2
𝜎1,2 = ± √( ) − 𝜏𝑥𝑦 2
2 2
499.78 − 0 499.78 − 0 2
𝜎1,2 = ± √( ) − 602
2 2
√𝜎𝑦 2
√(𝜎1 2 − 𝜎1 𝜎2 + 𝜎2 2 ) ≤
𝑛
509.668 𝑀𝑃𝑎 ≤ 280 𝑀𝑃𝑎
√𝜎𝑦 2
√(𝜎1 2 − 𝜎1 𝜎2 + 𝜎2 2 ) ≤
𝑛
509.668 𝑀𝑃𝑎 ≤ 220.8 𝑀𝑃𝑎
√𝜎𝑦 2
√(𝜎1 2 − 𝜎1 𝜎2 + 𝜎2 2 ) ≤
𝑛
509.668 𝑀𝑃𝑎 ≤ 640 𝑀𝑃𝑎
BRITTLE MATERIALS
1. Cast Iron
Max. Normal Stress Theory
𝜎𝑦
|𝜎1 | ≤
𝑛
506.88 𝑀𝑃𝑎 ≤ 640 𝑀𝑃𝑎
Material Life:
Cast Iron: Known for high durability, cast iron is less prone to fatigue and can sustain heavy loads and
vibrations over time, which is crucial for components like a propeller shaft.
Low-Carbon Steel: While durable, it may not perform as well as cast iron under cyclic loads in high-
stress applications.
Al6061 T6: Although lightweight, aluminum alloys typically have a shorter fatigue life under high
stress compared to cast iron, especially in automotive power transmission.
Conclusion
Cast iron (ASTM A536) emerges as the best choice for the rear propeller shaft due to its superior design
strength, durability, local availability, and cost-effectiveness.
We will change the safety factor, bending moment and inner diameter respectively in order to check if
the design safety will be compromised or not.
i. When n = 1.5
1. Low Carbon Steel (ASTM A1018)
For,
𝜎𝑦 = 350 MPa
a. Max. Shear Stress Theory
𝜎𝑦
|𝜎1 − 𝜎2 | ≤
𝑛
513.98 𝑀𝑃𝑎 ≤ 233.3 𝑀𝑃𝑎
√𝜎𝑦 2
√(𝜎1 2 − 𝜎1 𝜎2 + 𝜎2 2 ) ≤
𝑛
509.668 𝑀𝑃𝑎 ≤ 233.3 𝑀𝑃𝑎
√𝜎𝑦 2
2
√(𝜎1 − 𝜎1 𝜎2 + 𝜎2 2) ≤
𝑛
509.668 𝑀𝑃𝑎 ≤ 184 𝑀𝑃𝑎
√𝜎𝑦 2
2
√(𝜎1 − 𝜎1 𝜎2 + 𝜎2 2) ≤
𝑛
509.668 𝑀𝑃𝑎 ≤ 533.3 𝑀𝑃𝑎
BRITTLE MATERIALS
1. Cast Iron
Max. Normal Stress Theory
𝜎𝑦
|𝜎1 | ≤
𝑛
506.88 𝑀𝑃𝑎 ≤ 533.3 𝑀𝑃𝑎
√𝜎𝑦 2
2
√(𝜎1 − 𝜎1 𝜎2 + 𝜎2 2) ≤
𝑛
509.232 𝑀𝑃𝑎 ≤ 280 𝑀𝑃𝑎
√𝜎𝑦 2
2
√(𝜎1 − 𝜎1 𝜎2 + 𝜎2 2) ≤
𝑛
509.232 𝑀𝑃𝑎 ≤ 220.8 𝑀𝑃𝑎
√𝜎𝑦 2
2
√(𝜎1 − 𝜎1 𝜎2 + 𝜎2 2) ≤
𝑛
509.232 𝑀𝑃𝑎 ≤ 640 𝑀𝑃𝑎
√𝜎𝑦 2
2
√(𝜎1 − 𝜎1 𝜎2 + 𝜎2 2) ≤
𝑛
317.228 𝑀𝑃𝑎 ≤ 280 𝑀𝑃𝑎
2. Al6061 T6
For,
n= 1.25
𝜎𝑦 = 276 MPa
a. Max. Shear Stress Theory
𝜎𝑦
|𝜎1 − 𝜎2 | ≤
𝑛
322.85 𝑀𝑃𝑎 ≤ 220.8 𝑀𝑃𝑎
√𝜎𝑦 2
√(𝜎1 2 − 𝜎1 𝜎2 + 𝜎2 2 ) ≤
𝑛
317.228 𝑀𝑃𝑎 ≤ 220.8 𝑀𝑃𝑎
√𝜎𝑦 2
√(𝜎1 2 − 𝜎1 𝜎2 + 𝜎2 2 ) ≤
𝑛
317.228 𝑀𝑃𝑎 ≤ 640 𝑀𝑃𝑎
Conclusion
It is noticed that even after changing the parameters only CAST IRON is SAFE for rear propeller shaft
design. Whereas, LOW CARBON STEEL and Al6061 T6 stays UNSAFE for the model.
𝜎𝑋 = 499.78 MPa
𝜎𝑌 = 0 MPa
𝜏𝑥𝑦 = 60 MPa
𝜎𝑥 + 𝜎𝑦 𝜎𝑥 − 𝜎𝑦
𝜎𝑥′ = + cos 2𝜃 + 𝜏𝑥𝑦 sin 2𝜃
2 2
For𝜃𝑃1 :
499.78 + 0 499.78 − 0
𝜎𝑥′ = + cos 2(6.750) + 60 sin 2(6.750)
2 2
𝝈′𝒙 = 𝟓𝟎𝟔. 𝟖𝟖𝑴𝑷𝒂
For𝜃𝑃2 :
499.78 + 0 499.78 − 0
𝜎𝑦′ = + cos 2(96.750) + 60 sin 2(96.750)
2 2
𝝈′𝒚 = −𝟕. 𝟏𝟎𝟐 𝑴𝑷𝒂
𝜎𝑥 − 𝜎𝑦 2
𝜏𝑀𝑎𝑥−𝐼𝑛𝑝𝑙𝑎𝑛𝑒 = √( ) + 𝜏𝑥𝑦 2
2
499.78 − 0 2
𝜏𝑀𝑎𝑥−𝐼𝑛𝑝𝑙𝑎𝑛𝑒 √
= ( ) + 602
2
𝝉𝑴𝒂𝒙−𝑰𝒏𝒑𝒍𝒂𝒏𝒆 = 𝟐𝟓𝟔. 𝟗𝟓𝟐 𝑴𝑷𝒂
For𝜎𝐴𝑣𝑔 :
𝜎𝑥 + 𝜎𝑦
𝜎𝐴𝑣𝑔 =
2
499.78 + 0
𝜎𝐴𝑣𝑔 =
2
𝝈𝑨𝒗𝒈 = 𝟐𝟒𝟗. 𝟖𝟗 𝑴𝑷𝒂
𝜃𝑝1 = 6.750°