UNIVERSITI TEKNOLOGI MALAYSIA

FACULTY OF MECHANICAL ENGINEERING

Beam Design

Course Name : MECHANICS OF SOLIDS I

Course Code : SEMM1113
Section : 81
Lecturer Name : DESMOND DANIEL CHIN
Date : 17/01/2025
Group members :
1. AHMED MAJDY AHMED A23KM3002
2. MOHAMMED SOFIAN A23KM3007
3. RAYYAN RAFAT A23KM3009
4. RONALD CALIST MUNISHI A23KM3010
5. SOLEHUDDIN WAHID A23KM3012
Table of Contents
1. Introduction: ................................................................................................................... 5
2. Theory:........................................................................................................................... 6
3. Analysis: ........................................................................................................................ 6
Statical loading calculation.................................................................................................... 6
Shear-force-diagram (SFD) and bending-moment-diagram (BMD) ............................................ 8
Cross-sectional area and design ............................................................................................. 9
Bending stress calculation ..................................................................................................... 9
Shear stress calculation ....................................................................................................... 10
Macaulay’s deflection calculation ........................................................................................ 10
Safety factor ...................................................................................................................... 13
Material selection............................................................................................................... 13
4. Discussion .................................................................................................................... 14
5. Conclusion: ................................................................................................................... 15
6. Reference: .................................................................................................................... 15
7. Appendix ...................................................................................................................... 15
FIGURE TABLE
FIGURE 1 ........................................................................................................................................... 5
FIGURE 2 ........................................................................................................................................... 5
FIGURE 3 ........................................................................................................................................... 6
FIGURE 4 ........................................................................................................................................... 7
FIGURE 5 ........................................................................................................................................... 8
FIGURE 6 ........................................................................................................................................... 8
FIGURE 7 ........................................................................................................................................... 9
FIGURE 8 ......................................................................................................................................... 13
 1. Introduction:
Beams play a vital role in structural engineering, especially in indoor construction
where they support various components such as fans, lamps, and ceilings. Their ability to bear
loads and maintain structural integrity is critical in ensuring safety and functionality in
buildings. This project focuses on the analysis and design of a beam used to support fans and
lamps in a building, like the structure illustrated in Figures 1 and 2 below.

Figure 1

Figure 2

Fixed supports support the specific beam under consideration and carries loads from
KDK brand fans, each weighing 5.1 kg, and EST brand lamps, each weighing 1.3 kg. The
primary objective of this project is to select the most appropriate material for the beam, propose
a suitable cross-sectional shape and size, and perform necessary calculations to ensure the beam
can safely support the attached loads. Additionally, a suitable safety factor will be incorporated
into the design to prevent catastrophic failure.
 This project applies theoretical concepts from the Mechanics of Solid I course,
including stress analysis, bending moment calculations, and deflection analysis. The analysis
will guide the selection of materials and the optimization of the beam's geometry. Relevant
computational tools, such as Excel and MSOLID, will be used to perform and validate the
calculations.

The final deliverable is a comprehensive report detailing the design process, analysis,
and justification for material and design choices, ensuring that the beam design meets both
safety and performance standards.

2. Theory:

3. Analysis:
Statical loading calculation
Based on Figure 3 below, a Free-Body-Diagram was drawn (Figure 4) to calculate the reaction
forces at the fixed supports as shown in Figure 3.

Figure 3
Figure 4

The following variables have given values:

The distance between each loading, 𝑥 = 2.5 𝑚
The weight of the fan, 𝑊 = 5.1(9.81) = 50.031 𝑘𝑔
The weight of the lamp, 𝑊 = 1.3(9.81) = 12.753 𝑘𝑔
Equilibrium equation:

𝐹 = 0 (+→)

𝐴 −𝐵 =0
Since the beam has symmetrical loadings and supports:
𝐴 =𝐵 =0𝑁

𝐹 = 0 (+↑)

𝐴 + 𝐵 − 4𝑊 − 4𝑊 = 0
From symmetrical loadings and supports:
2𝐴 = 4𝑊 + 4𝑊
4𝑊 + 4𝑊
𝐴 =𝐵 =
2
4(50.031) + 4(12.753)
𝐴 =𝐵 =
2
𝐴 = 𝐵 = 125.568 𝑁

𝑀 = 0 (+𝑐𝑐𝑤)

𝑀 − 𝑊 𝑥 − 2𝑊 𝑥 − 3𝑊 𝑥 − 4𝑊 𝑥 − 5𝑊 𝑥 − 6𝑊 𝑥 − 7𝑊 𝑥 − 8𝑊 𝑥 + 9𝐵 − 𝑀 = 0
From symmetrical loadings and supports:
2𝑀 = 18𝑊 𝑥 + 18𝑊 𝑥 − 9𝐵
18𝑊 𝑥 + 18𝑊 𝑥 − 9𝐵
𝑀 =
2
18(50.031)(2.5) + 18(12.753)(2.5)
𝑀 = = 1412.64 𝑁𝑚 (𝑐𝑐𝑤)
2
 𝑀 = 1412.64 𝑁𝑚 (𝑐𝑤)

Shear-force-diagram (SFD) and bending-moment-diagram (BMD)

The SFD and BMD were obtained by using the software MDSolids and are shown in Figure 5
and Figure 6. Figure 6 indicates that the maximum bending moment occurs at both fixed
supports with the magnitude of 𝑀 = 1412.64 𝑁𝑚.

Figure 5

Figure 6
Cross-sectional area and design
The proposed design shape of the cross-sectional area of the beam is H-beam due to its high
efficiency in resisting bending moment. The beam is also lightweight compared to solid
sections of the same length (Salmon, Johnson, & Malhas, 2008). Another factor for this
proposed design is the lack of torsional stress occurs in the beam according to the loads for this
project. Therefore, torsional efficient circular cross-sectional areas (both solid and hollow) are
not considered (Gere & Goodno, 2012). An I-beam is also suitable although due to difficulty
in calculating the second moment of inertia of the cross-sectional area specifically for this
project.

Figure 7

From the technical datasheet, the mounting diameter for a KDK fan is 150 mm (INSERT
REFERENCE) and the for a EST lamp is 115 mm (INSERT REFERENCE). Therefore, the
base of the H-beam is 150 mm. Figure 7 displays a simplified general cross-sectional area of
an H-beam. By considering the base length, slightly higher value of “a” is considered for higher
𝐼 . The values proposed for 𝑎 and 𝐼 are 200 mm and 25 mm, respectively.

1 0.2 0.025
𝐼 = 2[ (0.15)(0.025) + (0.15)(0.025) − ]
12 2 2
1
+ (0.025)[0.2 − 2(0.025)]
12

𝐼 = 6.484375 ∗ 10 𝑚

Bending stress calculation

The maximum bending stress that occurs at the fixed supports is calculated as follow:
 𝑀𝑦 1412.64(0.1)
𝜎 =
𝐼 6.484375 ∗ 10

σ = 2.1785 MPa

Shear stress calculation

The maximum shear stress happens at both fixed supports with the value, 𝑉 = 125.568 𝑁.
The transverse shear stress is calculated as follow:
𝑉𝑄
𝜏=
𝐼𝑡
Checking if maximum occurs at the seam line or the neutral axis.
0.2 − 0.025
𝑄 = Σ𝐴 𝑦 = 0.15(0.025)
2
𝑄 = 3.28125 ∗ 10 𝑚
𝑄 = (5.625 ∗ 10 )(0.1 − 0.0292)
𝑄 = 3.9825 ∗ 10 𝑚
Since 𝑄 >𝑄 , the maximum shear stress happens at the neutral axis considering
𝑉, 𝐼, 𝑎𝑛𝑑 𝑡 are similar for both.
Maximum shear stress of the beam:

(125.568)(3.9825 ∗ 10 )
𝜏 = = 0.03084797 𝑀𝑃𝑎
(6.484375 ∗ 10 )(0.025)
Since 𝜏 <𝜎 , the maximum stress experienced by the beam is by the bending moment.

Macaulay’s deflection calculation

Deflection of the beam is also significant before choosing the correct material of the beam.
Significant deflection of the beam affects the orientation of the fans causing extra dynamic
loading due to unstable motion and vibrations.

Deflection formulation by using Macaulay’s method:

𝑀(𝑥) = −𝑀 < 𝑥 − 0 > + 𝐴 < 𝑥 − 0 > − 𝑊 < 𝑥 − 2.5 > − 𝑊 < 𝑥 − 5 > − 𝑊
< 𝑥 − 7.5 > − 𝑊 < 𝑥 − 10 > − 𝑊 < 𝑥 − 12.5 > − 𝑊
< 𝑥 − 15 > − 𝑊 < 𝑥 − 17.5 > − 𝑊 < 𝑥 − 20 > + 𝐵
< 𝑥 − 22.5 > + 𝑀 < 𝑥 − 22.5 >

From Macaulay’s condition:

 < 𝑥 − 22.5 >= 0, 𝑥 = 𝐿 = 22.5 𝑚

𝑀(𝑥) = −1412.64 < 𝑥 > + 125.568 < 𝑥 > − 50.031 < 𝑥 − 2.5 > − 12.753
< 𝑥 − 5 > − 50.031 < 𝑥 − 7.5 > − 12.753 < 𝑥 − 10 > − 12.753
< 𝑥 − 12.5 > − 50.031 < 𝑥 − 15 > − 12.753 < 𝑥 − 17.5 > − 50.031
< 𝑥 − 20 >

Applying basic differential equation:

𝑑 𝑦
𝐼𝐸 = 𝑀(𝑥) = −1412.64 < 𝑥 > + 125.568 < 𝑥 > − 50.031 < 𝑥 − 2.5 > − 12.753
𝑑𝑥
< 𝑥 − 5 > − 50.031 < 𝑥 − 7.5 > − 12.753 < 𝑥 − 10 > − 12.753
< 𝑥 − 12.5 > − 50.031 < 𝑥 − 15 > − 12.753 < 𝑥 − 17.5 > − 50.031
< 𝑥 − 20 >

First integration – slope equation:

𝑑𝑦
𝐼𝐸 = 𝐼𝐸(𝜃) = −1412.64 < 𝑥 > + 62.784 < 𝑥 > − 25.0155 < 𝑥 − 2.5 > − 6.3765
𝑑𝑥
< 𝑥 − 5 > − 25.0155 < 𝑥 − 7.5 > − 6.3765 < 𝑥 − 10 > − 6.3765
< 𝑥 − 12.5 > − 25.0155 < 𝑥 − 15 > − 6.3765 < 𝑥 − 17.5 > − 25.0155
< 𝑥 − 20 > + 𝐶

Apply boundary condition: At 𝑥 = 0 𝑚, 𝜃 = 0 𝑟𝑎𝑑,

𝐼𝐸(0) = −1412.64 < 0 > + 62.784 < 0 > − 25.0155 < 0 − 2.5 > − 6.3765
< 0 − 5 > − 25.0155 < 0 − 7.5 > − 6.3765 < 0 − 10 > − 6.3765
< 0 − 12.5 > − 25.0155 < 0 − 15 > − 6.3765 < 0 − 17.5 > − 25.0155
< 0 − 20 > + 𝐶

𝐶 =0

Second integration – deflection equation:

𝐼𝐸𝑦 = −706.32 < 𝑥 > + 20.928 < 𝑥 > − 8.3385 < 𝑥 − 2.5 > − 2.1255
< 𝑥 − 5 > − 8.3385 < 𝑥 − 7.5 > − 2.1255 < 𝑥 − 10 > − 2.1255
< 𝑥 − 12.5 > − 8.3385 < 𝑥 − 15 > − 2.1255 < 𝑥 − 17.5 > − 8.3385
< 𝑥 − 20 > + 𝐶

Apply boundary condition at: 𝑥 = 0 𝑚, 𝑦 = 0 𝑚,

 𝐼𝐸(0) = −706.32 < 0 > + 20.928 < 0 > − 8.3385 < 0 − 2.5 > − 2.1255
< 0 − 5 > − 8.3385 < 0 − 7.5 > − 2.1255 < 0 − 10 > − 2.1255
< 0 − 12.5 > − 8.3385 < 0 − 15 > − 2.1255 < 0 − 17.5 > − 8.3385
< 0 − 20 > + 𝐶

𝐶 =0

Finalised equations:

𝐼𝐸(𝜃) = −1412.64 < 𝑥 > + 62.784 < 𝑥 > − 25.0155 < 𝑥 − 2.5 > − 6.3765
< 𝑥 − 5 > − 25.0155 < 𝑥 − 7.5 > − 6.3765 < 𝑥 − 10 > − 6.3765
< 𝑥 − 12.5 > − 25.0155 < 𝑥 − 15 > − 6.3765 < 𝑥 − 17.5 > − 25.0155
< 𝑥 − 20 >

𝐼𝐸𝑦 = −706.32 < 𝑥 > + 20.928 < 𝑥 > − 8.3385 < 𝑥 − 2.5 > − 2.1255
< 𝑥 − 5 > − 8.3385 < 𝑥 − 7.5 > − 2.1255 < 𝑥 − 10 > − 2.1255
< 𝑥 − 12.5 > − 8.3385 < 𝑥 − 15 > − 2.1255 < 𝑥 − 17.5 > − 8.3385
< 𝑥 − 20 >

Maximum deflection occurs at the centre of the beam, 𝑥 = 11.25 𝑚,

.
The maximum allowable deflection for a uniform beam is 𝑦 = = = 0.0625 𝑚.

Thus, the minimum allowable E for the beam without S.F. is calculated as follow:

1
𝐸= [−706.32 < 𝑥 > + 20.928 < 𝑥 > − 8.3385 < 𝑥 − 2.5 > − 2.1255
𝐼𝑦
< 𝑥 − 5 > − 8.3385 < 𝑥 − 7.5 > − 2.1255 < 𝑥 − 10 > − 2.1255
< 𝑥 − 12.5 > − 8.3385 < 𝑥 − 15 > − 2.1255 < 𝑥 − 17.5 > − 8.3385
< 𝑥 − 20 > ]

1
𝐸= [−706.32 < 11.25 > + 20.928 < 11.25 > − 8.3385
(6.484375 ∗ 10 )(−0.0625)
< 11.25 − 2.5 > − 2.1255 < 11.25 − 5 > − 8.3385
< 11.25 − 7.5 > − 2.1255 < 11.25 − 10 > − 2.1255
< 11.25 − 12.5 > − 8.3385 < 11.25 − 15 > − 2.1255
< 11.25 − 17.5 > − 8.3385 < 11.25 − 20 > ]
 𝐸 = (−246746.988)[−89393.625 + 29797.875 − 5586.143555 − 518.9208984
− 439.7255859 − 4.151367188 − 0 − 0 − 0 − 0]

𝐸 = 16.321 𝐺𝑃𝑎

Safety factor
Given the maximum stress and deflection experienced by the beam, a reference safety factor
is set at 2. Therefore, the references for Ashby’s method of material selection are set at:

𝜎 = 2.1785 ∗ 2 = 4.357 𝑀𝑃𝑎

𝐸 = 16.321 ∗ 2 = 32.642 𝐺𝑃𝑎

Material selection
Ashby’s approach is implemented for the material selection for this project, allowing
for a more lenient and accurate selection based on the dimension of the cross-sectional area
and material properties of the beam. The main functional requirement for the beam is the ability
to withstand the bending moment stress within the safety factor and minimal deflection due to
the weight of the loadings acting on the beam. The objective of the method is to select a suitable
material for the beam considering the stresses experienced by the beam.

From this method, we found the following:

1. Young’s modulus (𝐸) vs. Bending Strength (𝜎) → To visualize materials that are stiff
and strong.
2. Young’s modulus (𝐸) vs. Toughness or Elongation → To ensure ductility.

Figure 8
 Based on the charts, we chose the material as Aluminium 6061, because of its strong
and ductile properties. Below are the material technical specifications (ASM Aerospace
Specification Metals Inc.):

Property Value
Tensile Strength 310 𝑀𝑃𝑎

Yield Strength 276 𝑀𝑃𝑎

Elongation at Break 12%
Density 2.70 𝑔/𝑐𝑚³
Melting Point 582– 652°𝐶
Thermal Conductivity 151– 202 𝑊/(𝑚 · 𝐾)
Coefficient of Thermal Expansion 23.2 µ𝑚/𝑚 · °𝐶
Electrical Resistivity 32.5– 39.2 𝑛𝛺 · 𝑚
Modulus of Elasticity 68.9 𝐺𝑃𝑎

Poisson's Ratio 0.33

4. Discussion
5. Conclusion:

6. Reference:

7. Appendix