Problem 1 Dynamic stresses in machine members

Example

P = ω2·R·sinωt·Q2/g

R ω Q2
qs
C

B
A
z
Q1
0.5 L

h
x
x
Cross-section of the beam
Siju šķērsgriezums
b

Installation with weight Q1 = 9 kN is fixed in the middle section of horizontal steel beam,
made from two parallel standard double-T shapes No 22. Ends of the beam are mounted on two
pivot supports, and space between supports is equal to L = 4.5 m.
Material of the beam is steel St 3 with the following mechanical features: elasticity
modulus E = 2∙1011 N/m2; yield strength t = 250 MPa; ultimate strength b = 420 MPa; fatigue
limit under the symmetric stress cycle -1 = 200 MPa. Safety factor relative to yield strength is
k = 2. Making calculations, it is necessary to take into account own weight of the beam.
Installation is set in operation with the aid of electric motor. Shaft of the motor has
unbalanced rotating mass, which can be balanced by correction weight Q2 = 70 N under the
rotation radius R = 12 cm and rotational speed nw = 1600 R.P.M.
1. Determine maximal value of mechanical stress dmax in beam in dynamic regime under the
rotational speed nw = 1600 R.P.M. and compare the value of dmax with allowable static
stress [] = t/k.

1
2. A) If dmax < [], then it is necessary to determine reserve operation regime of driving motor
(allowable range of rotational speed nj = ?) under the increased value of safety factor kj =
2∙k = 4.
B) If dmax > [], then it is necessary to select two new standard double-T shapes (one
double-T shape with higher ordinal number, other double-T shape with smaller ordinal
number), which will ensure execution of strength condition under the rotational speed nw
= 1600 R.P.M.

Initial data for calculations:

Main parameters of the double-T shape No 22: h = 22 cm, b = 11 cm, d = 0.54 cm, F(1) = 30.6
cm2, Ix(1) = 2550 cm4, Wx(1) = 232 cm3, μ = 24 kg/m.
Q1 = 9 kN, L = 4.5 m, Q2 = 70 N, R = 12 cm, nw = 1600 R.P.M., g = 9.81 m/s2.

Allowable static stress

 = t =
250
= 125 N/mm2.
k 2
Principal moment of inertia of beam’s cross-section
Ix = 2·Ix(1) = 2·2500 = 5100 cm4 = 51·10-6 m4;
Bending rigidity of the beam:
E·Ix = 2·1011·51·10-6 = 102·105 N·m2;
Own weight of the beam:
Qb = 2·Qb(1) = 2·μ·L·g = 2 · 24 · 4.5 · 9.81 = 2119 N.

1. Maximal value of mechanical stress dmax in beam in dynamic regime

1) Natural frequency

48⋅𝐸𝐼𝑥 ⋅𝑔 48⋅102⋅105 ⋅9.81

𝜔0 = √ 17 3
=√ 17 = 72.4 rad/s
(𝑄 1 +35𝑄𝑏 )⋅𝐿 (9000+35⋅2119)⋅4.53

Critical rotation frequency of motor’s shaft (from resonant condition):

ωcr = ω0 = 72.4 rad/s ;
30 30
ncr =  cr =  72.4 = 692 R.P.M.
 3.14
2) Gain factor of vibrations:
1 02 72.42
= 2
= = (1)
  02 − 2 72.42 − 2
1 −  
 0 
3) Coefficient of dynamic amplification λd
This coefficient show, how much time maximal stress in dynamic regime σdmax is bigger
than static stress σstmax (due to the action of the same load, but applied statically):
 Pst
d = 1 +  ,
Qst

2
 𝑄2
where  Pst – displacement caused by the static action of excitation force 𝑃 = 𝜔 2 𝑅 ;
𝑔
 Qst – displacement caused by the action of static loads Q1 and Qb.

Displacements  Pst and  Qst can be calculated by formulae:

P  L3 Q  2  R  L3 Q1  L3 5 Qs  L3 8  Q1 + 5  Qs 3
 Pst = = 2 ;  Qst = +  = L .
48  E  I x 48  g  E  I x 48  E  I x 384 E  I x 384  E  I x

Formula for calculation of coefficient of dynamic amplification λd can be expressed in

the following form:

Q 2 RL3 384EI x 8Q22 R

d = 1 + 2    = 1 +  =
48gEI x (8Q1 + 5Qs )L3 (8Q1 + 5Qs )g
(2)
2
8  70    0.12
=1+   = 1 + 8.28  10−5  2
(8  9000 + 5  2119)  9.81
4) Maximal static stress σStmax

11318 N·m

Reactions of the supports A and B due to the action of static loads:

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 yi = 0;
R A − Q1 + RB − qs  L = 0;
 M A = 0;
− Q1  0.5  L + RB  L − 0.5  qs  L2 = 0;
Q  L q  L2 Q1 qs  L
 RB = 1 + s = +
2 L 2 L 2 2
Q1 qs  L Q1 qs  L
 R A = Q1 + qs  L + − − = +
2 2 2 2
Check
 M B = 0;
− R A  L + Q1  0.5  L + 0.5  qs  L2 = 0
− 0.5  Q1  L − 0.5  qs  L2 + 0.5  Q1  L + 0.5  qs  L2 = 0
0=0

Q 2119
qS = S = = 471 N/m;
L 4.50
nw = 1600 R.P.M.;
9000 471 4.50
RA = RB = + = 5560 N.
2 2
Analytical expressions for bending moment M
0 ≤ z1 ≤ 0.5·L
q  z2
M1 = RB  z1 − S 1 ;
2
M1(0) = 0;
L qS  L2 5560  4.50 471 4.502
M1 max (0.5  L ) = RB  − = − = 11318 N·m.
2 8 2 8
0 ≤ z2 ≤ 0.5·L
qS  z22
M 2 = R A  z2 − ;
2
Similarly M 2 max = 11318 N·m.
Therefore, M Xst (max) = M1 max = M 2 max = 11318 N·m .
Maximal static stress:
M Xst (max) M Xst (max) 11318 103
 St max = = = = 24.4 N/mm²   = 125 N/mm2.
WX 2  WX (1) 3
2  232  10
Therefore, maximal static stress σStmax is sufficiently smaller than allowable stress [σ].
By the results of calculations, the diagram of normal stresses σ for beam’s dangerous cross-
section C is constructed.

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5) Dynamic stress dmax
Angular velocity:
  nw 3.14  1600
w = = = 167.5 rad/s.
30 30
Gain factor by formula (1):
1 02 72.42 72.42
= 2
= = = = 0.23 .
 0  02 − 2 72.42 − 2 72.42 − 167.52
1−  
 
Coefficient of dynamic amplification λd by formula (2):
 d = 1 + 8.28  10−5  2   = 1 + 8.28  10−5  167.52  0.23 = 1.534 .
Maximal stress in dynamic regime:
 d max = St max  d = 24.4 1.534 = 37.4 N/mm2.
Check of strength condition:
d max = 37.4 N/mm2   = 125 N/mm2

On the base of calculations, a graph of d versus time t is plotted.

σd, N/mm2

[σ]=125

σdmax=37.4
σstmax=24.4

t, s

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 Conclusion
Under the rotation speed nw = 1600 R.P.M. the condition dmax < [] is satisfied. This
condition is enough for strength, if dynamic load acts on the beam during a comparatively short
time. In this case, in accordance with the problem’s formulation, it is necessary to consider
point 2A.

2A. Reserve operation regime of driving motor (allowable range of rotational

speed nj = ?) under the increased value of safety factor kj

Increased value of safety factor kj = 2∙k = 2∙2 = 4.

Allowable stress:  j  = k t = 250
4
= 62.5 MPa.
j

The graph of d versus time t is as follows.

σ, N/mm2

[σj]=62.5

σmax(d)=37.4
σst=24.4

t, s

Strength condition:
 
 −5
max( d ) =  st max   d = 24.4  1 + 8.28  10   
2 72.42 
 
   j = 62.5 MPa. (3)
 72.42 − 2 
 
Two solutions of inequality (3) are possible.
a)   72.4 rad/s

1 + 8.28  10−5  2 
72.42
72.4 − 
2 2

62.5
24.4
(
 72.42 − 2 ; )
5241.76 − 2 + 0.43 2  13415.64 − 2.56  2 ;
1.99  2  8173.88 ;
(1)  64 rad/s or n(1)  612 R.P.M.

b)   72.4 rad/s

1 + 8.28  10−5  2 
72.42
 − 72.4
2 2

62.5 2
24.4
(
 − 72.42 ; )
2 − 5241.76 + 0.43  2  2.56  2 − 13415.64 ;
1.13  2  8173.88 ;
( 2)  85 rad/s or n( 2)  812 R.P.M.

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 On the base of calculations, a graph of stress max versus rotation frequency n can be plotted.
Characteristic points of the graph  max = f (n) :
n = 0 →  st max = 24.4 MPa ;
n = n(1) = 612 R.P.M. →  max( d ) = [ j ] = 62.5 MPa (point 1);
n = nkr = 692 R.P.M. →  max  
n = n(2) = 812 R.P.M. →  max( d ) = [ j ] = 62.5 MPa (point 2);
n = n0 = 1600 R.P.M. →  max(d ) = 37.4 MPa (point d).
By these points, a graph  max = f (n) is plotted.

Conclusion
There are two reserve operation regimes of driving motor:
1) n(1)  612 R.P.M.
This is so called before resonance frequency range. Within this frequency range overload
is impossible even in transient process (turning on or turning off of driving electric motor).
2) n( 2)  812 R.P.M.
This is so called after resonance frequency range. Danger of overload exists in transient
process, when rotation frequency of driving motor n is close to critical resonant frequency ncr
= 692 R.P.M.
Therefore, first reserve regime ( n(1)  612 R.P.M.) is the more suitable.