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SIMPLE/DIRECT STRESS
Definition of Terms:
1. Stress – a total resistance that a material offers to an
applied load
- is force per unit area
2. Strength – the ability of a material to withstand load
without failure
3. Strain – is the amount by which a dimension of a body
changes when the body is subjected to a load, divided
by the original value of the dimension.

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STRESS-STRAIN CURVE

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where:
P - proportional limit
- is the point on the stress-strain curve at which it begins to deviate
from the straight-line relationship between stress and strain
E – elastic limit
- is the maximum stress to which a test specimen may be subjected
and still return to its original length upon release of the load
Y – yield point
- is the point on the stress-strain curve at which there is a sudden
increase in strain without a corresponding increase in stress
U – ultimate point
- is the maximum stress obtained on a stress-strain curve
B – breaking or rupture point
- is the stress which failure occurs

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Objective of Machine Design:

- to design a machine member, component, parts or

elements within a “SAFE” operating capability

SAFE CONCEPT:
- there’s no failure or break
- the applied load (to the machine or component)
must not exceed its strength

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Types of Simple Loading

1. Tensile load
2. Compressive load
3. Shearing load
4. Bearing load
5. Bending load
6. Tortional load

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1. Tension
A

D
F F

where: let,

A = 4 D for solid circular
2
St = induced tensile stress
 F
A = 4 (D − D ) for solid circular
2
O i
2
= , KPa pr psi
A
A = bh for rectangular

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For design calculations,

let,
Sd = design stress
= working stress
= allowable stress

for ductile materials,

> if no deformation is allowed
S yt
Sd = where,
N Sy
Syt = yield strength in tension
Nsy = factor of safety

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for ductile materials,

> if deformation is allowed
Su
Sd = t

N S u where,
Sut = ultimate strength in tension
Nsu = factor of safety

for brittle materials,

> design is based on the ultimate strength
Su
Sd = t

N Su

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Example 1:
A steel tie rod on bridge must be made to withstand a pull
of 5,000 lbs. Find the diameter of the rod assuming a
factor of 5 and ultimate stress of 64,000 psi?
from,
subs,
Su
Sd =
N Su 4 (5000 lb )
=
64 ,000  (12 ,800 lb / in 2 )
=
D=? 5 = 0 .92 in
Sd = 12,800 psi
let,
S d = St
F
=
F = 5,000 lbs A
F
=

d2
4
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Example 2:
A steel weighing 480 lb/ft3 has an ultimate strength of 80,000 psi.
What is the maximum length of steel rod that could be hung
vertically from its upper end without rupturing?

from, from, equate eq 1 & 2,

S u A = AL
F W
St = = Su
A V L=
L=? 
let, W = V
St = S u lb 144 in 2
80 ,000 x
but , in ft 2
=
lb
then, V = AL 480 3
ft
F = Su A --- eq 1 W = AL − eq .2 L = 24 ,000 ft
W

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Example 3:
A rectangular rod 2 in x 3 in in cross section is subjected to
100,000 lb of tension. What material should be selected to
carry the loading above?
F

from,
F 100 ,100 lb
2 in
St = = 2inx 3in
3 in
A
= 16,666.67 lb/in2 or psi

F = 100,000 lb

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Example 3, con’t.:
Let, substituting,
S d = St Su = 16,666.67(4)
= 66,666.67 psi
If design is based on ultimate
strength, select steel material having ultimate
from, Su strength greater than 66,666.67
Sd = psi
N Su
from Table AT 7, p. 576, Machine
Su = Sd x NSu Design by Faires
from Table 1.1, p.20, Machine use, AISI C1010, cold drawn
Design by Faires
steel
for dead load and steel(ductile)
based on ultimate strength, (with Su = 67 ksi)
NSu = 3 – 4
use,
NSu = 4
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2. Compression A

D
F F

where: let,

A = 4 D for solid circular
2
Sc= induced compressive stres
F

A = 4 (D − D ) for solid circular
2
O i
2
= A , KPa pr psi
A = bh for rectangular

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For design calculations,

let,
Sd = design stress
= working stress
= allowable stress

for ductile materials,

> if no deformation is allowed
S yc
Sd = where,
N Sy
Syc = yield strength in compression
Nsy = factor of safety

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for ductile materials,

> if deformation is allowed
Su
Sd = c

N Su where,
Suc = ultimate strength in compression
Nsu = factor of safety

for brittle materials,

> design is basd on the ultimate strength
Su
Sd = c

N Su

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Example 4:
Calculate the compressive stress of a sign board support with a
load of 2000 lb. A hollow cylinder is used with an outside
diameter of 6 inches and thickness of 0.75 inch.
F = 2,000 lb
from, from,
Do = Di + 2t Sc =
F
A
Di = Do – 2t
F
=
= 6 – 2 (0.75) 
( D o − Di )
2 2

Di = 4.5 in 4
t= 0.75 in 2000 lb
=

D = 6 in ( 6 2 − 4 .5 2 )in 2
4
= 161 .68 psi

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Example 5:
A column supports a compressive load of 400 KN. Determine the
outside diameter of column if inside diameter is 150 mm and
compressive stress of 50 MPa.
F = 400 KN
but, subs,

F N 4 ( 400 x10 3 )
Sc = 50 x10 6
=
 ( Do − 0 .15 2 )
2 2
m
A
F Do = 0 .1808 m
=
 or
( D o − Di )
2 2

4 Do = 180 .8 mm

Di = 150 mm
Do = ?

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Example 6:
Design the diameter of a circular rod to carry a compressive
load of 50,000 lb using C1045, as rolled steel.
F = 50,000 lb
from, Table AT 7, p.576, Machine Design by Faires
for C1045, as rolled
Su = 66 ksi
Sy = 59 ksi
D=? If design is based on yield strength,
from Table 1.1, p.20, MD by Faires
for dead load, steel material
NSy = 1.5 – 2
thus,
S yc 59 ,000 psi
Sd = =
N Sy 2
Sd = 29,500 psi

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Example 6, con’t:
If design is based on ultimate strength,
let,
from Table 1.1, p.20, MD by Faires
S c = Sd
F F for dead load, steel material
Sc = = NSu = 3 – 4
A 
D2 use, NSu = 4
4
then, S uc 96 ,000 psi
4F 4F Sd = =
D2 = D= N Su 4
S c or S c Sd = 24,000 psi
4 (50 ,000 lb )
D= let, Sc = Sd
lb F F
 ( 29 ,000 2 ) = 1.469 in Sc = =
in A 
D2
Note: Standardize dimensions to nearest 4
commercial size! D=
4F
=
4 (50 ,000 )
S d  ( 24 ,000 )
from Chapter 1.22 Preferred
Sizes(Standard D = 1.6287 in
Fractions), p.32, MD by Faires ( note: standardized)
use, D= 1 ½ in use, D = 1 5/8 in

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3. Bearing

where: let,
A = projected area Sb = induced bearing stress
A=DxL F
= A , KPa pr psi

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For design calculations,

let,
Sd = design stress
= working stress
= allowable stress

for ductile materials,

> if no deformation is allowed
S yb
Sd = where,
N Sy
Syb = yield strength in bearing
Nsy = factor of safety

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for ductile materials,

> if deformation is allowed
Su
Sd = b

N S u where,
Sub = ultimate strength in bearing
Nsu = factor of safety

for brittle materials,

> design is based on the ultimate strength
Su
Sd = b

N Su

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Example 7:
A 2.5” diameter by 2” long journal bearing is to carry a 5500 lb.
Load at 3600 rpm using SAE 40 lube oil at 200 °F through a
single hole at 25 psi. compute the bearing pressure.
from, subs,

= 5500 lb F 5500 lb
Sb = Sb =
A ( 2 .5in )( 2in )

= 2.5 in =
F S b = 1,100 psi
= 2.5 in
dxL

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Example 8:
Two 30 mm thick plate is fastened by a bolt, 25 mm in diameter. If
the plate is subjected to 50 KN tension, find the bearing stress in
bolts.
from, subs,
50 ,000 N
F F = 50 KN F Sb =
Sb = ( 0 .025 m )( 0 .03 m )
t = 30 mm
A S b = 66 ,666 ,666 .67 Pa
F
= or
dxt S b = 66 .67 MPa
d = 25 mm

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4. Shearing

let,
Ss = induced shearing stress
where: F
A = area normal to the applied
= A , KPa pr psi
load

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For design calculations,

let,
Sd = design stress
= working stress
= allowable stress

for ductile materials,

> if no deformation is allowed
S ys
Sd = where,
N S ys
Sys = yield strength in shearing
Nsy = factor of safety

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for ductile materials,

> if deformation is allowed
Su
Sd = s

N Su where,
Sub = ultimate strength in shearing
Nsu = factor of safety

for brittle materials,

> design is based on the ultimate strength
Su
Sd = s

N Su

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Example 9:
The ultimate shear strength of a 5/8 in. thick steel plate is 42,000
psi. What force is necessary to punch a 3/4 in diameter hole?
from, subs,
=?
F 3 5
F = ( 42 ,000 lb )( )( in )( in )
S us = 4 8
A F = 61,850 lb
5/8 in =
F = S us A
= ¾ in
F = dt

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Example 10:
How many ¾ in. holes could be punched in one stroke in annealed steel
plate of AISI C1040 Sus = 58.5 ksi), 3/16 in thick, by a force of 60
tons.
from, subs,
S s = S us FT
= 60 tons n=
F F F
S us = =
A dt 2000 lb
60 tonsx
F = S us dt n= ton
lb 3 3 25 ,844 lbs / holes
3/16 in = F = 58 ,500 ( )( in )( in )
= ¾ in in 2
4 16 n = 4 .64 holes
F = 25 ,844 .51lbs / hole
therefore ,
n = 4 holes

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Practice problems:

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