MSA University

Faculty of Engineering
Industrial Engineering Department

Lectures Notes on

Stress Analysis

(DES 262: Mechatronics Eng. Students)

(DES 352: Industrial Eng. Students)

(Semester: Spring 2022)

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 Chapter III
Torsion

This chapter is devoted to the study of torsion and of the stresses and
deformations it causes.
Objectives:

• Introduce students to the concept of torsion in structural members and

machine parts.
• Define shearing stresses and strains in a circular shaft subject to torsion.
• Define angle of twist in terms of the applied torque, geometry of the shaft,
and material.
• Design shafts for power transmission.

References:

 Ferdinand P. Beer, E. Russell Johnston Jr., John T. DeWolf, David

F. Mazurek, “Mechanics of Materials”, 8th Edition-McGraw-Hill,
2020.
 Hibbeler, R. C – “Mechanics of materials” , Pearson, 10th ed.,
2018.

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 2.1 Introduction:
 In this chapter, structural members and machine parts that are in torsion will
be analyzed, where the stresses and strains in members of circular cross
section are subjected to twisting couples, or torques, T and T′ (Fig. a and b).

 Members in torsion are encountered in many engineering applications.

The most common application is provided by transmission shafts, which are
used to transmit power from one point to another. These shafts can be either
solid, or hollow.

 Consider the system shown in Fig. 3.2a, which consists of a steam turbine A
and an electric generator B connected by a transmission shaft AB.

 By breaking the system into its three

component parts (Fig. b), you can see
that the turbine exerts a twisting couple
or torque (T) on the shaft and that the
shaft exerts an equal torque on the
generator.

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3.2 Discussion of the Stresses in a Circular Shaft:

 Considering a shaft AB subjected at A and B to

equal and opposite torques T and T’, and pass a
section perpendicular to the axis of the shaft
through some arbitrary point C.
 The free-body diagram of the portion BC of the
shaft must include the elementary shearing
forces dF, perpendicular to the radius of the
shaft, that portion AC exerts on BC as the shaft
is twisted.
 The conditions of equilibrium for BC require
that the system of these elementary forces be equivalent to an internal
torque T, equal and opposite to T’.
 Denoting by ρ the perpendicular distance from the force dF to the axis of
the shaft, and expressing that the sum of the moments of the shearing
forces dF about the axis of the shaft is equal in magnitude to the torque T,
we write: T    dF     dA ……………....(3.1)

 While the relation obtained expresses an important condition that must be

satisfied by the shearing stresses in any given cross section of the shaft, it
does not tell us how these stresses are distributed in the cross section.

 Distribution of shearing stresses is statically indeterminate – must

consider shaft deformations. Unlike the normal stress due to axial loads,
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 the distribution of shearing stresses due to torsional loads cannot be
assumed uniform.

3.3 Deformations in a Circular Shaft:

 Consider a circular shaft that is attached to a fixed
support at one end. If a torque T is applied to the other
end, the shaft will twist, with its free end rotating
through an angle Φ called the angle of twist.
 From observation, the angle of twist of the shaft is
proportional to the applied torque and to the shaft
length. In other words, the angle of twist for a shaft of the   T
same material and same cross section, but twice as long,   L

will be twice as large under the same torque T.

 When subjected to torsion, every cross-section of a circular shaft(hollow or

solid) remains plane and undistorted because a circular
shaft is axisymmetric, (Fig. a).
 Cross-sections for hollow and solid circular shafts remain
plain and undistorted
 Cross-sections of noncircular (non-axisymmetric) shafts
are distorted, and do not remain plane, when subjected to torsion.(Fig. b).

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 Shearing Strains:

 Now we will determine the distribution of shearing strains in a circular

shaft of length L and radius c that has been twisted through an angle Φ.
 Detaching from the shaft a cylinder of radius ρ,
consider the small square element formed by
two adjacent circles and two adjacent straight
lines traced on the surface before any load is
applied (Fig. b).
 As the shaft is subjected to a torsional load, the
element deforms into a rhombus (Fig. c).
 Since the ends of the element remain planar,
the shear strain is equal to angle of twist.
 it follows that: 
L   or  
L
Where γ and φ are in radians. This equation shows that the shearing
strain γ at a given point of a shaft in torsion is proportional to the angle
of twist φ. It also shows that γ is proportional to the distance ρ from the
axis of the shaft to that point.
 Thus, the shearing strain in a circular shaft varies linearly with the
distance from the axis of the shaft.

c 
 max  and    max
L c

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3.4 STRESSES IN THE ELASTIC RANGE
 When the torque T is such that all shearing stresses in the shaft remain

below the yield strength τY, the stresses in the shaft will remain below both
the proportional limit and the elastic limit.
 Applying Hooke’s law for shearing stress and strain , we write:

𝝉 = 𝑮𝜸
Where: G is the modulus of rigidity or shear modulus of the material.

and since:   max
c

𝝆
Then: 𝝉 = 𝑮𝜸 = 𝑮𝜸𝒎𝒂𝒙
𝒄
𝝆
𝝉= 𝝉 ………….(3.2)
𝒄 𝒎𝒂𝒙
Or:

The equation obtained shows that, as long as the yield strength (or
proportional limit) is not exceeded in any part of a circular shaft, the
shearing stress in the shaft varies linearly with the distance ρ from the axis
of the shaft.
Figure (a): shows the stress distribution in a solid circular
shaft of radius c, and
Figure (b): in a hollow circular shaft of inner radius c1 and
𝒄𝟏
outer radius c2. : 𝝉𝒎𝒊𝒏 = 𝝉𝒎𝒂𝒙
𝒄𝟐

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Substitute from equation 3.2 into equation 3.1, we get:
𝜏𝑚𝑎𝑥
𝑇 = ∫ 𝜌 (𝜏 𝑑𝐴) = ∫ 𝜌2 𝑑𝐴
𝑐
But the integral: ∫ 𝜌2 𝑑𝐴 in the last member represents the polar moment
of inertia J of the cross section with respect to its center.

𝑇𝑐
We have therefore: 𝜏𝑚𝑎𝑥 =
𝐽

We can express the shearing stress at any distance ρ from the axis of the shaft
as: 𝑇𝜌
𝜏=
𝐽

We recall from statics that the polar moment of inertia of a circle of

𝜋 𝜋
radius c is: 𝐽= 𝑑4 = 𝑐4
32 2

In the case of a hollow circular shaft of inner radius c1 and outer radius c2, the
polar moment of inertia is:
𝜋 𝜋
𝐽= [𝑑2 4 − 𝑑1 4 ] = [𝑐2 4 − 𝑐1 4 ]
32 2

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 Example 3.01:
Given: A hollow cylindrical steel shaft is 1.5 m long and has inner and outer
diameters respectively equal to 40 and 60 mm.
Determine:
(a) The largest torque that can be applied to the shaft
if the shearing stress is not to exceed 120 MPa.
(b) The corresponding minimum value of the shearing stress in the shaft.

Solution:
(a) Largest Permissible Torque:
𝑇𝑐
Since: 𝜏𝑚𝑎𝑥 =
𝐽
The polar moment of inertia J of the cross section is given by:
𝝅 𝝅
𝑱= [𝒅𝟐 𝟒 − 𝒅𝟏 𝟒 ] = [𝟔𝟎𝟒 − 𝟒𝟎𝟒 ] = 1.021x106 mm4
𝟑𝟐 𝟑𝟐
𝑻 𝒙 𝟑𝟎
∴ 120 MPa = 𝟏.𝟎𝟐𝟏𝒙𝟏𝟎𝟔
From which: T=4.08x106 N.mm = 4.08 kN.m

(b) Minimum Shearing Stress:

The minimum value of the shearing stress occurs on the inner surface of
𝑐1
the shaft. It is obtained from the equation: 𝜏𝑚𝑖𝑛 = 𝜏𝑚𝑎𝑥
𝑐2
20
𝜏𝑚𝑖𝑛 = 30 𝑥120 = 80𝑀𝑃𝑎.

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 SAMPLE PROBLEM 3.1
Given:
 Shaft BC is hollow with inner and outer
diameters of 90 mm and 120 mm, respectively.
 Shafts AB and CD are solid and of diameter d.

For the loading shown and if the allowable

shearing stress in these shafts is 65 MPa:
Determine:
(a) The maximum and minimum shearing stress in
shaft BC,
(b) The required diameter d of shafts AB and CD

Solution:
Equations of Statics:
Denoting by TAB the torque in shaft AB, we pass a section
through shaft AB and, for the free body shown, we write:

M x  0  6 kN  m   TAB
TAB  6 kN  m  TCD

We now pass a section through shaft BC (Fig. 2) and, for the free body shown,
we have: M x  0  6 kN  m   14 kN  m   TBC
TBC  20 kN  m
(a) Shaft BC.
For this hollow shaft we have:
𝝅 𝝅
𝑱= [𝒅𝟐 𝟒 − 𝒅𝟏 𝟒 ] = [𝟏𝟐𝟎𝟒 − 𝟗𝟎𝟒 ] = 13.92x106 mm4
𝟑𝟐 𝟑𝟐
Maximum Shearing Stress. On the outer surface, we have:

𝑇𝐵𝐶 . 𝑐2 (20𝑥106 𝑁.𝑚𝑚)(60𝑚𝑚)

𝜏𝑚𝑎𝑥 = = = 𝟖𝟔. 𝟐 𝑴𝑷𝒂
𝐽 13.92𝑥106 𝑚𝑚4
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 Minimum Shearing Stress. On the inner surface,: the stresses are proportional to the
distance from the axis of the shaft:
 min c1  min 45 mm
 
 max c2 86.2 MPa 60 mm
 min  64.7 MPa
 max  86.2 MPa
(b) Shafts AB and CD.
We note that both shafts have the same torque of
 min  64.7 MPa
TAB=TAC= T = 6 kN·m.
Denoting the radius of the shafts by c and knowing that τall = 65 MPa, we
write:
𝑑
𝑇. 𝑐 𝑇( ) 16𝑇
𝜏𝑚𝑎𝑥 = = 𝜋 4
2
=
𝐽 𝑑 𝜋𝑑 3
32

16(6𝑥106 𝑁.𝑚𝑚)
∴ 65𝑀𝑃𝑎 =
𝜋𝑑 3
From which the diameter is calculated as: d=77.8 mm

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 3.5 ANGLE OF TWIST IN THE ELASTIC RANGE:

 In this section, a relation will be derived

between the angle of twist φ of a circular shaft
and the torque T exerted on the shaft.
 The entire shaft will be assumed to remain
elastic. Considering first the case of a shaft of
length L and of uniform cross section of adius c
subjected to a torque T at its free end.
 Recall that the angle of twist and maximum shearing strain are related as:
c
 max 
L
 In the elastic range, the shearing strain and shear are related by Hooke’s
 max Tc
Law:  max  
G JG
 Equating the right-hand members of the two equations and solving for the
angle of twist φ ,we write: TL

JG
Where φ is expressed in radians. The relation obtained shows that,
within the elastic range, the angle of twist f is proportional to the torque T
applied to the shaft.
 If the torsional loading or shaft cross-section changes along the length, the
angle of rotation is found as the sum of segment rotations

Ti Li
 
i J i Gi

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Concept Application 3.02

What torque should be applied to the end of the

shaft of Concept Application 3.01 to produce a
twist of 2°?
Use the value G = 77 GPa for the modulus of
rigidity of steel.

Solution:
TL
Since: 
JG

and

The polar moment of inertia J of the cross section is given by:

𝝅 𝝅
𝑱= [𝒅𝟐 𝟒 − 𝒅𝟏 𝟒 ] = [𝟔𝟎𝟒 − 𝟒𝟎𝟒 ] = 1.021x106 mm4
𝟑𝟐 𝟑𝟐

−3 𝑇 (1.5𝑥103 𝑚𝑚 )
∴ 34.9𝑥10 = (77𝑥103 𝑀𝑃𝑎)𝑥(1.021𝑥106 𝑚𝑚4 )

Then: T = 1.829x103 N.mm = 1.829 N.m

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SAMPLE PROBLEM 3.3:

Given:
 The horizontal shaft AD is attached to a
fixed base at D and is subjected to the
torques shown.
 A 44-mm-diameter hole has been drilled
into portion CD of the
Determine: the angle of twist at end A knowing
that the entire shaft is made of steel for which G = 77 GPa.
Solution;
Passing a section through the shaft between A and B and using the free body
shown, we find:

Passing now a section between B and C, we have:

And TCD = TBC = 2250 N. m

Polar Moments of Inertia:
𝝅 𝝅
𝑱𝑨𝑩 = 𝒅𝟒 = [𝟑𝟎𝟒 ] = 𝟎. 𝟎𝟕𝟗𝟓𝒙𝟏𝟎𝟔 𝒎𝒎𝟒
𝟑𝟐 𝟑𝟐
𝝅 𝝅
𝑱𝑩𝑪 = 𝒅𝟒 = [𝟔𝟎𝟒 ] = 𝟏. 𝟐𝟕𝟐𝒙𝟏𝟎𝟔 𝒎𝒎𝟒
𝟑𝟐 𝟑𝟐
𝝅 𝝅
𝑱𝑪𝑫 = [𝒅𝟐 𝟒 − 𝒅𝟏 𝟒 ] = [𝟔𝟎𝟒 − 𝟒𝟒𝟒 ] = 𝟎. 𝟗𝟎𝟒𝒙𝟏𝟎𝟔 𝒎𝒎𝟒
𝟑𝟐 𝟑𝟐

𝟏 𝟐𝟓𝟎𝒙𝟏𝟎𝟑 𝒙𝟒𝟎𝟎 𝟐𝟐𝟓𝟎𝒙𝟏𝟎𝟑 𝒙𝟐𝟎𝟎 𝟐𝟐𝟓𝟎𝒙𝟏𝟎𝟑 𝒙𝟔𝟎𝟎

𝜱𝑨 = [ + + ]
𝟕𝟕𝒙𝟏𝟎𝟑 𝟎.𝟎𝟕𝟗𝟓𝒙𝟏𝟎𝟔 𝟏.𝟐𝟕𝟐𝒙𝟏𝟎𝟔 𝟎.𝟗𝟎𝟒𝒙𝟏𝟎𝟔

= 0.01634 + 0.00459 + 0.01939 = 0.0403 rad

= (0.0403 rad) x 360°/2π = 2.31º

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Sample Problem 3.4
Given:
Two solid steel shafts are connected by the
gears shown. Knowing that for each shaft
G = 77 GPa and the allowable shearing
stress is 55 MPa,
Determine:
(a) The largest torque T0 that may be applied 19 mm

to end A of shaft AB and

60 mm
(b) The corresponding angle through which 22 mm

end A of shaft AB rotates.

Solution;

MODELING: Denoting by F the magnitude of the

tangential force between gear teeth, we have
Gear B: ΣMB = 0: F(22mm) − T0 = 0
TCD = 2.73T0 …..(1) rc =60 mm rB =22 mm
Gear C: ΣMC = 0: F(60mm) − TCD = 0
Using kinematics, we see that the peripheral motions of the gears are equal
and write:
𝟔𝟎𝒎𝒎
rB. ϕB = rC ϕC then: 𝝓𝑩 = 𝝓𝑪 = 𝟐. 𝟕𝟑𝝓𝑪 …………(2)
𝟐𝟐𝒎𝒎

(a)-The largest torque T0:

For shaft AB: TAB = T0 and c = 9.75mm; considering maximum
permissible shearing stress, we write:
𝑻𝑨𝑩 . 𝒄
𝝉𝒎𝒂𝒙 =
𝑱
𝑻𝒐 (𝟗.𝟕𝟓)
∴ 𝟓𝟓𝑴𝑷𝒂 = 𝝅 ⟾ 𝑻𝟎 = 𝟕𝟒. 𝟏𝒙𝟏𝟎𝟑 𝑵. 𝒎𝒎 = 𝟕𝟒. 𝟏 𝑵. 𝒎
(𝟗.𝟕𝟓)𝟒
𝟐
For shaft CD using Eq. (1) we have TCD = 2.73T0. With c = 12.5 mm, and
𝟐.𝟕𝟑𝑻𝒐 (𝟏𝟐.𝟓)
𝟓𝟓𝑴𝑷𝒂 = 𝝅 ⟾ 𝑻𝟎 = 𝟔𝟏. 𝟖𝒙𝟏𝟎𝟑 𝑵. 𝒎𝒎 = 𝟔𝟏. 𝟖 𝑵. 𝒎
(𝟏𝟐.𝟓)𝟒
𝟐
The maximum permissible torque is the smaller value obtained for T0.
To = 61.8 N.m
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(b) Angle of Rotation at End A:
We first compute the angle of twist for each shaft.
Shaft AB: For TAB = T0 = 61.8 N.m, we have:

𝑻𝑨𝑩 𝑳 𝟔𝟏. 𝟖𝒙𝟏𝟎𝟑 𝒙𝟔𝟎𝟎 𝟎. 𝟎𝟑𝟕𝟔𝒙𝟑𝟔𝟎

𝜱𝑨/𝑩 = = 𝝅 𝟒
= 𝟎. 𝟎𝟑𝟕𝟔 𝒓𝒂𝒅 = = 𝟐. 𝟏𝟓°
𝑮𝑱 𝟕𝟕𝒙𝟏𝟎 𝒙𝟑 (𝟏𝟗 ) 𝟐𝝅
𝟑𝟐
Shaft CD: For TCD = 2.73T0 = 2.73(61.8)= 168.7 N.m , we have:

𝑻𝑪𝑫 𝑳 𝟏𝟔𝟖. 𝟕𝒙𝟏𝟎𝟑 𝒙𝟗𝟎𝟎 𝟎. 𝟎𝟓𝟏𝟒𝒙𝟑𝟔𝟎

𝜱𝑪/𝑫 = = 𝝅 𝟒
= 𝟎. 𝟎𝟓𝟏𝟒 𝒓𝒂𝒅 = = 𝟐. 𝟗𝟓°
𝑮𝑱 𝟕𝟕𝒙𝟏𝟎 𝒙
𝟑 (𝟐𝟓 ) 𝟐𝝅
𝟑𝟐
Since end D of shaft CD is fixed, we have: ϕC = ϕC∕D = 2.95°. Using
Eq. (2), we find the angle of rotation of gear B is:
ϕB = 2.73ϕC = 2.73(2.95°) = 8.05°
For end A of shaft AB, we have
ϕA = ϕB + ϕA/B = 8.05° + 2.15°=10.2º ϕA = 10.2° ◂

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 3.7 DESIGN OF TRANSMISSION SHAFTS
 The principal specifications to be met in the design of a transmission shaft
are the power to be transmitted and the speed of rotation of the shaft.

 The role of the designer is to select the material and the dimensions of the
cross section of the shaft so that the maximum shearing stress does not
exceed the allowable shearing stress when the shaft is transmitting the
required power at the specified speed.

 To determine the torque exerted on the shaft, the power P associated with
the rotation of a rigid body subjected to a torque T is:
P = T. ω
Where ω is the angular velocity of the body in radians per second (rad/s).
But: ω = 2πf
Where f ….. is the frequency of the rotation (i.e., the number of revolutions
per second). The unit of frequency is 1 s−1 and is called a hertz (Hz).
Then: P = 2π f T
When SI units are used with f expressed in Hz and T in N・m, the power
will be in N・m/s—that is, in watts (W).
Solving for T, the torque exerted on a shaft transmitting the power P at a
frequency of rotation f is:

𝑷
𝑻=
𝟐𝝅𝒇

T=
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After determining the torque T to be applied to the shaft and selecting the
material to be used, the designer carries the values of T and the maximum
allowable stress into this equation:
𝑻. 𝒄
𝝉𝒎𝒂𝒙 =
𝑱

Solve this equation and find the shaft dimensions knowing that the polar
𝜋 𝜋
moment of inertia of a circle of radius c is:
𝐽= 𝑑4 = 𝑐4
32 2

In the case of a hollow circular shaft of inner radius c1 and outer radius c2, the
polar moment of inertia is:
𝜋 𝜋
𝐽= [𝑑2 4 − 𝑑1 4 ] = [𝑐2 4 − 𝑐1 4 ]
32 2

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Concept Application 3.07
Given:
A shaft consisting of a steel tube of 50-mm outer diameter is to transmit
100 kW of power while rotating at a frequency of 20 Hz.

Determine: the tube thickness that should be used if the shearing stress is
not to exceed 60 MPa.

Solution:

The torque exerted on the shaft is:

𝑷 100𝑥103 𝑊𝑎𝑡𝑡𝑠
𝑻= = = 𝟕𝟗𝟓. 𝟖 𝑵. 𝒎
𝟐𝝅𝒇 2𝑥𝜋𝑥20

The maximum shearing stress on the outer surface is given by:

𝑻 . 𝒄𝟐 𝑇 . 𝑐2
𝝉𝒎𝒂𝒙 = = 𝜋
𝑱 (𝑐2 4 − 𝑐1 4 )
2

(795.8𝑥103 𝑁. 𝑚𝑚)𝑥(25𝑚𝑚)
∴ 60 𝑀𝑃𝑎 = 𝜋
[(25)4 − (𝑐 )4 ]
2 1

From which: c1 = 20.6 mm

The corresponding tube thickness is:
c2 − c1 = 25 mm − 20.6 mm = 4.4 mm
A tube thickness of 5 mm should be used.

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