Engineering School

Department of Industrial and Mechanical Engineering

Class: Mechanical Systems Design

Activity: Mechanical Bracket

Abraham Alberto Ramírez Serrano

ID: 157963

Profe: Dr. Javier Flores Mendez

 • INTRODUCTION In this mechanical bracket we will
analyze the total deformation that it will
Mechanical bracket.
suffer when we applied a distributed
A mechanical bracket is used to pressure in the inclined face. Also, we will
construct items of some structure and hold analyze the stress that it suffers, where
the pieces together. Besides, a mechanical going to be the principal points of the
bracket is a support where the different parts maximum stress and if the piece going to
are united and function as a joint. These resist the pressure without reach the plastic
brackets retain, support, and locate the zone or if the piece will collapse.
workpiece.
• FAILURE THEORIES
Many different types of fasteners are
Failure is the loss of function of an element
commonly used in constructions where
both by deformation and by separation of its
abutting structural components are Secured
parts. The failure mechanisms depend some
to one another.
factors like, the microscopic structure of the
In the same way, the mechanical material, the effort concentrators, the type
brackets are elements that support another of material that we use, the geometry of the
element. Some examples of this brackets are component and the safety factor to the loads
the axis of an automobile, the guide, and the applied.
bearings.
Effort concentrators
In this occasion we will analyze the
The effort concentrators are a
behavior of the mechanical bracket shown
difficulty when we must to design a
in the figure 1.
mechanical part that support loads, motion
or rotation because, as its name implies, in
this point the effort will concentrate and it
provoke a failure in the part. Some effort
concentrators are holes, wedges, corners,
etc.

If we have a body with a constant

cross section, the load will be distributed
Ilustración 1: mechanical bracket
uniformly. However, is very difficult to coating method, photostress, photo-elastic
have a body with a cross section constant in analysis, etc. However, in our case we will
the real life. Is very common to have effort use the finite element to determine
concentrators in the mechanical parts. indirectly the stress factor to find the zone
where we will have the maximum stress
In our case, we have a cross section
concentration.
irregular where we have internal corners,
external corners and a hole as we can see in Chamfers and Fillets
the figure 2. All of these are effort
To reduce the effort concentration,
concentrators and depending our
we could use chamfers or fillets. This is a
application is the concentration zone that we
way to get a lower stress in a point and make
will have. For us, the principal effort
a better flux of the load across the piece. In
concentration is the internal corner because
the figure 3 we can see a chamfer and a fillet
the bracket will be fixed in the left ending
applied to our bracket. this figure is just
face and the pressure will be applied in the
demonstrative to see the difference between
inclined face. Then, the hole and the
the chamfer and the fillet.
external corners do not have relevance to the
effort concentrators. If we had a load in the
hole, then the hole would be an effort
concentration, but in our case this do not
happen. chamfer fillet

corners
hole
Ilustración 3: chamfer and fillet

Further in the results section we will analyze

this bracket with chamfer, with fillet and
without modifications to see what is our
better option to reduce the point of stress
Ilustración 2: corners and hole
maximum.
To calculate the effort concentrator
factor, we have different methods like brittle
Material

The material is very important when

we design any component either a
mechanical component or any other type of
component. Great traits we have two
different type of materials, ductile and
Ilustración 4: Mohr circle
fragile.
This circle indicates that the absolute
The fragile material is the material maximum shear stress is:
that have less than 5% of deformation 𝜎1 −𝜎3
𝜏𝑚𝑎𝑥 = (1)
2
before the it fractures. The fracture is the
With this equation we can calculate
failure of the fragile materials. the shear stress and if the load applied to a
component reach a shear stress to make the
The ductile material is the material
material collapse.
that can deform more than 5% without reach
For our case, we will work with
the fracture. Its failure is the plastic structural steel which have the next
deformation of the material. properties:
1. Elastic modulus E=200 GPa
To calculate the failure in a material
2. Poisson´s ratio v=0.3
we use the theory of the maximum normal 3. Shear modulus =76.9 GPa
stress and the maximum shear stress. Both 4. Yield strength = 250 MPa
5. Ultimate strength = 460 MPa
indicates that when the maximum stress in
We must pay attention to the yield strength
the piece, normal o shear, is equal to or
because is in the analysis we obtain a von
greater than the effort in a test tube, normal mises stress equal or higher than the yield
or shear, then the failure will occur. To strength, the component will have an
irreversible failure like reach the plastic
reduce this theory, we take the help of the zone or suffer a fracture.
Mohr circle in the figure 4.
We chose the structural steel
because this material can support great
efforts and the climate change, is a ductile
material that can deform without a fracture.
However, this does not indicate that the
structure will be ductile. Has a high tenacity
and is easy to weld. This is why we chose With this figure we can find each
the structural steel. normal and shear stress and the components
Von mises of the normal and shear stress which are:

The von mises criterion is often use 𝑀𝑟 𝑇𝑟

𝜎𝑥 = (2) 𝜏𝑥𝑦 = (3)
to determinate if an isotropic and ductile 𝐼 𝐽
material will yield when a force be applied.
Where:
To know if the component will yield, we
M = moment 𝐹 ∗ 𝐿 (4)
need to compare the calculus of the von
r = radius
mises against the yield strength of the
𝜋∗𝑟 4
material. I = inertia (5)
4

T = torque 𝐹 ∗ 𝑙 (6)
The objective of von mises stress is
𝜋∗𝑟 4
to develop a yield criterion for ductile J = inertia polar moment (7)
2

metals that works for any complex 3-D Whit this, we can find the maximum
loading condition, regardless of the mix of normal stress, the maximum shear stress and
normal and shear stresses. the von mises stress.

For our problem, we need to find the As we mentioned before, the

von mises stress with the help of the finite equation for the maximum shear stress is:
element analysis and compare against the 𝜎1 −𝜎3
𝜏𝑚𝑎𝑥 = (8)
yield strength. To calculate the von mises 2

stress we need to find the stress state where Where we can transform as:
we can find the normal and shear stresses as 𝜎𝑚𝑎𝑥 −𝜎𝑚𝑖𝑛
𝜏𝑚𝑎𝑥 = (9)
is shown in the figure 5. 2

We have the next equation to find

the maximum and minimum normal stress
in a 2-D problem:

𝜎𝑥 +𝜎𝑦 𝜎𝑥 −𝜎𝑦 2
𝜎𝑚𝑎𝑥,𝑚𝑖𝑛 = ± √( 2 (10)
) + 𝜏𝑥𝑦
2 2

This equation is for the maximum

and minimum normal stress with which we
Ilustración 5: stress state. will calculate the maximum shear stress.
 However, to calculate the von mises stress 𝜎𝑟𝑒𝑎𝑙 = 𝑣𝑜𝑛 𝑚𝑖𝑠𝑒𝑠 𝑠𝑡𝑟𝑒𝑠𝑠
we will use just the coefficient that we have
In the real life we have different
in the stress state and then our equation is
norms that indicated the safety factor. Whit
the following:
this safety factor, we must ensure to do not
1 2 2 2 + 𝜏2 + 𝜏2 )
𝜎𝑣𝑜𝑛 = √ [(𝜎𝑥 − 𝜎𝑦 ) + (𝜎𝑦 − 𝜎𝑧 ) + (𝜎𝑧 − 𝜎𝑥 )2 ] + 3(𝜏𝑥𝑦 𝑦𝑧 𝑧𝑥
reach or overcome the yield strength.
2

In the same way, we have 2 different

(11)
safety factors. One is the safety factor
Once we get the von mises stress with this
applied to the load 𝑁𝑃 or unforeseen loads.
equation, we can compare our result with
The other safety factor is the stresses safety
the yield strength of the material and make
factor NS. to obtain a final safety factor we
a conclusion.
just multiplied NP and NS as is shown:
Safety factor FS=NP*NS. (13)

When we will build any component, Whit this equation we can find the
we must considerer a safety factor to do not maximum load that our system or material
reach the maximum stress that the material could support in the real life to prevent
can support and do not provoke accidents, accidents and is:
monetary losses, and life risks.
𝜎𝑚𝑎𝑥 = 𝐹𝑆 ∗ 𝜎𝑟𝑒𝑎𝑙
The safety factor is the quotient 𝜎𝑚𝑎𝑥 = 𝑁𝑃 ∗ 𝑁𝑆 ∗ 𝜎𝑟𝑒𝑎𝑙 (14)
between the maximum capacity of a system
To find the factor Ns we have
or material and the real load that the system
𝜎𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙
will have. Is a number higher than 1 and this 𝑁𝑆 = (15)
𝜎𝑣𝑜𝑛

factor is applied because no one knows if a

And to find the Np factor we have
system will support more load or less load
0.5𝜎𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙
than the calculated load. Then the safety 𝑁𝑃 = (16)
𝜏𝑚𝑎𝑥
factor equation is:
If we know all the load that the
𝜎𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙
𝐹𝑠 = (12) component will suffer, we can use a lower
𝜎𝑟𝑒𝑎𝑙

safety factor. But, if we do not know what

Where in our case:
the behavior of the loads will be, we must
𝜎𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 𝑦𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 use a higher safety factor. In the same way,
if we are not sure about the behavior of our
material, we must use a higher safety factor.
This is because, normally the data of the
material which we will work is a little
different than the test material.

Ilustración 7: interest points and stress element in point A

• Example
First, we must apply the equation 5 and 7 to
Determine the normal and shear stress, the
obtain the inertia moment and the inertia
von mises stress and the safety factor of the
polar moment to could apply the equation 2
figure 6.
and 3.

𝜋 ∗ 𝑟 4 𝜋 ∗ (0.75 𝑖𝑛)4
𝐼= = = 0.249 𝑖𝑛4
4 4
𝜋 ∗ 𝑟 4 𝜋 ∗ (0.75 𝑖𝑛)4
𝐽= = = 0.497 𝑖𝑛4
2 2
𝑀𝑟 𝑓 ∗ 𝑙 ∗ 𝑟
𝜎𝑥 = =
𝐼 𝐼
1000 𝑙𝑏 ∗ 6 𝑖𝑛 ∗ 1.5 𝑖𝑛
=
0.249 𝑖𝑛4
𝜎𝑥 = 18108 𝑝𝑠𝑖 (R1)
In this problem, 𝜎𝑦 , 𝜏𝑥𝑦 , 𝜏𝑦𝑧 = 0
Ilustración 6: example
𝑇𝑟 𝐹 ∗ 𝑎 ∗ 𝑟 1000 ∗ 8 ∗ 1.5
𝜏𝑥𝑧 = = =
➢ 2024-T4 aluminum with a yield 𝐽 𝐽 0.497
strength of 47,000 psi. 𝜏𝑥𝑧 = 12072 𝑝𝑠𝑖 (R2)
➢ L=6 in
➢ A=8 in Once the stress components are
➢ D=1.5 in known, the equation 10 is applied to know
➢ F=1000 lb
the maximum and minimum normal stress.
For this example, the figure 7 shows the
interest points and the stress element in the 𝜎𝑥 + 𝜎𝑦 𝜎𝑥 − 𝜎𝑦 2
𝜎𝑚𝑎𝑥 = + √( 2
) + 𝜏𝑥𝑧
point A 2 2

18108 18108 2
𝜎𝑚𝑎𝑥 = √
+ ( ) + 120722
2 2
𝜎𝑚𝑎𝑥 = 24144 𝑝𝑠 (R3) To find the safety factor, we must apply
the equation 15 and 16. Once we get Ns and Np,
𝜎𝑥 + 𝜎𝑦 𝜎𝑥 − 𝜎𝑦 2
𝜎𝑚𝑖𝑛 = √
− ( 2
) + 𝜏𝑥𝑧 we apply the equation 14.
2 2
𝜎𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 47000
𝑁𝑆 = = 27661 = 1.69 (R7)
18108 18108 2 𝜎𝑣𝑜𝑛
𝜎𝑚𝑖𝑛 = − √( ) + 120722
2 2 0.5𝜎𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 0.5(47000)
𝑁𝑃 = = = 1.58 (R8)
𝜏𝑚𝑎𝑥 15090
𝜎𝑚𝑖𝑛 = −6036 𝑝𝑠𝑖 (R4)
𝐹𝑠 = 1.69 ∗ 1.58 = 2.67 (R9)
With the maximum and minimum normal
This is the safety factor. We can take
stress, the equation 9 find form the Mohr
any of these values.
circle to find the maximum shear stress is
applied. The function of the finite element
analysis (FEA) is similar to this process. But the
𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛 24144 − (−6036)
𝜏𝑚𝑎𝑥 = = FEA does this process in every point of the
2 2
𝜏𝑚𝑎𝑥 = 15090 𝑝𝑠𝑖 (R5) piece and shows whit a color pallet the intensity
of the load and stresses in the piece.
When the normal and shear stress are known,
the equation 11 to find the von mises stress is • Standards

applied. This equation is reduced to have a For the analysis of any mechanical
better view of it. component we must follow international
standards to ensure the correct analysis of
1 2 )
𝜎𝑣𝑜𝑛 = √ [(𝜎𝑥 )2 + (−𝜎𝑥 )2 ] + 3(𝜏𝑥𝑧
2 the component a this could have a good
𝜎𝑣𝑜𝑛 functioning.
1 2 2 2
=√ [(18108) + (−18108) ] + 3 (12072 ) For the analysis of fluctuating efforts
2
𝜎𝑣𝑜𝑛 = 27661 𝑝𝑠𝑖 (R6) and fatigue is used the ASME-elliptical
model which correspond to the norm
At first sight, with this result of the von
ANSI/ASME B106.1M-1985.
mises stress, the material could resist the
applied load. However, the calculus for the This norm is about the analysis of

safety factor will say us if the rod-arm will components under cyclical stress and

support the load apply. fatigue in components with efforts

concentrators. For the case of this
experiment, this is the right standard for our
analysis because in this case we have a Fillet with r =.5 cm
component that will suffer fatigue, could be
under cyclical loads, and our component
have some effort concentrators as are
corners and a hole.

• Results

To analyze the piece shown in the

figure 1, we work with analyze by FEA in
𝜎𝑣𝑜𝑛 = 3.8033 𝑀𝑃𝑎
ANSYS. Whit this program we found the
Deformation = 3.23e-6 m
total displacement and the von mises stress.
Chamfer length = 0.4 cm angle = 45º
Besides, we applied corrections in the
geometry to see if the correction helps us to
decrease the maximum von mises stress or
if the correction increases the von mises
stress. These corrections are chamfers and
fillets. In the table 1 we can see the three
different experiments.
𝜎𝑣𝑜𝑛 = 4.16𝑀𝑃𝑎
Remember that the load applied is Deformation = 3.20e-6 m
60 𝑁/𝑐𝑚2. Table 1: Von mises stress in different configurations.

In this table we can see the

Geometry without changes
difference between the deformation and the
stress von mises found in the different
configurations of the mechanical bracket.

In this case, the deformation can be

neglected because we have a very small
deformation in all cases.

In the first configuration, without

𝜎𝑣𝑜𝑛 = 3.9424 𝑀𝑃𝑎 changes in the geometry, the maximum
Deformation = 3.32e-6 m stress von mises is applied in the upper left
inner corner. This point is an effort this case act equal to the von mises stress in
concentrator. However, the stress provoke the second and in the first case.
in this point is smaller than the yield
• CONCLUSION
strength of material. Even if we applied the
To have a good analyze of any piece,
safety factor found in the behind example,
artefact, or machine, we must consider the
the von mises stress will be by far smaller
effects of the geometry, if the piece has
than the yield strength.
effort concentrators or defects. In the same
In the second configuration where way, we must considerer the material
we have the fillets, we can see that the influence in the piece, if the material is
variation of the von mises is very similar to ductile or fragile, the yield strength of the
the first configuration. However, this stress material and the young modulus among
is a little lower than the first configuration other material considerations. At the same
and this could be a significant difference if time, we must find the stress correctly in the
we applied a higher load. The difference piece and to do this part, the FEA can help
between the first and the second us because whit the programs of FEA, we
configuration is the location of the can find quickly the maximum stresses and
maximum stress point. the probably points of failure. We also must

In the last configuration where we considerer the thermal effects of the

have the chamfers, we can see that the materials, the vibrations, etc. Finally, all the

variation of the von mises is very similar to pieces must be under standards and

the first configuration. However, the regulations.

difference with the second case is that this The analysis performed in this
configuration does not have the reaction that project explain all the mentioned points
we could expect because the von mises before, as consider the geometry of the
stress is a little higher than the second and component, the material factors including
the first configuration. This means that the the behavior of the material, calculus of
third configuration has the higher von mises stress and safety factor, and finally the
stress and has a point of maximum stress international standards.
similar to the second case with the fillets.
In conclusion, this project has a good
However, the maximum von mises stress in
develop about the consideration mentioned
throughout the entire project. Considering
the effort concentrators, the geometry
modifications, and the applied loads, the
mechanical bracket has a right behavior and
is under the failure load permissible. The
geometry modification with fillets decrease
the von mises stress and indicates that our
component could resist a higher load than
the other two configurations. With this
information we can say that our better
option to a mechanical bracket is the second
configuration, the mechanical bracket with
fillets.
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