Ghulam Ishaq Khan Institute of

Engineering Sciences and Technology

Mechanics of Solids - II
Design of Beams

Muhammad Ashmeel Rafi

2017911
ME314 Ι Section A
Dr. Massab Junaid
December 30, 2021
Problem Statement:
Design the following cantilever beam under given loading conditions .

Where w0 = 1 KN/m and L = 3m.

Design Requirements:
• The cross section of beam should be a hollow square.
• Mean perimeter of the cross section should be divisible by 5.
• Total length of beam is 3m.
• Allowable thickness should be 1mm or more, but not in decimals form. •
Factor of safety based on distortion energy theory should be at least 2.
• Strength to weight ration of the beam should be maximized.
• Beam material is Aluminium Alloy (6061 TS), whose properties are given
below.

Density 2700 kg/m3

Yield Strength 275 MPa
Ultimate Stress 310 MPa
Poisson’s Ratio 0.33
Young’s Modulus 69 GPa

1
Assumptions:
• The material is homogenous throughout the beam.
• The material shows isotropic behaviour.
• The deformations produced are very small.
• The material deforms within elastic range.
• The material behaves in the elastic region.
• Maximum Shear-Stress (Tresca) Criterion is applicable here.
• The loading is symmetric, i.e., the load acts in the plane which is
perpendicular to x-axis.
Finding the Maximum Moment and Shear in the Beam:
The distributed load shown in figure (a) is replaced by the resultant force and the
reactions have been determined as shown in figure (b).

A free body diagram of a beam segment of length “x” is shown in figure (c). The
intensity of the triangular load at the section is found by linear interpolation, that is,
𝑤 𝑤0
=
𝑥 𝑙
𝑤0 𝑥
𝑤=
𝐿

2
 𝑤 𝑜
𝑥 𝑙 𝐿
.

As the load intensity at the section located “x” from the L.H.S origin is known, the
resultant of the distributed loading is determined from figure (c). Applying the
conditions of equilibrium, i.e., summing all the forces in vertical direction which
represents the Moment (M) at different sections, located at distance “x” from the
origin. The corresponding shear (V) and moment diagrams (M) are shown in figure
(d).

𝑤0
𝑀= (−2𝐿3 − 3𝐿2 𝑥 − 𝑥 3 )
6𝐿

3
4
 • Maximum Shear (V):
From figure (d), the maximum shear is given as
𝑤0 𝑤0 𝐿
𝑉𝑚𝑎𝑥 = (𝐿2 ) = (at x = 0, as shown in the shear diagram)
2𝐿 2

𝑤0 𝐿
𝑉𝑚𝑎𝑥 = − − − − − − − (3)
2

Putting wo = 1KN/m and L = 3m in equation (3), we

get Vmax = 1.5 kN
• Maximum Moment (M):
From figure (d), the maximum moment is given as

𝑤0 𝐿2
𝑀𝑚𝑎𝑥 = − − − − − − − − (4) (at x = 0, by setting the derivative of
2
equation (2)

equal to zero, and then putting the critical point in equation (2))
Putting wo = 1KN/m and L = 3m in equation (4), we
get Mmax = -3kNm

Bending Stesses:
The bending stresses in the given beam are given by the flexure formula as

5
 𝑏
𝑀𝑚𝑎𝑥 ( )
2
𝜎=
𝐼

𝑀 𝑏
𝜎 = 𝑚𝑎𝑥 − − − − − − − (5)
2𝐼
Where Mmax = Known
b = Design parameter, shown in the cross
section of beam and
1
𝐼= ((𝑏4 − 𝑎4), a = Design
12
parameter, shown in the cross section of
beam
Beam thickness, 𝑡 = 𝑎 + 2𝑏
4𝑎+4𝑏
Mean perimeter 𝑝=
2

Shear Stresses:
The shear stresses produced on the outer surface of the beam are negligible, and so
they can be neglected from the design considerations.

Maximum Shear-Stress (Tresca) Criterion:

The effective stresses based on the Maximum Shear-Stress (Tresca) Criterion can be
computed as

𝜃𝑒 = 𝜏𝑚𝑎𝑥

|𝜃2 − 𝜃3 |
𝜏1 =
2

|𝜃3 − 𝜃1 |
𝜏2 =
2

6
 |𝜃1 − 𝜃2 |
𝜏3 =
2

According to the previous assumptions, 𝜎𝑦𝑦 = 𝑧𝑧 = 𝜎𝑥𝑦 = 𝜎𝑦𝑧 = 𝜎𝑥𝑧 = 0, so the effective
stress is given as
𝑀𝑚𝑎𝑥𝑏
𝜎𝑒 = 𝜎𝑥𝑥 = − − − − − − − (6)
2𝐼
Therefore, Factor of safety (FoS) based on the Maximum Shear-Stress (Tresca)
Criterion is given as
𝑌𝑖𝑒𝑙𝑑 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝑌)
FoS = − − − − − − − (7)
𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑆𝑡𝑟𝑒𝑠𝑠 (𝜎𝑒)

Ist design iteration for thickness, t = 4mm

t a b p A I 𝜎𝑒 FoS Strength to
(mm) (mm) (mm) (mm) (m2) (m4) (MPa) weight ratio
(MPa/N)
4 60 68 256 0.001024 7.01781E-07 145.3444188 1.892057516 3.813736143
4 61 69 260 0.00104 7.35107E-07 140.7958936 1.953181965 3.755063279
4 62 70 264 0.001056 7.69472E-07 136.457207 3.698168381
2.01528381
4 63 71 268 0.001072 8.04893E-07 132.3156692 2.078363067 3.642971838
4 64 72 272 0.001088 8.41387E-07 128.3595335 2.142419753 3.589398722
4 65 73 276 0.001104 8.78968E-07 124.5779141 2.207453881 3.537378451
4 66 74 280 0.00112 9.17653E-07 120.9607114 2.273465465 3.486844473
4 67 75 284 0.001136 9.57459E-07 117.4985448 2.340454519 3.437733988
4 68 76 288 0.001152 9.984E-07 114.1826923 2.408421053 3.389987682
4 69 77 292 0.001168 1.04049E-06 111.0050361 2.477365079 3.343549495
4 70 78 296 0.001184 1.08375E-06 107.9580126 2.54728661 3.298366394
4 71 79 300 0.0012 1.1282E-06 105.0345683 2.618185654 3.254388175
4 72 80 304 0.001216 1.17385E-06 102.2281186 2.690062222 3.211567278
4 73 81 308 0.001232 1.22071E-06 99.53251122 2.762916324 3.169858612
4 74 82 312 0.001248 1.2688E-06 96.94199243 3.129219399
2.836747967
4 75 83 316 0.001264 1.31814E-06 94.45117671 2.911557162 3.089609027
4 76 84 320 0.00128 1.36875E-06 92.0550187 2.987343915 3.050988914
4 77 85 324 0.001296 1.42063E-06 89.74878786 3.064108235 3.013322384
4 78 86 328 0.001312 1.47381E-06 87.52804516 3.141850129 2.97657455
4 79 87 332 0.001328 1.52831E-06 85.38862183 3.220569604 2.940712206
7
4 80 88 336 0.001344 1.58413E-06 83.32659987 3.300266667 2.905703728
4 81 89 340 0.00136 1.64129E-06 81.33829419 3.380941323 2.871518978
4 82 90 344 0.001376 1.69982E-06 79.4202362 3.46259358 2.838129222
4 83 91 348 0.001392 1.75972E-06 77.56915873 3.545223443 2.805507047
4 84 92 352 0.001408 1.82101E-06 75.78198219 2.773626286
3.628830918
4 85 93 356 0.001424 1.88371E-06 74.0558018 3.71341601 2.742461945
4 86 94 360 0.00144 1.94784E-06 72.3878758 3.798978723 2.711990146
4 87 95 364 0.001456 2.01341E-06 70.77561465 3.885519064 2.682188056
4 88 96 368 0.001472 2.08043E-06 69.21657096 3.973037037 2.653033838
4 89 97 372 0.001488 2.14892E-06 67.70843028 2.624506593
4.061532646
4 90 98 376 0.001504 2.2189E-06 66.24900251 4.151005896 2.59658631
4 91 99 380 0.00152 2.29039E-06 64.83621397 4.24145679 2.569253822
4 92 100 384 0.001536 2.36339E-06 63.46810009 2.542490762
4.332885333
4 93 101 388 0.001552 2.43793E-06 62.14279855 4.425291529 2.516279517
4 94 102 392 0.001568 2.51403E-06 60.858543 4.518675381 2.490603195
4 95 103 396 0.001584 2.59169E-06 59.6136572 4.613036893 2.465445587
4 96 104 400 0.0016 2.67093E-06 58.40654952 2.440791131
4.708376068
4 97 105 404 0.001616 2.75178E-06 57.23570791 4.80469291 2.416624882
4 98 106 408 0.001632 2.83424E-06 56.09969516 4.901987421 2.392932482
4 99 107 412 0.001648 2.91833E-06 54.99714449 5.000259605 2.369700127
4 100 108 416 0.001664 3.00407E-06 53.92675548 2.346914549
5.099509465
4 101 109 420 0.00168 3.09148E-06 52.88729023 5.199737003 2.324562982
4 102 110 424 0.001696 3.18057E-06 51.87756977 5.300942222 2.302633143
4 103 111 428 0.001712 3.27135E-06 50.89647077 5.403125125 2.281113207
4 104 112 432 0.001728 3.36384E-06 49.94292237 2.259991788
5.506285714
4 105 113 436 0.001744 3.45806E-06 49.01590332 5.610423992 2.239257919
4 106 114 440 0.00176 3.55403E-06 48.11443921 2.218901028
5.715539961
4 107 115 444 0.001776 3.65175E-06 47.23759992 5.821633623 2.198910929
4 108 116 448 0.001792 3.75125E-06 46.38449727 5.928704981 2.179277796
4 109 117 452 0.001808 3.85255E-06 45.55428271 2.159992152
6.036754036
4 110 118 456 0.001824 3.95565E-06 44.74614526 2.141044852
6.145780791
4 111 119 460 0.00184 4.06057E-06 43.95930952 6.255785247 2.122427071
4 112 120 464 0.001856 4.16734E-06 43.19303383 6.366767407 2.104130286
4 113 121 468 0.001872 4.27596E-06 42.44660848 2.086146266
6.478727273
4 114 122 472 0.001888 4.38645E-06 41.71935413 6.591664845 2.06846706
4 115 123 476 0.001904 4.49883E-06 41.01062023 2.051084984
6.705580126
4 116 124 480 0.00192 4.61312E-06 40.31978357 6.820473118 2.033992609
4 117 125 484 0.001936 4.72933E-06 39.64624693 2.017182753
6.936343822
4 118 126 488 0.001952 4.84747E-06 38.98943778 7.05319224 2.000648468
4 119 127 492 0.001968 4.96756E-06 38.34880706 1.984383034
7.171018373

8
 4 120 128 496 0.001984 5.08962E-06 37.72382805 7.289822222 1.968379945
4 121 129 500 0.002 5.21367E-06 37.11399527 7.40960379 1.952632905
4 122 130 504 0.002016 5.33971E-06 36.51882349 7.530363077 1.937135818

2nd design iteration for thickness, t = 3mm

t a b p A I 𝜎𝑒 FoS Strength to
(mm) (mm) (mm) (mm) (m2) (m4) (MPa) weight ratio
(MPa/N)
3 60 66 252 0.000756 5.01228E-07 197.5149034 1.3923 5.165695516
3 61 67 256 0.000768 5.2544E-07 191.2682704 1.437771144 5.084981523
3 62 68 260 0.00078 5.5042E-07 185.3130337 1.48397549 5.006751038
3 63 69 264 0.000792 5.7618E-07 179.6313652 1.530913043 4.930891174
3 64 70 268 0.000804 6.02732E-07 174.2067785 1.57858381 4.857295784
3 65 71 272 0.000816 6.30088E-07 169.0240093 1.626987793 4.785864963
3 66 72 276 0.000828 6.5826E-07 164.0689089 1.676125 4.716504601
3 67 73 280 0.00084 6.8726E-07 159.3283474 1.725995434 4.649125964
3 68 74 284 0.000852 7.171E-07 154.7901269 1.776599099 4.583645317
3 69 75 288 0.000864 7.47792E-07 150.4429039 1.827936 4.519983576
3 70 76 292 0.000876 7.79348E-07 146.276118 1.88000614 4.458065993
3 71 77 296 0.000888 8.1178E-07 142.2799281 1.932809524 4.397821858
3 72 78 300 0.0009 8.451E-07 138.4451544 1.986346154 4.339184233
3 73 79 304 0.000912 8.7932E-07 134.7632261 2.040616034 4.282089704
3 74 80 308 0.000924 9.14452E-07 131.2261332 2.095619167 4.226478149
3 75 81 312 0.000936 9.50508E-07 127.8263834 2.151355556 4.172292532
3 76 82 316 0.000948 9.875E-07 124.556962 2.207825203 4.119478703
3 77 83 320 0.00096 1.02544E-06 121.4112966 2.265028112 4.067985219
3 78 84 324 0.000972 1.06434E-06 118.3832234 2.322964286 4.017763179
3 79 85 328 0.000984 1.10421E-06 115.4669574 2.381633725 3.968766067
3 80 86 332 0.000996 1.14507E-06 112.6570649 2.441036434 3.920949608
3 81 87 336 0.001008 1.18692E-06 109.948438 2.501172414 3.874271637
3 82 88 340 0.00102 1.22978E-06 107.3362715 2.562041667 3.828691971
3 83 89 344 0.001032 1.27366E-06 104.816042 2.623644195 3.784172297
3 84 90 348 0.001044 1.31857E-06 102.3834876 2.68598 3.740676063
3 85 91 352 0.001056 1.36453E-06 100.0345907 2.749049084 3.698168381
3 86 92 356 0.001068 1.41154E-06 97.76556102 2.812851449 3.656615927
3 87 93 360 0.00108 1.45962E-06 95.57282032 2.877387097 3.615986861
3 88 94 364 0.001092 1.50878E-06 93.45298851 2.942656028 3.576250742
3 89 95 368 0.001104 1.55903E-06 91.4028705 3.008658246 3.537378451
3 90 96 372 0.001116 1.61039E-06 89.41944426 3.07539375 3.499342124
3 91 97 376 0.001128 1.66286E-06 87.49984966 3.142862543 3.46211508
3 92 98 380 0.00114 1.71646E-06 85.64137819 3.211064626 3.425671763
3 93 99 384 0.001152 1.7712E-06 83.84146341 3.28 3.389987682
3 94 100 388 0.001164 1.82709E-06 82.09767215 3.349668667 3.355039356
3 95 101 392 0.001176 1.88415E-06 80.40769621 3.420070627 3.32080426
3 96 102 396 0.001188 1.94238E-06 78.76934482 3.491205882 3.287260783
3 97 103 400 0.0012 2.0018E-06 77.18053752 3.563074434 3.254388175

9
 3 98 104 404 0.001212 2.06242E-06 75.63929752 3.635676282 3.22216651
3 99 105 408 0.001224 2.12425E-06 74.14374566 3.709011429 3.190576642
3 100 106 412 0.001236 2.18731E-06 72.69209457 3.783079874 3.15960017
3 101 107 416 0.001248 2.2516E-06 71.28264345 3.85788162 3.129219399
3 102 108 420 0.00126 2.31714E-06 69.91377301 3.933416667 3.09941731
3 103 109 424 0.001272 2.38394E-06 68.58394087 4.009685015 3.070177524
3 104 110 428 0.001284 2.45201E-06 67.2916772 4.086686667 3.041484276
3 105 111 432 0.001296 2.52137E-06 66.03558068 4.164421622 3.013322384
3 106 112 436 0.001308 2.59202E-06 64.8143147 4.242889881 2.985677225
3 107 113 440 0.00132 2.66398E-06 63.6266038 4.322091445 2.958534705
3 108 114 444 0.001332 2.73726E-06 62.47123035 4.402026316 2.931881239
3 109 115 448 0.001344 2.81187E-06 61.34703144 4.482694493 2.905703728
3 110 116 452 0.001356 2.88783E-06 60.25289595 4.564095977 2.879989535
3 111 117 456 0.001368 2.96514E-06 59.18776179 4.646230769 2.854726469
3 112 118 460 0.00138 3.04382E-06 58.15061337 4.72909887 2.829902761
3 113 119 464 0.001392 3.12388E-06 57.14047915 4.81270028 2.805507047
3 114 120 468 0.001404 3.20533E-06 56.15642935 4.897035 2.781528355
3 115 121 472 0.001416 3.28819E-06 55.19757386 4.98210303 2.757956081
3 116 122 476 0.001428 3.37246E-06 54.2630602 5.067904372 2.734779979
3 117 123 480 0.00144 3.45816E-06 53.35207162 5.154439024 2.711990146
3 118 124 484 0.001452 3.5453E-06 52.46382535 5.241706989 2.689577004
3 119 125 488 0.001464 3.63389E-06 51.59757087 5.329708267 2.667531291
3 120 126 492 0.001476 3.72395E-06 50.75258838 5.418442857 2.645844045
3 121 127 496 0.001488 3.81548E-06 49.92818728 5.507910761 2.624506593
3 122 128 500 0.0015 3.9085E-06 49.12370475 5.598111979 2.60351054

3rd design iteration for thickness, t = 2mm

t a b p A I 𝜎𝑒 FoS Strength to
(mm) (mm) (mm) (mm) (m2) (m4) (MPa) weight ratio
(MPa/N)
2 60 64 248 0.000496 3.18101E-07 301.7906244 0.911227778 7.873519778
2 61 65 252 0.000504 3.33732E-07 292.1505879 0.941295385 7.748543274
2 62 66 256 0.000512 3.49867E-07 282.964939 0.971851852 7.627472285
2 63 67 260 0.00052 3.66513E-07 274.2055769 1.002897181 7.510126558
2 64 68 264 0.000528 3.8368E-07 265.8465388 1.034431373 7.396336761
2 65 69 268 0.000536 4.01375E-07 257.863808 1.066454428 7.285943675
2 66 70 272 0.000544 4.19605E-07 250.2351416 1.098966349 7.178797445
2 67 71 276 0.000552 4.3838E-07 242.9399151 1.131967136 7.074756902
2 68 72 280 0.00056 4.57707E-07 235.9589839 1.16545679 6.973688946
2 69 73 284 0.000568 4.77593E-07 229.2745572 1.199435312 6.875467975
2 70 74 288 0.000576 4.98048E-07 222.8700848 1.233902703 6.779975365
2 71 75 292 0.000584 5.19079E-07 216.7301552 1.268858963 6.68709899
2 72 76 296 0.000592 5.40693E-07 210.8404024 1.304304094 6.596732787
2 73 77 300 0.0006 5.629E-07 205.1874223 1.340238095 6.50877635
2 74 78 304 0.000608 5.85707E-07 199.758696 1.376660969 6.423134556
10
2 75 79 308 0.000616 6.09121E-07 194.5425214 1.413572714 6.339717224
2 76 80 312 0.000624 6.33152E-07 189.5279491 1.450973333 6.258438798
2 77 81 316 0.000632 6.57807E-07 184.7047258 1.488862826 6.179218054
2 78 82 320 0.00064 6.83093E-07 180.0632417 1.527241192 6.101977828
2 79 83 324 0.000648 7.0902E-07 175.5944825 1.566108434 6.026644769
2 80 84 328 0.000656 7.35595E-07 171.2899858 1.60546455 5.953149101
2 81 85 332 0.000664 7.62825E-07 167.1418009 1.645309542 5.881424413
2 82 86 336 0.000672 7.9072E-07 163.1424524 1.685643411 5.811407455
2 83 87 340 0.00068 8.19287E-07 159.2849064 1.726466156 5.743037956
2 84 88 344 0.000688 8.48533E-07 155.5625393 1.767777778 5.676258445
2 85 89 348 0.000696 8.78468E-07 151.9691099 1.809578277 5.611014095
2 86 90 352 0.000704 9.09099E-07 148.4987328 1.851867654 5.547252571
2 87 91 356 0.000712 9.40433E-07 145.1458547 1.89464591 5.48492389
2 88 92 360 0.00072 9.7248E-07 141.905232 1.937913043 5.423980292
2 89 93 364 0.000728 1.00525E-06 138.77191 1.981669056 5.364376113
2 90 94 368 0.000736 1.03874E-06 135.7412047 2.025913948 5.306067677
2 91 95 372 0.000744 1.07297E-06 132.8086847 5.249013186
2.070647719
2 92 96 376 0.000752 1.10795E-06 129.970155 2.11587037 5.19317262
2 93 97 380 0.00076 1.14367E-06 127.2216425 2.161581901 5.138507645
2 94 98 384 0.000768 1.18016E-06 124.5593818 2.207782313 5.084981523
2 95 99 388 0.000776 1.21741E-06 121.979802 2.254471605 5.032559034
2 96 100 392 0.000784 1.25545E-06 119.4795154 2.301649778 4.98120639
2 97 101 396 0.000792 1.29426E-06 117.0553057 2.349316832 4.930891174
2 98 102 400 0.0008 1.33387E-06 114.7041184 2.397472767 4.881582263
2 99 103 404 0.000808 1.37427E-06 112.4230502 2.446117584 4.833249765
2 100 104 408 0.000816 1.41549E-06 110.2093412 2.495251282 4.785864963
2 101 105 412 0.000824 1.45752E-06 108.0603656 2.544873862 4.739400255
2 102 106 416 0.000832 1.50037E-06 105.9736243 2.594985325 4.693829099
2 103 107 420 0.00084 1.54406E-06 103.9467378 2.64558567 4.649125964
2 104 108 424 0.000848 1.58859E-06 101.9774391 2.696674897 4.605266285
2 105 109 428 0.000856 1.63396E-06 100.0635674 2.748253007 4.562226414
2 106 110 432 0.000864 1.68019E-06 98.20306251 2.80032 4.519983576
2 107 111 436 0.000872 1.72729E-06 96.39395893 2.852875876 4.478515837
2 108 112 440 0.00088 1.77525E-06 94.63438082 2.905920635 4.437802057
2 109 113 444 0.000888 1.8241E-06 92.92253714 2.959454277 4.397821858
2 110 114 448 0.000896 1.87383E-06 91.25671706 3.013476803 4.358555592
2 111 115 452 0.000904 1.92447E-06 89.63528571 3.067988213 4.319984303
2 112 116 456 0.000912 0.000001976 88.05668016 3.122988506 4.282089704
2 113 117 460 0.00092 2.02845E-06 86.51940565 3.178477683 4.244854141
2 114 118 464 0.000928 2.08181E-06 85.02203207 3.234455744 4.208260571
2 115 119 468 0.000936 2.13611E-06 83.56319063 3.290922689 4.172292532
2 116 120 472 0.000944 2.19134E-06 82.14157069 3.347878519 4.136934121
2 117 121 476 0.000952 2.24751E-06 80.75591691 3.405323232 4.102169969
2 118 122 480 0.00096 2.30464E-06 79.40502638 3.463256831 4.067985219
2 119 123 484 0.000968 2.36273E-06 78.08774608 3.521679313 4.034365506
2 120 124 488 0.000976 2.42178E-06 76.80297038 3.580590681 4.001296937
2 121 125 492 0.000984 2.48181E-06 75.54963873 3.639990933 3.968766067
2 122 126 496 0.000992 2.54283E-06 74.3267335 3.699880071 3.936759889

11
4th design iteration for thickness, t = 1mm
t a b p A I 𝜎𝑒 FoS Strength to
(mm) (mm) (mm) (mm) (m2) (m4) (MPa) weight ratio
(MPa/N)
1 60 62 244 0.000244 1.51361E-07 614.423763 0.447573835 16.00518775
1 61 63 248 0.000248 1.58927E-07 594.613868 0.462485009 15.74703956
1 62 64 252 0.000252 1.6674E-07 575.7466715 0.477640625 15.49708655
1 63 65 256 0.000256 1.74805E-07 557.7633024 0.493040684 15.25494457
1 64 66 260 0.00026 1.83127E-07 540.6094142 0.508685185 15.02025312
1 65 67 264 0.000264 1.91708E-07 524.2347737 0.524574129 14.79267352
1 66 68 268 0.000268 2.00553E-07 508.592893 0.540707516 14.57188735
1 67 69 272 0.000272 2.09667E-07 493.6406995 0.557085346 14.35759489
1 68 70 276 0.000276 2.19052E-07 479.3382393 0.573707619 14.1495138
1 69 71 280 0.00028 2.28713E-07 465.6484099 0.590574335 13.94737789
1 70 72 284 0.000284 2.38655E-07 452.5367197 0.607685494 13.75093595
1 71 73 288 0.000288 2.4888E-07 439.9710704 0.625041096 13.55995073
1 72 74 292 0.000292 2.59393E-07 427.9215606 0.642641141 13.37419798
1 73 75 296 0.000296 2.70199E-07 416.3603077 0.66048563 13.19346557
1 74 76 300 0.0003 2.813E-07 405.2612869 0.678574561 13.0175527
1 75 77 304 0.000304 2.92701E-07 394.600184 0.696907937 12.84626911
1 76 78 308 0.000308 3.04407E-07 384.3542629 0.715485755 12.67943445
1 77 79 312 0.000312 3.1642E-07 374.5022439 0.734308017 12.5168776
1 78 80 316 0.000316 3.28745E-07 365.024193 0.753374722 12.35843611
1 79 81 320 0.00032 3.41387E-07 355.9014217 0.772685871 12.20395566
1 80 82 324 0.000324 3.54348E-07 347.1163941 0.792241463 12.05328954
1 81 83 328 0.000328 3.67633E-07 338.652643 0.812041499 11.9062982
1 82 84 332 0.000332 3.81247E-07 330.4946928 0.832085979 11.76284883
1 83 85 336 0.000336 3.95192E-07 322.6279884 0.852374902 11.62281491
1 84 86 340 0.00034 4.09473E-07 315.0388304 0.872908269 11.48607591
1 85 87 344 0.000344 4.24095E-07 307.7143154 0.893686079 11.35251689
1 86 88 348 0.000348 4.3906E-07 300.6422812 0.914708333 11.22202819
1 87 89 352 0.000352 4.54373E-07 293.8112565 0.935975031 11.09450514
1 88 90 356 0.000356 4.70039E-07 287.2104139 0.957486173 10.96984778
1 89 91 360 0.00036 4.8606E-07 280.8295272 0.979241758 10.84796058
1 90 92 364 0.000364 5.02441E-07 274.658932 1.001241787 10.72875223
1 91 93 368 0.000368 5.19187E-07 268.6894887 1.02348626 10.61213535
1 92 94 372 0.000372 5.363E-07 262.9125489 1.045975177 10.49802637
1 93 95 376 0.000376 5.53785E-07 257.3199242 1.068708538 10.38634524
1 94 96 380 0.00038 5.71647E-07 251.9038567 1.091686343 10.27701529
1 95 97 384 0.000384 5.89888E-07 246.6569925 1.114908591 10.16996305
1 96 98 388 0.000388 6.08513E-07 241.5723567 1.138375283 10.06511807
1 97 99 392 0.000392 6.27527E-07 236.6433299 1.16208642 9.962412781
1 98 100 396 0.000396 6.46932E-07 231.8636271 1.186042 9.861782349
1 99 101 400 0.0004 6.66733E-07 227.2272773 1.210242024 9.763164525
1 100 102 404 0.000404 6.86935E-07 222.728605 1.234686492 9.66649953
1 101 103 408 0.000408 7.0754E-07 218.3622127 1.259375405 9.571729927

12
1 102 104 412 0.000412 7.28553E-07 214.1229651 1.284308761 9.47880051
1 103 105 416 0.000416 7.49979E-07 210.0059735 1.309486561 9.387658197
1 104 106 420 0.00042 7.7182E-07 206.0065818 1.334908805 9.298251929
1 105 107 424 0.000424 7.94081E-07 202.1203538 1.360575493 9.210532571
1 106 108 428 0.000428 8.16767E-07 198.34306 1.386486626 9.124452827
1 107 109 432 0.000432 8.3988E-07 194.6706672 1.412642202 9.039967153
1 108 110 436 0.000436 8.63425E-07 191.0993269 1.439042222 8.957031674
1 109 111 440 0.00044 8.87407E-07 187.6253653 1.465686687 8.875604114
1 110 112 444 0.000444 9.11828E-07 184.2452743 1.492575595 8.795643716
1 111 113 448 0.000448 9.36693E-07 180.9557023 1.519708948 8.717111183
1 112 114 452 0.000452 9.62007E-07 177.7534459 1.547086745 8.639968606
1 113 115 456 0.000456 9.87772E-07 174.6354422 1.574708986 8.564179408
1 114 116 460 0.00046 1.01399E-06 171.5987613 1.60257567 8.489708283
1 115 117 464 0.000464 1.04067E-06 168.6405998 1.6306868 8.416521142
1 116 118 468 0.000468 1.06782E-06 165.7582739 1.659042373 8.344585064
1 117 119 472 0.000472 1.09543E-06 162.9492134 1.68764239 8.273868242
1 118 120 476 0.000476 1.12352E-06 160.2109563 1.716486852 8.204339937
1 119 121 480 0.00048 1.15208E-06 157.541143 1.745575758 8.135970438
1 120 122 484 0.000484 1.18112E-06 154.9375114 1.774909107 8.068731012
1 121 123 488 0.000488 1.21065E-06 152.397892 1.804486902 8.002593873
1 122 124 492 0.000492 1.24066E-06 149.9202038 1.83430914 7.937532134
1 123 125 496 0.000496 1.27117E-06 147.5024492 1.864375822 7.873519778
1 124 126 500 0.0005 1.30217E-06 145.1427109 1.894686949 7.81053162
1 125 127 504 0.000504 1.33367E-06 142.8391474 1.92524252 7.748543274
1 126 128 508 0.000508 1.36567E-06 140.5899898 1.956042535 7.687531122
1 127 129 512 0.000512 1.39819E-06 138.3935383 1.987086994 7.627472285
1 128 130 516 0.000516 1.43121E-06 136.2481589 2.018375897 7.568344593
1 129 131 520 0.00052 1.46475E-06 134.1522805 2.049909245 7.510126558
1 130 132 524 0.000524 1.49881E-06 132.1043918 2.081687037 7.452797347
1 131 133 528 0.000528 1.5334E-06 130.103039 2.113709273 7.396336761
1 132 134 532 0.000532 1.56851E-06 128.1468227 2.145975954 7.340725207
1 133 135 536 0.000536 1.60416E-06 126.2343958 2.178487078 7.285943675
1 134 136 540 0.00054 1.64034E-06 124.364461 2.211242647 7.231973722
1 135 137 544 0.000544 1.67706E-06 122.5357689 2.24424266 7.178797445
1 136 138 548 0.000548 1.71433E-06 120.7471155 2.277487118 7.126397464
1 137 139 552 0.000552 1.75214E-06 118.9973404 2.310976019 7.074756902
1 138 140 556 0.000556 1.79051E-06 117.285325 2.344709365 7.023859371
1 139 141 560 0.00056 1.82943E-06 115.6099907 2.378687155 6.973688946
1 140 142 564 0.000564 1.86891E-06 113.9702971 2.41290939 6.92423016
1 141 143 568 0.000568 1.90895E-06 112.3652403 2.447376068 6.875467975

13
Material Optimization and Selection of the Most Appropriate
Design*:
t (mm) a (mm) b (mm) 𝜎𝑒 (MPa) FoS MPa/N
04 mm 66 74 120.9607114 2.273465465 3.486844473
03 mm 77 83 121.4112966 2.265028112 4.067985219
02 mm 93 97 127.2216425 2.161581901 5.138507645
01 mm 129 131 134.1522805 2.049909245 7.510126558
*In all these cases, the perimeter is divisible by 5
For every allowable thickness, the most appropriate design for the beam based on the maximum
strength to weight ratio is mentioned in above table. Further comparison of the designs based on
allowable thickness shows that the design with allowable thickness of 1mm gives the highest
strength to weight ratio. Also, the condition for factor of safety greater than 2 is satisfied.

Final Design:
Length of beam, L 3m
Allowable thickness, t 1mm
Inner square side, a 129mm
Outer square side, b 131mm
Mean perimeter, p 520mm
Maximum Stress, 𝜎𝑚𝑎𝑥 134.1522805MPa
FoS 2.049909245
Strength to weight ratio, UTS/𝜌𝑔𝐴𝐿 7.510126558MPa/N

FEA Analysis:
The followings results are obtained from the finite element analysis using
SOLIDWORKS.

• Meshing

14
• Load Application:
The distributed load is first concentrated at a specific point to simplify the
analysis.

• Stress Profile:

15
• Displacement at Free End:

16
 • Strain:

Comparing the Results:

The theoretical calculations show that the maximum bending stress at the outer beam
surface is 134.15MPa, while the computational analysis gives maximum bending
stress of 166.3MPa. The FEA results deviate, because the theoretical calculations
are based Maximum Shear-Stress (Tresca) on while the computational results are
based on meshing quality. The meshing quality used in this case is coarse meshing,
and so the results deviates.

Production Drawings:

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See Next Page---------------------------------→

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