Roymech engineering encyclopedia

Mechanics and Stress Analysis Guide


Engineering mechanics covers a wide range of problems, from determining the forces acting on a stationary component to calculating stresses, deformation, buckling and the motion of machines.

The first step is normally to identify what type of engineering problem you are trying to solve. This guide helps select the appropriate RoyMech reference for the problem rather than reproducing the detailed equations, tables and derivations contained on those pages.

Already know the analysis method? Go directly to the appropriate technical reference below. This guide is primarily intended to help students, apprentices and engineers who are unsure which mechanics or stress-analysis method applies.

Start with the Engineering Question

Engineering Question Start Here
I need to resolve forces into components or work with force directions. Vectors
I need reactions, forces or moments in a stationary structure or component. Statics
I know how something moves but I am not yet considering the forces causing the motion. Kinematics
I need to relate force, mass, acceleration, momentum or energy to motion. Dynamics and Kinetics
I need to analyse a four-bar or other mechanical linkage. Mechanical Linkages
I need mechanical advantage, velocity ratio or efficiency for a simple machine. Simple Machines
I need to identify whether a component is in tension, compression, shear, bending or torsion. Component Loading
I need basic elastic stress, strain, Young's modulus, Poisson's ratio or shear modulus. Stress and Strain
I have combined stresses and need to assess yielding or failure. Yield and Failure Criteria
I need principal stresses or maximum shear stress from a plane-stress state. Mohr's Circle
I have a slender member in compression and need to check buckling. Column and Strut Buckling
I need stresses in a thick pressure cylinder or an interference fit. Thick-Walled Cylinders
I need stresses in a high-speed rotating disc or cylinder. Rotating Discs and Cylinders
I need shear stress or angular twist caused by torque. Torsion
I need yield strength, proof strength, UTS, ductility or tensile-test behaviour. Stress-Strain Curve
I need stress or deflection in a thin circular, rectangular or annular plate. Loaded Flat Plates

1. Is the Problem About Forces or Motion?

A useful first distinction in mechanics is whether the problem concerns forces in equilibrium, motion itself, or the forces producing motion.

Forces in Equilibrium → Statics

Use Engineering Statics when the component or system is being treated as being in equilibrium.

Typical problems include:

  • support reactions;
  • forces acting on brackets, frames and structures;
  • moments and couples;
  • free-body diagrams;
  • truss forces;
  • distributed loads and their resultants.

Statics is often the first stage of a stress calculation. The external forces and reactions are determined first, after which the resulting component loading and stresses can be calculated.

Motion without Considering its Causes → Kinematics

Use Kinematics when the main question is how something moves rather than what forces cause the motion.

Typical quantities include:

  • displacement;
  • velocity;
  • acceleration;
  • angular displacement and velocity;
  • relative motion;
  • rigid-body motion;
  • Coriolis acceleration.

Forces Causing Motion → Dynamics and Kinetics

Use Dynamics and Kinetics when forces, moments, mass or inertia must be related to acceleration and motion.

This includes problems involving:

  • Newton's laws;
  • force and acceleration;
  • linear and angular momentum;
  • impulse;
  • work and energy;
  • power;
  • rotating inertia;
  • equivalent rotating mass.

Need to Resolve Forces or Directions First? → Vectors

Many statics and dynamics calculations depend on vector operations. Use Vectors in Engineering Mechanics for vector components, addition, scalar and vector products, force directions and related vector operations.


2. Is the Problem About a Mechanism?

Mechanism problems can involve either the selection of a mechanism or the detailed kinematic analysis of a linkage.

If you are deciding how to produce a particular type of motion, start with the:

Mechanism Help and Selection Guide

That guide covers mechanisms for reciprocating, rocking, intermittent, indexing and one-way motion, including ratchets, escapements, cams and linkages.

If the mechanism has already been selected and you need to analyse a four-bar linkage, mobility, Grashof condition, mechanical advantage, velocity or acceleration, use:

Mechanical Linkages – Four-Bar Mechanisms and Kinematic Analysis

Simple Machines

Use Simple Machines when the problem concerns mechanical advantage, velocity ratio or ideal efficiency in arrangements such as:

  • levers;
  • inclined planes;
  • wedges;
  • wheel and axle systems;
  • pulley systems;
  • simple screw mechanisms.

For the detailed engineering design of screws transmitting substantial axial load or power, use the RoyMech Power Screw references instead.


3. What Type of Load is Acting on the Component?

If the load is known but you are unsure which stress calculation applies, start with:

Component Loading – Stress, Strain and Loading Conditions

The principal loading modes are:

Loading Typical Effect Common Next Step
Tension Normal tensile stress and extension Stress and Strain
Compression Normal compressive stress and shortening Stress and Strain
Shear Shear stress and shear deformation Stress and Strain
Bending Normal bending stress and deflection Beam Calculations
Torsion Shear stress and angular twist Torsion
Combined loading Multiaxial stress state Mohr's Circle / Yield and Failure Criteria

4. Stress, Strain or Material Strength?

These terms are closely related but answer different engineering questions.

Stress and Elastic Deformation

Use Stress and Strain – Basic Elastic Theory when you need relationships involving:

  • normal stress;
  • normal strain;
  • Young's modulus;
  • Poisson's ratio;
  • three-dimensional elastic strain;
  • shear stress and shear strain;
  • shear modulus;
  • elastic constants.

Material Tensile Properties

Use the Stress-Strain Curve reference when the question concerns properties obtained from a tensile test, including:

  • Young's modulus;
  • yield strength;
  • 0.2% proof strength;
  • ultimate tensile strength;
  • strain hardening;
  • necking;
  • elongation and ductility;
  • engineering and true stress-strain behaviour.
Stiffness is not strength. Young's modulus describes elastic stiffness. Yield strength and tensile strength describe different aspects of material strength. A material can have a high Young's modulus without having a correspondingly high yield or tensile strength.

5. Do You Have Combined Stresses?

Components are often subjected to more than one stress component at the same time. A shaft, for example, may experience bending stress and torsional shear stress simultaneously.

Need Principal Stress or Maximum Shear? → Mohr's Circle

Use Mohr's Circle to transform a plane stress state and determine:

  • principal stresses;
  • principal directions;
  • maximum in-plane shear stress;
  • stress on a rotated plane.

Need to Assess Yielding? → Failure Criteria

Use Yield and Failure Criteria when the stress state must be compared with material strength.

The page covers:

  • maximum principal stress / Rankine criterion;
  • Tresca maximum shear stress criterion;
  • von Mises distortion-energy criterion;
  • maximum strain-energy theory.

For ductile metals under multiaxial static loading, Tresca and von Mises are commonly encountered yield criteria. Material behaviour, loading conditions and the applicable design standard should determine which criterion is used.


6. Is a Compression Member Slender?

A compression member does not necessarily fail by simple compressive yielding. A sufficiently slender member may become unstable and buckle at a much lower load.

Use:

Column and Strut Buckling – Euler, Rankine and Perry-Robertson

for:

  • effective length;
  • slenderness ratio;
  • Euler critical load;
  • critical buckling stress;
  • Rankine-Gordon calculations;
  • legacy Perry-Robertson / BS 449 design information.
New structural steel design: Classical Euler and Rankine calculations are useful for understanding and preliminary engineering analysis, but structural members should be designed to the applicable current structural design standard. Legacy RoyMech data is retained where it remains useful for older structures and equipment.

7. Is the Component Subjected to Pressure?

Pressure-loaded components require different treatment depending on their geometry and wall thickness.

Thick Cylinders

Use Thick-Walled Cylinders where radial stress cannot reasonably be neglected through the wall thickness.

The reference covers:

  • Lamé equations;
  • radial stress;
  • hoop stress;
  • closed-end axial stress;
  • radial displacement;
  • interference and shrink fits;
  • contact pressure;
  • frictional torque and axial-force capacity of fitted joints.

Do not confuse a pressure-stress calculation with an external-pressure buckling calculation. A cylinder can become unstable under external pressure even when an elastic stress calculation alone appears acceptable.


8. Is the Component Rotating at High Speed?

Rotation creates body forces throughout the material. At sufficiently high speed these can produce important radial and circumferential stresses even when no external mechanical load is applied.

Use:

Rotating Discs and Cylinders – Radial and Hoop Stresses

for:

  • solid rotating discs;
  • annular rotating discs;
  • radial stress;
  • hoop stress;
  • long rotating cylinders;
  • effects of rotational speed and material density.

These calculations can be relevant to flywheels, rotors, high-speed discs and other rotating machinery.


9. Is the Component Subjected to Torque?

Torque produces torsional deformation and generally creates shear stress. For circular shafts, the familiar elastic torsion relationship is:

T J = τ r = G θ L

Use the RoyMech:

Torsion Reference

for shaft torsion, torsional section properties and the associated torsion references.

Non-circular sections: The simple circular-shaft stress relationship τ = Tr/J is not generally applicable to non-circular sections. Non-circular sections warp under torsion and require the appropriate torsion constant and stress solution for the section geometry.

10. Is the Component a Thin Loaded Plate?

A flat plate carrying transverse load behaves differently from a beam because the load can be carried by bending in two directions.

Use:

Loaded Flat Plates – Stress and Deflection

for preliminary elastic calculations involving:

  • circular plates;
  • rectangular plates;
  • annular plates;
  • uniform pressure;
  • central concentrated loads;
  • simply supported edges;
  • clamped edges.

The RoyMech plate equations are based on thin-plate, small-deflection assumptions. If deflection becomes significant relative to plate thickness, membrane action and geometric nonlinearity may become important.


Choosing Between Beam, Plate and Column Analysis

These are frequently confused when first approaching a structural mechanics problem.

Component Behaviour Usually Start With
A long member carrying transverse loads, with bending predominantly about one axis. Beam Analysis
A broad thin surface carrying transverse load and bending significantly in two directions. Plate Analysis
A slender member carrying axial compression where instability may govern. Column / Strut Buckling
A short member primarily carrying axial load without an instability problem. Component Loading and Stress and Strain

A Typical Stress-Analysis Route

Many practical engineering calculations follow approximately this sequence:

  1. Define the component and loading. Identify forces, moments, torque, pressure, acceleration and support conditions.
  2. Determine reactions and internal actions. Use statics or dynamics as appropriate.
  3. Identify the loading mode. Tension, compression, shear, bending, torsion, pressure or a combination.
  4. Calculate nominal stresses and deformation. Use the appropriate beam, shaft, plate, cylinder or other component theory.
  5. Determine the combined stress state if necessary. Principal stresses or equivalent stresses may be required.
  6. Compare with an appropriate material or stability limit. This may involve yield strength, proof strength, fatigue strength, fracture, buckling or another design criterion.
  7. Apply the appropriate design standard and safety factors. The required factors and acceptance criteria depend on the application.
  8. Check serviceability as well as strength. Deflection, stiffness, vibration, alignment, wear and functional performance can govern a design even when calculated stresses are acceptable.

Strength is Not the Only Design Check

A calculated stress below yield strength does not automatically mean that a component is satisfactory.

Depending on the application, also consider:

  • fatigue under repeated or fluctuating loading;
  • buckling and structural instability;
  • fracture and crack propagation;
  • excessive elastic deflection;
  • vibration and resonance;
  • wear and contact damage;
  • creep at elevated temperature;
  • corrosion and environmental effects;
  • impact and shock loading;
  • stress concentrations;
  • manufacturing tolerances and residual stresses.

The appropriate checks depend on the component, material, operating environment and consequences of failure.


Quick Selection Guide

Forces and Motion

Stress and Structural Behaviour

Specialised Stress Problems


Engineering Judgement

Engineering equations describe an idealised model of a real component. Before using a result, check that the assumptions behind the calculation are reasonable for the actual geometry, material, loading and supports.

A calculation can be mathematically correct and still be the wrong calculation for the engineering problem. Selecting the correct model is therefore just as important as evaluating the equation correctly.

Where a recognised design standard governs the component or application, the standard should take precedence over a general reference calculation, particularly where safety factors, load combinations, material limits, fatigue, instability or inspection requirements are specified.


Mechanics Technical References

Experienced engineers who already know the required method can go directly to the RoyMech Mechanics reference pages:

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