Mechanics of Materials · Margin and heat
Margin, and the stress nobody applied
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Margin, and the stress nobody applied

FS=σuσallowFS = \dfrac{\sigma_u}{\sigma_{allow}}F S equals sigma-u over sigma-allowable. σu\sigma_u is the strength of the material, the stress at which it yields or breaks; σallow\sigma_{allow} is the working stress the design actually puts into it; FSFS is the factor of safety, a bare ratio with no units at all, because it is a stress divided by a stress.

Read it as a declaration of ignorance rather than of strength. A factor of safety of 3 does not say the part is three times better than it needs to be; it says the engineer is keeping a threefold reserve against the load being heavier than assumed, the steel weaker than certified and the weld worse than drawn — all on the same bad morning. FSFS below 1 means the working stress has already passed the strength: the part is failing on paper. FSFS at 1.4 means it survives the load you wrote down, and nothing else.

Then a stress nobody applies. Heat a bar and it wants to grow by αΔT\alpha \, \Delta T per unit of length; hold both ends and it cannot, so the stress arrives anyway: σ=EαΔT\sigma = E \alpha \, \Delta Tsigma equals E alpha delta-T. α\alpha (alpha) is the coefficient of thermal expansion, about 12×10612 \times 10^{-6} per °C for carbon steel; ΔT\Delta T is the temperature change from the condition it was installed at; EE is the same Young's modulus as ever. Notice what is NOT in that formula: length. A restrained run builds the same stress at two metres as at two hundred — which is why expansion is designed around anchors, never around lengths.