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I am wondering if there is a formula (or how to derive one) for calculating the minimum radius a rod (with a given radius/diameter) can be bent around while staying in the elastic range. Obviously, this will depend on the modulus of elasticity for the material.

I am searching for a general formula for this rather than a specific solution for a particular material. With a general formula, I can evaluate trade offs using different materials (with different moduli), different rod radii, and different radii of bending.

Stated more simply, if I wanted to wind a rod of radius X made of a material with modulus of elasticity M around a spool, how would I calculate the minimum radius S of the spool?

user1805103
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1 Answers1

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If we're staying within the realms of beam theory, we can go with this approach which is valid for any material that exhibits linear-elastic behaviour before yield:

The curvature of a beam is related to the applied moment and it's flexural stiffness:

$$ \begin{align} \kappa = \frac{M}{EI} \end{align} $$

where, for a cicular rod, $I = \frac{\pi d^4}{64}$. The curvature is also equal to the inverse of the bent radius, giving the following:

$$ \begin{align} R = \frac{1}{\kappa} = \frac{EI}{M} \end{align} $$

For a rod of circular cross-section, the stress at the extreme fibre is related to the applied bending moment and the elastic section modulus:

$$ \begin{align} \sigma = \frac{M}{Z} \end{align} $$

where for a circular rod, $Z = \frac{\pi d^3}{32}$. This gives:

$$ \begin{align} \therefore M = \frac{\sigma \pi d^3}{32} \end{align} $$

Therefore, if a given material has a certain yield strength, $\sigma = f_y$, the minimum radius can be determined through the substitution of the above equations:

$$ \begin{align} R_{min} = E \, \frac{\pi d^4}{64} \frac{32}{f_y \pi d^3} \end{align} $$

$$ \begin{align} \boxed{\therefore R_{min} = \frac{E d}{2 f_y}} \end{align} $$

where $E$ is the elastic modulus of the material, $d$ is the diameter of the rod and $f_y$ is the yield strength of the material.

Refer to this solution to question 6a on page 8 for a similar solution for a rectangular section. Note that the end result is the same for both a rectangle and circle as both have a distance of $D/2$ from the neutral axis to the extreme fibre.