Combined Loading

Checked one at a time, each load looks acceptable; together they are not. This combines them at a point and gives you both failure criteria — von Mises (what FEA reports, matches ductile test data) and Tresca (what pressure-vessel codes use, always the conservative one). They differ by up to 15%, and quoting the wrong one is a standard review comment.

Axial and bending stresses add because they act in the same direction — put the bending stress at the fibre where it has the same sign as the axial stress. Torsional and direct shear likewise add. Defaults are a 25 mm solid shaft. For the stress state on an arbitrary plane use Mohr’s Circle; for a stress raiser multiply by K_t from Stress Concentration.