Failure Theories Static Loads

Static load a stationary load that is gradually applied having an unchanging

magnitude and direction

Failure A part is permanently distorted and will not function properly.

A part has been separated into two or more pieces (fracture)

Material Strength Sy = Yield strength in tension, Syt = Syc

Sys = Yield strength in shear

Su = Ultimate strength in tension, Sut Suc = Ultimate strength in compression Sus = Ultimate strength in shear = .67 Su

Ken Youssefi

Mechanical Engineering Dept., SJSU

Ductile and Brittle Materials

A ductile material deforms significantly before fracturing. Ductility is measured by % elongation at the fracture point. Materials with 5% or more elongation are considered ductile.

Ken Youssefi

Brittle material yields very little before fracturing, the yield strength is approximately the same as the ultimate strength in tension. The ultimate strength in compression is much larger than the ultimate strength in tension. 2 Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

Yield strength of a material is used to design components made of ductile material

Maximum shear stress theory (Tresca 1886)

(max )component > ( )obtained from a tension test at the yield point
= Sy

Failure

=
= Sy

Sy 2 To avoid failure

(max )component <

Sy
2

max =
=Sy

Sy 2n

n = Safety factor

Design equation
Ken Youssefi
Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

Distortion energy theory (von Mises-Hencky)
Simple tension test (Sy)t

t
(Sy)h >> (Sy)t

Hydrostatic state of stress (Sy)h

h h h

Distortion contributes to failure much more than change in volume.

t
(total strain energy) (strain energy due to hydrostatic stress) = strain energy due to angular distortion > strain energy obtained from a tension test at the yield point failure
Ken Youssefi
Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

The area under the curve in the elastic region is called the Elastic Strain Energy.

U =
3D case UT =
Strain energy

11 + 22 + 33

Stress-strain relationship

1 = 2 =

1
E

v v v

2
E

v v

3
E

2
E

1
E

3
E

3 =
UT =
Ken Youssefi

3
E

1
E

2
E

2E

( 1 2 + 2 2 + 3 2 ) - 2 v ( 1 2 + 1 3 + 2 3)
Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

Distortion strain energy = total strain energy hydrostatic strain energy

Ud = UT Uh
UT =
1

2E

( 1 2 + 2 2 + 3 2 ) - 2 v ( 1 2 + 1 3 + 2 3) 1 = 2 = 3 = h ( h 2 + h 2 + h 2 ) - 2 v ( h h + h h+ h h)

(1)

Substitute

Uh =

2E

Simplify and substitute

1 + 2 + 3 = 3h into the above equation ( 1 + 2 + 3 ) 2 ( 1 2 v)

6E

Uh =

3h 2E

( 1 2 v) =

Subtract the hydrostatic strain energy from the total energy to obtain the distortion energy

Ud = UT U h =
Ken Youssefi

1+v

6E

( 1 2 ) 2 + ( 1 3 ) 2 + (2 3 )2
Mechanical Engineering Dept., SJSU

(2)
6

Failure Theories Ductile Materials

Strain energy from a tension test at the yield point

1= Sy and 2 = 3 = 0
Ud = UT Uh =
1+v

Substitute in equation (2)

6E

(1 2)2 + ( 1 3)2 + (2 3)2

2

(2)

Utest = (Sy)

1+v

3E

To avoid failure, Ud < Utest

(1 2)2 + (1 3)2 + (2 3)2

2

<

Sy

Ken Youssefi

Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

(1 2)2 + (1 3)2 + (2 3)2
2
2D case, 3 = 0

<

Sy

= (1

2 12 + 2 ) < Sy
Where is von Mises stress

Sy n

Design equation

Ken Youssefi

Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

Pure torsion,

= 1 = 2
(12 2 1 + 22) = Sy2

3 = Sy
2

Sys = Sy / 3 Sys = .577 Sy

Relationship between yield strength in tension and shear

If y = 0, then

1, 2 = x/2

[(x)/2]2 + (xy)2

the design equation can be written in terms of the dominant component stresses (due to bending and torsion)

(x) + 3(xy)
2
Ken Youssefi

1/2

Sy n
9

Mechanical Engineering Dept., SJSU

Design Process
Distortion energy theory Maximum shear stress theory

Sy n

Sy max = 2n

Select material: consider strength, environment, cost, weight, availability, codes and standards, manufacturing process Choose a safety factor

Sy , Su

Size

Weight

Cost

The selection of an appropriate safety factor should be based on the following: Degree of uncertainty about loading (type, magnitude and direction) Degree of uncertainty about material strength Uncertainties related to stress analysis Consequence of failure; human safety and economics Type of manufacturing process Codes and standards
Ken Youssefi
Mechanical Engineering Dept., SJSU

10

Design Process
Use n = 1.2 to 1.5 for reliable materials subjected to

loads that can be determined with certainty.

Use n = 1.5 to 2.5 for average materials subjected to

loads that can be determined. Also, human safety and economics are not an issue.
Use n = 3.0 to 4.0 for well known materials subjected to

uncertain loads.

Ken Youssefi

Mechanical Engineering Dept., SJSU

11

Design Process - Static load & Ductile material

Select material

Sy , Su

Choose a safety factor, n Choose a cross section: round, rectangular, hollow, I-beam, C channel, Formulate the maximum stresses in the component in terms of size: x, xy Determine the principal stresses, maximum shear stress and von Mises stress in terms of the size; 1,

2 , max and

Use appropriate failure theory to calculate the size.

Ken Youssefi

Sy n

Sy max = 2n
Maximum shear stress theory

Distortion energy theory

Optimize for weight, size, or cost.

Mechanical Engineering Dept., SJSU

12

Failure Theories Brittle Materials

Characteristics of brittle materials;

1. Sut Syt

2. Suc >> Sut

3. elongation < 5%

Perform two tests, one in compression and one in tension, draw the Mohrs circles for both tests.

Suc

Stress state

Sut

Tension test

Compression test

Failure envelope The component is safe if the state of stress falls inside the failure envelope. 1 > 2 and 3 = 0
Ken Youssefi
Mechanical Engineering Dept., SJSU

13

Failure Theories Brittle Materials

Modified Coulomb-Mohr theory
2 or 3
Sut
Safe Safe Safe

2 or 3
Sut
Sut

Suc -Sut
Safe

1
-Sut

I
II III

Sut

Suc

Suc

Cast iron data

Three design zones

Ken Youssefi

Mechanical Engineering Dept., SJSU

14

Failure Theories Brittle Materials

Zone I

1 > 0 , 2 > 0 and 1 > 2 1 =

Sut

Sut

I
Design equation

Sut

II
-Sut

Zone II

III

1 > 0 , 2 < 0 and 2 < Sut 1 =

Zone III

Sut

Design equation

Suc

1 > 0 ,

2 < 0 and 2 > Sut

1 (

1 1 1 ) 2 = n Sut Suc Suc Design equation

Ken Youssefi

Mechanical Engineering Dept., SJSU

15