Machine Design I (254325)

Chapter 3
Failures Resulting From Static Loading
Failure of a truck drive-shaft
Failure of an overhead-pulley retaining
bolt
Failure of a Chain test fixture
Failure of a Valve-spring
Static Strength
.a::aaa.v -aa.
..aa..v..a.-..+ .-...|..++...
.a.....:-.aa+.. aa
.++.a.u+......:aa.+..aa.
.++.-..a..a::a...a...!....+
u.:.a:
-.a.:.a:: ++.a+.a: a+.u:...vu.u!
.....+...u!.!..a+.a..a..v.:v..a
Stress Concentration
+.u....!.
Failure Theories
...a.a..a+a.:..:a.:a. ..a. va.a..
.... a. a+.. aa.va::.a| .a:..aa
...:+a.:..aa+.+a..+...+a::..|
..!-...a+..a:v.v:.a.:.a..:
..a.v:.!.v+a::!-
.a. a.
f
0.05 ; S
yt
= S
yc
= S
y
.a.v..
f
< 0.05 ; S
ut
, S
uc
Failure Theories
.a. a. (yield criteria)
Maximum shear stress (MMS) , Sec. 54
Distortion energy (DE), Sec. 55
Ductile Coulomb-Mohr (DCM), Sec. 56
.a.v.. (fracture criteria)
Maximum normal stress (MNS), Sec. 58
Brittle Coulomb-Mohr (BCM), Sec. 59
Modified Mohr (MM) , Sec. 59
Maximum-Shear-Stress Theory for Ductile
Materials
.+.. a..++...+.
.a!-.!a| .+r.v:.o
.. .+...+..a!.a
.aa.!-a:a.a.a.a.. a
.+.
n S n S
S S
S
S
S
A P
y y
y sy
y
y
y
/ or 2 /
5 . 0
or
2 2
2 / ) ( ;
2 / 2 /
45 surface a on occurs shear ; /
3 1 max
3 1
3 1
max
3 1 max 3 2 1
max
= =
=

=
=
= =
=

Maximum-Shear-Stress Theory for Ductile

Materials (Plane stress problems)
y B
B B A
y B A
B A B A
y A
A B A
B A
S
S
S

= =

= =

= =

; 0 ; 0 case3.

; ; 0 case2.

0 ; ; 0 case1.
Assume
3 1
3 1
3 1
Distortion-Energy Theory for Ductile
Materials
a. yield .a..u+....v+a.v. ..av.....
-..:. ..u+....v+a. v. ..av...... yield
..a.:.a. .a: !.a-a.aa.

av
= (
1
+
2
+
3
)/3
Distortion-Energy Theory for Ductile
Materials
| |
( ) | |
| |
( )
| |
(

+ + +
= =
+ + + + +

=
=
+ + + + =
+ =
+ + = =
2
) ( ) ( ) (
3
1
2 2 2
6
2 1
2 1
2
3
) ( 2
2
1
1
2
1
;
2
1
2
1 3
2
3 2
2
2 1
1 3 3 2 2 1
2
3
2
2
2
1
2
1 3 3 2 2 1
2
3
2
2
2
1
3 3 2 2 1 1

E
u u u
E
u
E
u
E
u
E
u u
v d
v
av
v
z y x x
Distortion-Energy Theory for Ductile
Materials
y
y
y d
y
v d
S
S
S
E
u
S
E
u u u

+ +
+
=
= = =
(

+ + +
= =

2 / 1
2
1 3
2
3 2
2
2 1
2
3 2 1
2
1 3
2
3 2
2
2 1
2
) ( ) ( ) (
3
1
0 , yield, at tensil, simple for
2
) ( ) ( ) (
3
1
Distortion-Energy Theory for Ductile
Materials
( )
( ) | |
( )
2 / 1
2 2 2
2 / 1
2 2 2 2 2 2
2 / 1
2 2
2 / 1
2
1 3
2
3 2
2
2 1
3
stress plane for
6 ) ( ) ( ) (
2
1
Stress D 3 of componets using
2
) ( ) ( ) (
, stress, plane for
xy y xy x
zx yz xy x z z y y x
B B A A
B A
xyz

+ + =
+ + + + + =

+ =
(

+ +
=
Distortion-Energy Theory for Ductile
Materials
( )
( ) | |
( )
( )
y sy
y y xy y
y y x
xy y xy x
B A
zx yz xy x z z y y x
B B A A
B A
S S
S S S
S
xyz
577 . 0
is ory energy the - distortion by the predicted strength yield shear
577 . 0 3 / ; 3
; 0 ; shear pure for
3
; stress plane for
6 ) ( ) ( ) (
2
1
Stress D 3 of componets using
2
) ( ) ( ) (
, stress, plane for
xy
2 / 1
2
xy
2 / 1
2 2 2
2 / 1
2 2 2 2 2 2
2 / 1
2 2
2 / 1
2
1 3
2
3 2
2
2 1
=
= = =
= =
+ + =
= =
+ + + + + =

+ =
(

+ +
=

Distortion-Energy Theory for Ductile
Materials
The von Mises or von Mises-Hencky theory
The shear-energy theory
The octahedral-shear-stress theory
Coulomb-Mohr Theory for Ductile
Materials
.a.a.++..a.a..a.a
.:a .a.- a
a.+a. Mohr ..
a:.u.a .+ a. a .
.... Mohr a ...
.va+.uaa.a.a..+. ..
.a+a.. :.....aa.
.v..a..
Coulomb-Mohr Theory for Ductile
Materials
Coulomb-Mohr theory
or the internal-friction
theory
...!:...v....
1
3 1
=
c t
S S

Coulomb-Mohr Theory for Ductile
Materials
For plan stress,
A

B
Case 1 :
A

B
0,
1
=

A
and
3
= 0

A
S
t
Case 2 :
A
0
B
,
1
=

A
and
3
=
B
(
A
/ S
t
) - (
B
/ S
c
) 1
Case 3 : 0
A

B
,
1
= 0
and
3
=
B

B
-S
c
yc yt
yc yt
sy
sy
c t
S S
S S
S
S
n S S
+
=
= = =
=
max 3 1
3 1
;
, shear pure For
1



Failure of Ductile Materials Summary
Maximum-Normal-Stress Theory (MNS)
for Brittle Materials
..aa.a ..+...++
!a|.+....:+ +..
a.a..

1

2

3

1
S
ut
or
3
-S
uc

A

B

A
S
ut
or
B
-S
uc
Maximum-Normal-Stress Theory (MNS)
for Brittle Materials

A
= S
ut
/n

A

B
0 line 1

A
0
B
and
|
B
/
A
| S
uc
/S
ut
line 2

B
= -S
uc
/n

A
0
B
and
|
B
/
A
| > S
uc
/S
ut
line 3
0
A

B
line 4
Modifications of the Mohr Theory
for Brittle Materials
Brittle-Coulomb-Mohr

A

B
0

A
= S
ut
/n

A
0
B
(
A
/S
ut
) - (
B
/S
uc
) = 1/n
0
A

B

B
= -S
uc
/n
Modifications of the Mohr Theory
for Brittle Materials
Modified Mohr

A

B
0

A
0
B
and |
B
/
A
| 1

A
= S
ut
/n

A
0
B
and |
B
/
A
| > 1
[(S
uc
-S
ut
)
A
/ (S
uc
S
ut
)] -
(
B
/S
uc
) = 1/n
0
A

B

B
= -S
uc
/n
Failure of Brittle Materials Summary
.+! Q a!.+...aa
. !-a
.+! Q Modified
Mohr aa.aaa
.+! Q .a.v
Selection of Failure Criteria
Introduction to Fracture Mechanics
...a.aa. .aa..+a.va!.a.aa
Linear Elastic Fracture Mechanics (LEFM)
.!-.ru+...v+a.v!.. .+..
Stress-concentration .a:...aa...v+a.v.. .
a+.a
.aa..:u..a..++. .....a.+.|
.a.aaaa...+. (yield) a :...a.aa.
(relatively brittle)
Introduction to Fracture Mechanics
Quasi-Static Fracture
( )
|

\
|
+ =
b
a
y
2 1
max
Introduction to Fracture Mechanics
Crack Modes and the
Stress Intensity Factor

+
=
=
|

\
|
+ =
|

\
|
=
strain) plane (for ) (
stress) plane (for 0
2
3
cos
2
cos
2
sin
2
2
3
sin
2
sin 1
2
cos
2
2
3
sin
2
sin 1
2
cos
2
y x
z
xy
y
x
r
a
r
a
r
a

Introduction to Fracture Mechanics
Crack Modes and the
Stress Intensity Factor
a K
r
K
r
K
r
K
a K
a K
r
a
I
y x
z
I
xy
I
y
I
x
I
y

+
=
=
|

\
|
+ =
|

\
|
=
=
=
=
=
strain) plane (for ) (
stress) plane (for 0
2
3
cos
2
cos
2
sin
2
2
3
sin
2
sin 1
2
cos
2
2
3
sin
2
sin 1
2
cos
2
2
0
Introduction to Fracture Mechanics
Introduction to Fracture Mechanics
Fracture Toughness
critical stress intensity factor (K
Ic
)

+ +a.:.a.
...a a:.a .va::.aa. .++. a.. ...
... a+..u.:...a.aa.
20 K
Ic
200MPa.m .+
1 K
Ic
5 MPa.m .+..
40 K
Ic
190MPa.m steel 4340
Introduction to Fracture Mechanics
+a::..+.a+..a!..!-...a.....a:.
S
y
/S
u
.aa..+....a!.a a+:u+..!-..u+.
a ...v brittle fracture
Strength-to-stress ratio ..a!-.v++..v+a.a
n = K
Ic
/K
I
Reference
Budynas, R.G. and Nisbett, J.K., Shigleys
Mechanical Engineering Design, 8
th
ed.,Mc
Graw Hill, 2008.