Static Failure Theories

Design of Machine Elements

Dr Moudar Zgoul, @zgoul_ju, 2011 [extracted from different sources]

Introduction
Strength is a property or characteristic of a
mechanical element.
This property results from the material identity, the
treatment and processing incidental to creating its
geometry, and the loading, and it is at the controlling
or critical location.
strengths of the mass-produced parts will all be
somewhat different from the others in the collection
or ensemble because of variations in dimensions,
machining, forming, and composition.

Introduction
A static load is a stationary force or couple
applied to a member.
To be stationary, the force or couple must be
unchanging in magnitude, point or points of
application, and direction.
A static load can produce axial tension or
compression, a shear load, a bending load, a
torsional load, or any combination of these.
To be considered static, the load cannot change
in any manner.

Introduction
Failure can mean a part has separated into two
or more pieces; has become permanently
distorted, thus ruining its geometry; has had its
reliability downgraded; or has had its function
compromised, whatever the reason.
Mechanical components fail, simply because the
applied stresses exceeds the materials strength.
Under any load combination, there is always a
combination of normal and shearing stresses in
the material.

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.

Ductile and Brittle Materials

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.

Ductile and Brittle Materials

Which stress causes the material

to fail?
Usually ductile materials are limited by their
shear strengths.
While brittle materials(ductility < 5%) are limited
by their tensile strengths.

Failure Theories

Failure Theories

Failure Theories -

Ductile Materials
Maximum shear stress theory (Tresca 1886)
Yield strength of a material is used to design components made of ductile material

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

Sy

Failure

To avoid failure

(max )component <

= Sy

max =

Sy
2n

Design equation
=Sy

Sy
2

n = Safety
factor

Failure Theories -

Ductile Materials
Distortion energy theory (von Mises-Hencky)
Yield strength of a material is used to design components made of ductile material
Simple tension test (Sy)t

Hydrostatic state of stress (Sy)h

(Sy)h >> (Sy)t

Distortion contributes to
failure much more than
change in volume.

h
h

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

Failure Theories -

Ductile Materials
Distortion energy theory (von Mises-Hencky)
The area under the curve in the elastic region is called the Elastic Strain Energy.

U =
3D case
UT =

11 + 22 + 33

Stress-strain relationship
Strain
energy

1 =
2 =
3 =

UT =

2E

1
E

2
E

3
E

v
v
v

2
E

1
E

1
E

v
v
v

3
E

3
E

2
E

(12 + 22 + 32) - 2v (12 + 13 + 23)

Failure Theories -

Ductile Materials
Distortion energy theory (von Mises-Hencky)
Distortion strain energy = total strain energy hydrostatic strain energy

Ud = UT Uh
UT =

2E

Substitute

Uh =

2E

(12 + 22 + 32) - 2v (12 + 13 + 23)

1 = 2 = 3 = h
(h2 + h2 + h2) - 2v (hh + hh+ hh)

Simplify and substitute

Uh =

3h
2E

(1)

(1 2v) =

1 + 2 + 3 = 3h into the above equation

(1 + 2 + 3)2 (1 2v)
6E

Failure Theories -

Ductile Materials
Distortion energy theory (von Mises-Hencky)

Subtract the hydrostatic strain energy from the total energy to

obtain the distortion energy
1+v
Ud = UT Uh =
6E

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

(2)

Failure Theories -

Ductile Materials
Distortion energy theory (von Mises-Hencky)
Strain energy from a tension test at the yield point

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

1+v

6E

Substitute in equation (2)

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

Utest = (Sy)

1+v
3E

To avoid failure, Ud < Utest

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

2

<

Sy

(2)

Failure Theories -

Ductile Materials
Distortion energy theory (von Mises-Hencky)
(1 2)2 + (1 3)2 + (2 3)2
2

<

Sy

2D case, 3 = 0

(1 12 + 2 ) < Sy =
2

Where is von Mises stress

Sy
n

Design equation

Design Process
Distortion energy theory

Maximum shear stress theory

Sy
max =
2n

Sy
n

Select material: consider environment, density, availability

Choose a safety factor

Size

Weight

Sy , Su

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

Design Process
Consequence of failure; human safety and economics
Type of manufacturing process
Codes and standards
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.

Design Process
Consequence of failure; human safety and economics
Type of manufacturing process
Codes and standards
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.

Design Process

Sy , Su

Select material, consider environment, density, availability

Choose a safety factor

Formulate the von Mises or maximum shear stress in terms of size.

Use appropriate failure theory to calculate the size.

Sy
n

Sy
max =
2n

Optimize for weight, size, or cost.

Failure Theories

Brittle Materials

One of the characteristics of a brittle material is that the ultimate strength

in compression is much larger than ultimate strength in tension.

Suc >> Sut

Mohrs circles for compression and tension tests.

Suc

Stress
state

Sut

Tension test
Compression test

Failure envelope

Failure Theories

Brittle Materials

Suc

Sut

Tension test
Compression test

Failure envelope

The component is safe if the state of stress falls inside the failure envelope.
1 > 3 and 2 = 0

Failure Theories

Brittle Materials
Modified Coulomb-Mohr theory
3 or 2

3 or 2

Sut
Safe

Suc

Sut
Safe

Sut

Safe

-Sut

II
-Sut

Safe

III

Suc

Cast iron data

Sut

Suc

Three design zones

Failure Theories

Brittle Materials
Modified Coulomb-Mohr theory
3
Zone I

Sut

1 > 0 , 2 > 0 and 1 > 2

1 =

Sut

Design equation

Sut

II
-Sut

III

Zone II

1 > 0 , 2 < 0 and 2 < Sut

1 =

Sut

Suc
Design equation

1 (
Zone III

1 > 0 , 2 < 0 and 2 > Sut

1
1

) 2 =
n
Suc
Sut
Suc
Design equation