Problem Sheet – 1: Theories of Failure and Factor of Safety

1. A hot-rolled steel has a yield strength of Syt = Syc = 750 N/mm2 and a true strain at fracture of εf =
0.55. Estimate the factor of safety for the following principal stress states:
(a) 490, 490, 0 N/mm2.
(b) 210, 490, 0 N/mm2.
(c) 490, 0, -210 N/mm2.
(d) 0, -210, -490 N/mm2.

2. The principal stress induced at a point in a machine component made of 50C4 steel (Syt = 460
N/mm2) are as follows: σ1 = 200 N/mm2, σ2 = 150 N/mm2, σ3 = 0. Calculate the factor of safety
following: (i). Maximum shear stress theory, (ii). Distortion energy theory.

3. The stresses induced at a critical point in a machine component made of 45C8 steel (Syt = 380
N/mm2) are as follows: σx = 100 N/mm2, σy = 40 N/mm2, τxy = 80 N/mm2. Calculate the factor of
safety following: (i). Maximum normal stress theory, (ii). Maximum shear stress theory and (iii).
Distortion energy theory.

4. A circular shaft is loaded by a torque of 5 kN-m. The material of the shaft has a yield point of
350 MPa. Find the required diameter of the shaft using –
(i). Maximum shear stress theory
(ii). Distortion energy theory
Consider a factor of safety of 2.5.

5. A shaft of 30 mm diameter is subjected to simultaneous action of an axial tensile load of 120 kN

and a torque of 300 N-m. The material is plain C-steel having tensile yield strength of 250 MPa.
Assuming the loads are static and steady, calculate the factor of safety for the shaft according to
maximum shear stress theory.

6. A shaft of circular cross-section is subjected to simultaneous action of a bending moment of 120

N-m and a torsional moment of 180 N-m. The material of the shaft is plain C-steel 30C8 having a
tensile yield strength (Syt) of 400 MPa. Assuming the loads are static and steady and a factor of
safety of 2.0, determine the shaft diameter according to:
(i) Maximum normal stress theory, (ii) Maximum shear stress theory and (iii). Distortion energy
theory.

Figure P1.7 Figure P1.8

7. A cantilever beam of rectangular cross-section is used to support a pulley such that the forces
acting on the beam are as shown in Figure P1.7. The beam is made of Cast Iron with Sut = 200
N/mm2 (MPa). The factor of safety can be considered as 2.5. The ratio of depth to width of the c/s is
2. Determine the dimensions of the beam using maximum normal stress theory.

8. The shaft of an overhang crank is subjected to force (P) of 1.0 kN as shown in Figure P1.8. The
shaft is made of Plain C-Steel (45C8) and the tensile yield strength is 380 N/mm2 (MPa). The factor
of safety can be considered as 2.0. Determine the diameter of the shaft using maximum shear stress
theory of failure.

9. A wall bracket with rectangular cross-section is shown in Figure P1.9. The depth of the cross-
section is twice the width. The force (P) acting on the bracket at 60o to the vertical has magnitude of
5 kN. The factor of safety can be taken as 3.5. Determine the dimensions of the cross-section of the
bracket using maximum normal stress theory of failure. Assume Sut = 200 N/mm2.
If the bracket were to be made of mild steel (Syt = 400 N/mm2), determine the dimensions of the
cross-section using - (i). Maximum shear stress theory, (ii). Distortion energy theory.

Figure P1.9

10. Compute the factors of safety at the critical location of the circular beam shown in Figure P1.10,
based upon the distortion energy theory. The beam is made of cold-drawn steel with Syt = 460
N/mm2 and is loaded simultaneously by axial tensile load, transverse bending load and twisting
moment. The magnitudes of the forces are as follows: F = 0.55 kN, P = 8.0 kN, and T = 30 N · m.

Figure P1.10