ME 304 Introduction to Machine Design

Chapter 5: Failures Resulting from Static Loading

Failure Examples:
Knife:

Gear:

Fan blade:

Broken fan blade:

• It’s the second time in less
than two years that a fan
blade of the same engine
type has broken on a
Southwest aircraft
• As the engine gets older,
the blades of the fan
(scimitar shaped, hollow,
and made of a titanium
alloy) may become more
Race car transmission input shaft: brittle and begin to crack
 Race car transmission shaft:

Marking – Indentation – stress riser: Fatigue – Overload Torsion

Stress Concentrations
Localized increase of stress near discontinuities
Kt is Theoretical (Geometric) Stress Concentration Factor
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 Theoretical Stress Concentration Factor

See Appendix A–15 and A–16 for common examples

Note the trend for higher Kt at sharper discontinuity radius, and at greater
disruption

Fig. A–15–1 Fig. A–15–9

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Stress Concentration for Static and Ductile Conditions

With static loads and ductile materials

◦ Stress Concentrations can lead to localized regions that exceed yield
ifductile
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strength– resulting in localized plastic deformation
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◦ This helps reduce chance of static failure, but should still be investigated. Inauw
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Stress concentration must be included for dynamic loading (See Ch. 6) – FATIGUE ammonia
Stress concentration must be included for brittle materials
 applied Strength
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Static Strength:
Can be necessary to design using published strength values
Experimental test data is better, especially when failure is very costly (in time,
expense, or life)

Need for Static Failure Theories

Uniaxial stress element

(e.g. tension test)
Strength S
n= =
Stress
Multi-axial stress element
◦ How to compare stress state to single strength?

Failure theories propose appropriate means of comparing

multi-axial stress states to uniaxial strength
Usually based on some hypothesis of what aspect of the
stress state is critical

Selection of Failure Criteria in Flowchart Form

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Ductile Failure Theories:

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1) Maximum Shear Stress Theory (MSS): Tresca

Theory: Yielding begins when the maximum shear stress in a stress element
exceeds the maximum shear stress in a tension test specimen that yields.
For a tension test specimen, the maximum shear stress is σ 1 /2.
At yielding, when σ1 = Sy, the maximum shear stress is Sy /2 .
Could restate the theory as follows:
◦ Theory: Yielding begins when the maximum shear stress in a stress
element exceeds Sy/2.

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Fracture line at ~45°

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 Ordering the principal stresses such that s1 ≥ s2 ≥ s3,

Incorporating a factor of safety n

Solving for factor of safety

Sy / 2 case
n=
max

Of S

O OBEsq

OBEsq OsE Sy
Comparison to experimental data:
2) Distortion Energy Theory (DE):
Also known as:
◦ Von Mises
◦ Octahedral Shear Stress
◦ Shear Energy
◦ Von Mises – Hencky
Originated from observation that ductile materials stressed hydrostatically
(equal principal stresses) exhibited yield strengths greatly in excess of expected
values.
Theorizes that if strain energy is divided into hydrostatic volume changing
energy and angular distortion energy, the yielding is primarily affected by the
angular distortion energy.

Hydrostatic
stress
feilding caused
by distortion
Theory: Yielding occurs when the distortion strain energy per unit volume
reaches the distortion strain energy per unit volume for yield in simple tension
or compression of the same material.
von Mises stress:

Distortion Energy failure theory simply compares von Mises stress to yield
strength.

Introducing a design factor,

 DE Theory compares well with Ductile Experimental Data!
Note that each data point represents a 50% reliability
σ’=Sy

Shear Strength Predictions:

For DE theory and pure shear, we obtain this failure criteria

Compared to MSS:
 3) Mohr Theory:
Some materials have compressive strengths different from tensile strengths
Mohr theory is based on three simple tests: tension, compression, and shear
Plotting Mohr’s circle for each mode, bounding curve defines failure envelope

Coulomb-Mohr Theory:
Curved failure curve is difficult to determine analytically
Coulomb-Mohr theory simplifies to linear failure envelope using only tension
and compression tests (dashed circles)

Tension

compassion

Incorporating factor of safety

safety
Feild factor of
strength

Similar to MSS theory, except with different strengths for compression and
tension
Brittle Failure Theories:
 soars to use
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1) Maximum Normal Stress Theory (MNS): for historical purpose
• Theory: Failure occurs when the maximum principal stress in a stress element
exceeds the strength.
• Predicts failure when

Not recommended for use

Included for historical comparison

Experimental data indicates some differences in failure for brittle materials.

Failure criteria is generally ultimate fracture rather than yielding
Compressive strengths are usually larger than tensile strengths

2) Brittle Coulomb-Mohr Theory (BCM):

Ultimate tensile strength
Same Ductile Coulomb-Mohr except uses _________
𝜎1 𝜎3 1
− =
𝑆𝑢𝑡 𝑆𝑢𝑐 𝑛
 Coulomb-Mohr is conservative in 4th quadrant
Modified Mohr criteria adjusts to better fit the data in the 4th quadrant

3) Modified-Mohr Theory (MM):

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