Philippine Society of Agricultural & Biosystems Engineers in Collaboration with the

Institute of Agricultural and Biosystems Engineering

College of Engineering and Agro-industrial Technology - UP Los Baños

Online ABE Review Class 2021

MACHINE DESIGN
(Theories of Failure)

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
FAILURE . . .
A designer may mean that the part . . .

➢Has separated into two or more pieces (fracture)

➢Has become permanently distorted, thus ruining
its geometry (yielding)
➢Has had its reliability downgraded
➢Has had its function compromised . . .

Budynas-Nisbett, 2008.

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
FAILURE . . .
FOCUS:
➢Has separated into two or more pieces
(fracture)

➢Has become permanently distorted, thus

ruining its geometry (yielding)
Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
STATIC LOAD
▪ a stationary force or couple applied to a
member, i.e.,

it is unchanging in:
• magnitude
• point or points of application
• direction
Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
THEORIES OF FAILURE for
Static Loading
▪formulated and tested hypotheses on how
materials will fail (yield or fracture) due to static
loading

▪unfortunately, there is no universal theory of

failure for the general case of material properties
and stress state
Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
THEORIES OF FAILURE for Static Loading
- categorized according to structural metal behavior, i.e. ductile or
Ductile Materials
•exhibit true strain at
fracture that is greater than
or equal to 5% (εf ≥ 0.05)
•have an identifiable yield
strength that is often the
same in tension as in
compression (Syt = Syc = Sy)
Budynas-Nisbett, 2008
brittle.
Brittle Materials
•exhibit true strain at fracture that is less than
5% (εf < 0.05)
•do not exhibit an identifiable yield strength,
and are typically classified by ultimate tensile
(Sut) and ultimate compressive (Suc) strengths,
where Suc is given as a positive quantity
•in general, Suc is greater in magnitude than
Sut.

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
But . . .
there are instances when a ductile
material may fail by fracture
When a ductile material is subjected to:
o Cyclic loading
o Long term static loading at elevated temperature
o Impact loading
o Work hardening
o Severe quenching

NPTEL, 2010

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Commonly Used Failure Theories
for Static Loading
DUCTILE MATERIALS BRITTLE MATERIALS
(YIELD CRITERIA) (FRACTURE CRITERIA)
1. Maximum Shear 1. Maximum Normal Stress
Stress (MSS) (MNS)
2. Distortion Energy 2. Brittle-Coulomb-Mohr
(DE) (BCM)
3. Ductile Coulomb- 3. Mohr modifications
Mohr (DCM) (MM1, MM2)
Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
FAILURE THEORY SELECTION FLOWCHART

© Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Ductile Materials
Maximum Shear Stress Theory (MSS)
Mohr’s Circle of the
Tensile Test Specimen

The yield strength

in shear is given by:

S sy = 0.5S y
© UT Martin SOE, 2007

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Ductile Materials
Maximum Shear Stress Theory (MSS)
Mohr’s Circle of the
3D Stress State in Part

1 −  2 2 −3
1 2 = 2 3 =
2 2

1 −  3
 1 3 =  max =
2
© UT Martin SOE, 2007

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Ductile Materials
Maximum Shear Stress Theory (MSS)

If max = S sy = 0.5S y

1 −  3
and  1 3 =  max =
2
then,
1 −  3 = S y
Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Ductile Materials
Maximum Shear Stress Theory (MSS)
For a general state of stress (3D), yielding occurs when
1 −  3 Sy
 max =  or 1 −  3  S y
2 2
*”yielding begins whenever the largest of these three principal shear
stresses equals or exceeds to half the tensile yield strength obtained by
the simple test” Budynas-Nisbett, 2008

Design Equations:

1 −  3 Sy Sy
 max = = or 1 −  3 =
2 2nd nd

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Ductile Materials
Maximum Shear Stress Theory (MSS)

Mother Equation

1 −  3 = S y
© Budynas-Nisbett, 2008

For common plane stress (2D) problems, where one of the principal stresses is zero and
the other two (σ1 and σ2/3 ; σ1 ≥ σ2/3) are determined, the mother equation shall be
modified according to three cases which may be encountered.

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Ductile Materials
Distortion Energy Theory (DE)

For common plane stress

(2D) problems, where one
of the principal stresses is
zero and the other two
are determined, yielding
occurs when

Budynas-Nisbett, 2008

 ' = ( 2 x −  x y +  2 y + 3 )
1
2
xy 2  Sy

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Ductile Materials
Distortion Energy Theory (DE)
Pure Shear Condition  max =  1 = −  3 = S sy
1
 ( 1 −  2 )2 + ( 2 −  3 )2 + ( 3 −  1 ) 2 2
 '=    Sy
 2 

S sy = 0.577 S y
© UT Martin SOE, 2007 Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Ductile Materials
Maximum Shear Stress vs.
Distortion Energy

Comparison to
Experimental
Data

Experimental data
superposed on
failure theories.

© Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Brittle Materials
Maximum Normal Stress Theory (MNS)
▪Predicts that “failure occurs whenever one of the three principal stresses
equals or exceeds the strength”
▪Also called the Rankine Theory
Failure occurs when:

 1  S ut or  3  − S uc
where Sut = ultimate strength in tension
Suc = ultimate strength in compression
Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Brittle Materials
Maximum Normal Stress Theory (MNS)
Design Equations for plane stress, with σ1 ≥ σ2/3:

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2 Budynas-Nisbett, 2008
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Brittle Materials
Brittle Coulomb Mohr Theory (BCM)
Predicts that failure occurs when:

1 3
− 1
S ut S uc

where Sut = ultimate strength in tension

Suc = ultimate strength in compression
Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Brittle Materials
Brittle Coulomb Mohr Theory (BCM)
Design Equations for plane stress, with σ1 ≥ σ2/3:

Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Brittle Materials
Modified Mohr I Theory (MM1)
Design Equations for plane stress, with σ1 ≥ σ2/3:

Budynas-
Nisbett,
2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
 Static Load Failure Theories for Brittle Materials
Modified Mohr 2 Theory (MM2)
Design Equations for plane stress, with σ1 ≥ σ2/3:

Budynas-
Nisbett,
2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering
Static Load Failure Theories for Brittle Materials
Comparison to Experimental Data

Biaxial fracture
data of gray
cast iron
compared with
various failure
criteria.

© Budynas-Nisbett, 2008

Ralph Kristoffer B. Gallegos, PhD

Associate Professor 2
Agribiosystems Machinery and Power Engineering Division
Institute of Agricultural and Biosystems Engineering