UNIT-I

CHAPTER-3
Design for Static Strength:
Static Strength, Static loads, Theories of
elastic failure – Maximum normal stress
theory, Maximum shear stress theory,
Distortion energy theory; Failure of
brittle materials, Failure of ductile
materials, Stress concentration factor. Veeresh R. K., Associate Professor
Robotics and AI Enginnering.
NMAM Institute of Technology
Nitte, Karkala, India
27-07-2023 1
Factor of safety Chapter 2: Design for Static Strength
Factory of safety is the ratio of strength of a material to the design stress. The strength could
be yield strength or ultimate strength.
Yieldstress Ultimatestress
Factory of safety (n) n= n=
Designstress Designstress

For ductile materials the allowable For brittle materials the relationship is
stress σ is obtained by the following
 ut …….Brittle Material
relationship =
ny
 yt
= ……….Ductile Material
ny
Where  yt and  ut are the yield strength and the ultimate tensile strength of a materials.
The selection of an appropriate value of factor of safety is based primarily on the following factors

3. Uncertainties in relating the applied loads to

1. Degree of uncertainty about the material strength.
materials strength
2. Degree of uncertainty about the material strength
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4. Human safety and economy
Theories of failure

When material is subjected to one type of stress i.e axial or bending or

torsional then it is very easy to predict when the failure is likely to occur.
However if the material is subjected to complex stress system then it is difficult
to predict failure of the material strength away.

In order to predict the failure of the material under combined stresses the
following theories of failure have been formulated

1. Maximum normal stress theory or Rankine theory

2. Maximum shear stress theory or guests theory or tresca theory
3. Maximum distortion energy theory or hencky’s-mises theory

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1. Maximum principal stress theory

The theory states that the failure of the mechanical component subjected to bi-axial or tri-
axial stresses occurs when the maximum principal stress reaches the yield or ultimate
strength of the material.

If σ1, σ2, σ3 are principal stresses

If σ1>σ2>σ3 then the design equation is σ1=σy or σ1=σut

y
1 = where n=factor of safety and σy= yield point stress
n
 + y   x − y 
2

e =  x  +   +  xy
2
……….. 2.8(a)/21
 2   2  Therefore
y y
1 = 1 = = e where, σe =allowable stress ( x +  y ) ( x −  y )
2

n n e = + +  2 xy
2 2

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2. Maximum shear stress theory (tresca theory)
According to this theory yielding occur when the maximum shear stress
exceeds the shear stress at the tensile yield point (σe/2).

The condition of failure for bi-axial loading is

  x − y 
2

e = 2  +  xy = ( 1 −  2 ) …….(2.8c)/22
2

 2 
y
The design criteria Allowable stress e 
2n
Consider maximum shear stress theory condition

a  e b  e a −b  e

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3. Distortion energy theory or Shear Energy Theory or Henckey-von Mises Theory
Yielding would occur when the distortion energy exceeds the value of distortion energy at the yield point in a
simple tension test.
F F
Consider the element subjected to a tensile force F
σ /3 σ /3
Then consider small element as above
Failure due to strain energy σ
σ
σ /3 σ /3 σ /3

Therefore consider the strain energy producing a σ /3

σ /3
change of shape Change in volume Here due to compressive tensile they
(hydrostatic force) may undergoes a distortion but no
( 1 −  2 ) 2 + ( 2 −  3 ) 2 + ( 3 −  1 ) 2 change in volume
The failure equation is e =
2
When a bi-axial stress exists the above equation reduces  e =  x 2 +  y 2 −  x y + 3 2 xy …..(2.11a)
to
 e =  12 +  2 2 −  1 2 ………..(2.8d)/22  ys
If σx and τxy are present then e =
ny
If σx and σy are known then the above
 e =  x 2 + 3 2 xy
equation reduces to
27-07-2023 6
1. The load on a bolt consists of an axial force of 8kN and the transverse shear of 4.5kN.
Determine standard size of bolt. Assume factor of safety of 3.
F 8 X 103 10.186 X 103
x = =
A  2
=
d2
y = 0
d
4
Fs 4.5 X 103 5.73 X 103
 xy = = =
A  d 2
d 2
4

x + y    x − y  2
2

 1,2 =     +  xy ---------------1.8 c&d

 2   2 
2 2
 10.186 X 103 − 0   10.186 X 103 − 0   5.73 X 103 
 1,2 = 2   2  + 2 
 2 d   2 d   d 

12759.26 −2569.6
1 = and 2 =
d2 d2
Assuming bolt material is medium carbon of 0.3% of carbon σy=316 MPa (from Table 9.2/136) and Assume FOS n=3
•Maximum normal stress theory

 y ------------------------- 2.8 (a) 12759.26 316

=
 e = 1 = d 2
2 d=8.98=9mm
2
•Maximum shear stress theory
y 12759.26 −2569.6 316
 e = 1 −  2 = --------------2.8 (c) − = d=17mm
2n d 2
d 2
2X 3

•Distortion Energy theory

y  12759.26   −2569.6   12759.26 −2569.6  316

2 2
 e =  1 +  2 −  1 2 =
 +  − =
2 2
------------ 2.8 (d)
n  X
 d   d   d  3
2 2 2 2
d

11.688 X 103 316

2
= d=10.53mm
d 3

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2. A plate of 45C8 steel (σyt=353MPa) is subjected to the following stresses. σx =150N/mm2,
σy =100N/mm2, τxy=50N/mm2
Find the factor of safety by
i. Maximum Principal Stress Theory
ii. Maximum Shear Stress Theory

i. Maximum Principal Stress Theory

 + y   x − y 
2

e =  x  +   +  xy
2

 2   2  ……….. 2.8(a)/21

353  150 + 100   150 − 100 

2
 yt
x + y   x − y 
2

e = =  +   +  2 =  +   + 50 2
n=1.95
n  2   2 
xy
n  2   2 

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ii. Maximum Shear Stress Theory

  x − y 
2

e = 2   +  2
xy
…….(2.8c)/22
 2 

 yt   x − y 
2
 150 − 100 
2
353
e = =2   +  xy
2
=2   + 50
2
n=1.58
2n  2  2n  2 

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3. A bolt is subjected to a direct tensile load of 30kN and a transverse shear force of 15kN.
The material of the bolt has a normal stress of 350MPa at yield and FoS of 2.5. Compute the
root diameter of the bolt according to
i. Maximum Principal Stress Theory
ii. Maximum Shear Stress Theory
iii. Distortion Energy Theory
F 30 X 103 38.2 X 103 Fs 15 X 103 19.1X 103
x = = = y = 0  xy = =

=
A  d 2
d2 A d 2
d2
4 4
 x + y    x + y 
2

 1,2 =     +  2
xy
 2   2 
2 2
 38.2 X 10 + 0   38.2 X 10 + 0   15 X 10 
3 3 3
 1,2 =   2  + 2 
 2   2 d   d 
43386 −5186
1 = 2 =
27-07-2023
d 2 d2 11
•Maximum normal stress theory  =  =  y
e 1
2 --------- 2.8 (a)
43386 350
2
= d=16mm
d 2
y
•Maximum shear stress theory  e = 1 −  2 = ---2.8 (c)
2n
43386 −5186 350
2
− 2
= d=26.4mm
d d 2 X 2.5
y
•Distortion Energy theory  e =  +  −  1 2 =
2
1
2
2
------ 2.8 (d)
n
 43386   −5186   43386 −5186  350
2 2

 2  + 2  − 2 X =
 d   d   d d  2.5
2

46.17 X 103
2
= 140 d=18.2mm
d
27-07-2023 12
 STRESS CONCENTRATION
Stress concentration is the accumulation of stress in a body due to sudden
change in its geometry.
When there is a sudden change in the geometry of the body due to cracks
sharp corners, holes and decrease in the cross section area, then there is an
increase in the localised stress near these cracks, sharp corners, holes, and
decreased cross section area. The body tends to fail from these places
where the stress concentration is more. So to prevent a body from getting
failed, the stress concentration should be avoided or reduced.
It is also called as stress raisers or stress risers.
• The stress concentration factor is defined as the ratio of highest
stress in the body to the reference stress. It is denoted by Kt.

smax
Kt or
snom

27-07-2023 13
The maximum Stresses at the discontinuity

F
i) For a Direct Stress: Fig 2.1 (a) smax K t .............2.1( a) / 20
A

ii) For a Bending Stress: Fig 2.1 (b) M

smax K t .............2.1(b) / 20
Z

T
t max K t .............2.1(c) / 20
iii) For a Torsion: Fig 2.1 (c) Z

27-07-2023 14
 Methods of reducing stress concentration
A number of methods are available to reduce stress concentration in machine
parts. Some of them are as follows:
1. By providing small holes near big hole. If we have an object, that has an
internal hole within it. Then the intensity of stress near that hole is more. To
avoid this, some smaller holes are created near that hole. This distributes the
stress more uniformly than it was before.

27-07-2023 15
2. Provide a fillet radius so that the cross-section may change gradually.

3. Sometimes an elliptical fillet is also used.

27-07-2023 16
4. If a notch is unavoidable it is better to provide a number of small notches rather than a long
one. This reduces the stress concentration to a large extent.

5. If a projection is unavoidable from design considerations it is preferable to provide a narrow notch than a wide
notch.
6. Stress relieving groove are sometimes provided. These are demonstrated in Figure

27-07-2023 17
1. A flat bar as shown in Fig Q (1) is subjected to a tensile load of 100kN. Determine the
thickness of flat for a maximum stress of 210MPa.
To find the required thickness of the given plate, select two sections one across the notch (A-A) and other across hole (B-B).
B 200 r 5
= = 1.052 = = 0.026
b 190 b 190
We get kt=2.75 A B

 max = kt nom

F
 max = kt
A A B

100 X 103
210 = 2.75 Consider the section A-A
190 Xt From DDHB Fig 2.14/37

t=6.89mm
27-07-2023 18
Consider the section B-B From DDHB Fig 2.12/36
a 10
= = 0.05
B 200
We get kt=2.88
 max = kt nom
F
 max = kt
A
100 X 103
210 = 2.88
(200 − 10) Xt

t=7.22mm
27-07-2023 19
2. A flat bar as shown in Fig. Q(2) carries an axial load of P=25KN determine the maximum
stress in the member. If the is made of C40 steel, What is the value of FOS? If it C30 steel
and desired FOS is 2.5. What is the value of thickness t for the bar.

Consider section A-A From DDHB Fig 2.16/38

r 8 B 100
= = 0.16 = =2 We get kt=1.96
b 50 b 50
 max = kt nom  max = kt
F
25 X 103 A
 max = 1.96 X
27-07-2023  max = 98MPa 20
50 X 10
 From Table 1.8/463, for C40 steel σy=324MPa  y 324
n= = = 3.31
 max 98

From Table 1.8/463, for C30 steel σy=294MPa, and given FOS (n)=2.5

y 2.5 =
294
 max = 117.6MPa
n=  max
 max
F
 max = kt nom  max = kt
A

3
25 X 10
117.6 = 1.96 X t=8.33mm
50 Xt
27-07-2023 21
3. Find the diameter of the hole shown in Fig Q(3), if the stress concentration factor at the
hole is to be same as the fillet

i) Consider the section A-A

From DDHB Fig 2.16/38

r 5
= = 0.1
b 50

B 85
= = 1.7
b 50
We get Kt=2.15

27-07-2023 22
ii) Consider the section B-B

B=85 a= diameter of hole

From DDHB Fig 2.12/36

a
= 0.52
B
At Kt=2.15
Since stress concentration factor is
same near fillet and hole hence
Kt=2.15

a=0.52X85=44.2mm,
Diameter of the hole
27-07-2023 23
4. An infinite plate with an elliptical cutout having major axis 50mm and minor of 25mm is
subjected to tensile load F. determine the stress concentration factor when,
1. The load is perpendicular to major axis.
2. The load is parallel to the major axis.

ii) The load is parallel to major

i)The load is perpendicular Axis
to major Axis
From DDHB Fig 2.11/36
From DDHB Fig 2.11/36 50
= 12.5 c = = 25
25
b=
c=
25
= 12.5
50 2
2 b= = 25 2
2 We get Kt=2
c 12.5
= 27-07-2023
= 0.5 We get Kt=6.5 24
b 25
5. Find the value of the maximum stress induced on the fillet. If the stress concentration
factor for the filleted flat box shown in Fig. Q5. Having B/b ratio of 1.2, also determine the
factor of safety if the flat box is made of steel having a yield stress of 640MPa. Thickness of
the box is 25mm

From fig we can write B-b=2r=2X10=20mm 1.2b-b=20

b=100mm, B=120mm From DDHB Fig 2.16/32

r 10 B 120
= = 0.1 = = 1.2 We get Kt=1.8
b 100 b 100

 max = kt nom  max = kt

F
A
120 X 103 y 640
 max = 1.8  max = 86.4MPa n= = = 7.4
100 X 25  max 86.4
27-07-2023 25
6. A grooved shaft in the Fig. Q6, is to transmit 5kW at 120rpm. Determine the diameter of
the shaft at the groove if it is made of C15 steel. Factor of safety is 2

From DDHB Fig 2.22/41

r 0.1d D 1.4d
= = 0.1 = = 1.4
d d d d
We get Kt=1.58

 max = kt nom  max

T
= kt r
27-07-2023
J 26
 From Table1.8/418 for C15 steel, take σy=235MPa

According to maximum shear stress theory

y 235
 max =  max = = 58.75MPa
2n 2X 2
6
9.55 X 10 XP DDHB 3.3(a)/50
Torque T =
n T=
6
9.55 X 10 X 5
= 397.916 X 10 N − mm
3

120
6
397.916 X 10
58.75 = 1.58 X
 d3 d=37.91mm
27-07-2023
16 27
7. Determine the maximum stress induced in the semi circular grooved shaft shown in Fig.
Q7, if it is subjected to
(i) An axial load of 40kN.
(ii)A bending moment of 400Nm
(iii)A twisting moment 500Nm.
Take the stress concentration in account.

i) An axial load of 40kN is applied

From DDHB Fig 2.18/39
r 5 D 60
= = 0.1 = = 1.2 We get kt=2.17
d 50 d 50
 max = kt nom  max = kt
F
A
40 X 103
 max = 2.17
 502 σmax=44.20MPa
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4 28
ii) A bending moment of 400N-m or
400X103 N-mm is applied
From DDHB Fig 2.20/40
r 5 D 60
= = 0.1 = = 1.2
d 50 d 50
We get kt=1.89
M  = 1.89 X 400 X 103
 max = kt max
 503
Z 32

σmax=61.60MPa
27-07-2023 29
iii) A Twisting moment of 500N-m or 500X103 N-mm
is applied

From DDHB Fig 2.22/41

r 5 D 60
= = 0.1 = = 1.2
d 50 d 50
We get kt=1.52
 max = kt nom  max
T
= kt r
J
3
500 X 10
 max = 1.52 X τmax=30.96MPa
 50 3
27-07-2023 16 30
8. A shaft simply supported at ends carries a load W as shown in Fig 8. Determine the
magnitude of load so that where the stresses due to bending moment will exceed 250 N/mm2
[radius at groove=1.7mm, at filet =1.0mm]
i) At midpoint of shaft M =
wl w480
M = = 120w
4 4
kt=1, there is no sudden change in the cross section
M 120 w
 max = kt  max = 1X
 38 3
= 0.02227 w
Z 32
ii) At Groove From DDHB Fig 2.20/40
wl 160w r 1.7 D 38
M = = = 80w = = 0.05 = = 1.117
2 2 d 34 d 34
80 w
 max = 2.3 X = 0.047 w
We get Kt=2.3  34 3
32
27-07-2023 31
 wl 160w
iii) At Filet M = = = 80w
2 2
From DDHB Fig 2.25/41

r 1 D 38
= = 0.04 = = 1.52
d 25 d 25
We get Kt=2.2
80 w
 max = 2.2 X = 0.114 w
 253
32

Maximum stress at fillet

0.11473w=250 W=2178.9N
27-07-2023 32
9. A stepped shaft shown in Fig Q (9). is subjected to a transverse load. The shaft is made of
steel with tensile strength of 400MPa. Determine the diameter ‘d’ of the shaft based on the
FOS=2

Take Moment about A RBX500=8X103X350 RB=5600N

Also RA+RB=8000 RA=8000-5600=2400N

i) Consider right fillet

Since the possibility of failure is at fillet

The bending moment

Mb=RbX25=5600X25=140X103 N-mm
27-07-2023 33
r d D 2 d We get Kt=1.44
= = 0.2 = =2 From DDHB Fig 2.25 /43
d 5d d d

 max = kt nom

M
 max = kt
Z
u 200
FOS (n) =  max = = 100MPa
 max 2

3
140 X 10 d=21.73
200 = 1.5
 d3
32
27-07-2023
mm 34
•Consider left fillet Since the possibility of failure is at fillet
The bending moment Mb=RaX250=2400X250=600X103 N-mm
From DDHB Fig 2.16/38

r 1 D 2d
= = 0.1 = =2
d 10 d d
We get Kt=1.74
M
 max = kt nom  max = kt
Z
600 X 103
200 = 1.74
 d3
32
d=37.60mm
27-07-2023 35
 Review Questions

1. Discuss the following theories of failure

i. Maximum shear stress theory.
ii. Distortion energy theory.
2. Explain the following theories of failure.
i. Maximum normal stress theory.
ii. Maximum shear stress theory.
iii. Distortion energy theory.
3. Explain the following.
i. Factor of safety.
ii. Stress concentration factor.

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 THANK YOU
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