Machine Design 1

• Theories of Failure

At the end of the topic, the student is expected to:

1. Identify the different types and theories of failures.
2. Apply the theories of failure in the design of identified
machine members subjected to different types of
loading.
3. Show the effects of theories of failure in the design of
of machine members.
 Input
Two types of Mechanical Failures in Materials:
* Yielding
* Fracture
• Yielding or Permanent deformation -
pronounced sliding along a certain angular
planes in the material.
• Fracture - is a separation failure that
occurs on a cross section normal to the
tension stress.
 Related Terminologies
 Combined Stresses can be a combination of the following:
1. Normal Stresses which is either in tension or
compression, computed from F/A, ∞F/A,Mc/I,etc.
2.Shear Stresses, computed from F/A, Tc/J, etc.
 Induced Stresses are those tensile, compressive and shear
stresses induced within a body by application of external
forces and/or torques only to the body.
 Principal Stresses are called to a combined stresses existing
perpendicular to a plane in which there is no shear stress
on those planes. Normal Stresses are principal stresses.
 Related Terminologies
 Maximum Shear Stress – is that shear stress
existing on a plane perpendicular to which no
normal stress exists.
 Uni-axial state – is called to the state of stress
if two principal stresses are zero.
 Bia-axial state – is called to the state of stress
if one principal stress is zero.
 Tri-axial state - exists if all principal stresses
have finite values.
 Concepts on Induced Stresses
• Direct Tensile Loading or Uni-axial Loading
B BC Sn
F F
AB St
C A BC Sp

Maximum Shear Stress induced :

Ss = St /2
Maximum Normal Stress on a body:
Sn = S t
 Concepts on Induced Stresses
• Bi-axial Loading
F2

F1 F1

F2

Maximum Shear Stress induced :

Ss = [S1 - S2 ] /2
Maximum Normal Stress on a body:
Sn = S1 if S1 > S2
 Concepts on Induced Stresses
• Tri-axial Loading
F2 F3

F1 F1

F3
F2
Maximum Shear Stress:
Ss = [ S1 – S2]/2 or [ S1 – S3]/2 or [ S2 – S3]/2
whichever is the largest
Maximum Normal Stress: Sn = S1 ; S1 is the largest
 Other Induced Stresses
• Combined Shear and Tension
Maximum Shear Stress:
Ss max = ½ St 2 + 4Ss2

= (St /2 )2 + Ss2
Maximum Normal Stress:
Sn max = St /2 + ½ St 2 + 4Ss2

= St /2 + (St /2 )2 + Ss2

• Combined Biaxial Loading and Shear

 Theories of Failures
• Maximum Normal Stress Theory
(also called the Rankine Theory)
“states, that inelastic action occurs when
the maximum normal stress equal the tensile
yield stress of the material as determined in
a simple tension test”
– The stresses which cause failure in a machine
member are the principal stresses, not the direct
stresses, therefore, these combined stresses are
of extreme importance to the machine designers.
 Maximum Normal Stress Theory
• Pure tension or compression or for biaxial or triaxial
loading without any direct shear stress

Where : δ = maximum allowable stress

= tensile yield stress
• Combination of one direct tensile or compressive
stress and one direct shear stress
 Maximum Normal Stress Theory
• Pure tension or compression or for biaxial or
triaxial loading w/o any direct shear stress
If δ is equal or less than Sy, failure will
not occur. N = δ / Sd where Sd = design
stress
Maximum Shear Stress Theory
•Direct Tension or Compression without any direct shear

If τ is equal or less than ½ Sy and if Ssd is

½ Sd, failure will not occur.
N = τ / Ssd = Sy /Sd
 Maximum Normal Stress Theory
• Combined biaxial loading and one direct shear stress

This theory is particularly applicable to brittle materials such as

cast iron, hard steels and glass. The predictions of this theory
don’t agree well with experimental data, particularly for biaxial
loading of opposite signs
 Maximum Shear Stress Theory
• Also called Coulombs’ Law & the Guest-
Hancock Theory,
“ states that inelastic action occurs when
the maximum shear stress equals one half
the tensile yield stress of the material as
determined in a simple tension test”
This theory is applicable to ductile
materials such as mild steels, brasses and
most aluminum alloys
 Maximum Shear Stress Theory
• Direct Tension or Compression without any direct shear.

• Biaxial loading without any direct shear.

and

• Tri-axial loading with no direct shear stress

and or or

Note: whichever is the largest

 Maximum Strain Theory
• Also called Saint Venant’s Theory,
“ states that inelastic action occurs when
the maximum unit strain at the tensile
point for the material as determined in a
pure tensile test.”

This theory of failure is practically applicable to

thick cylinders and to brittle materials( Ref. p452 MD
by D & V where theory is applied by Clavarino’s
Equations for Closed Cylinders)
 SYNTHESIS

IF YOU ARE NOW READY, PLEASE PROCEED TO THE

ASSESTMENT TASK AT THE NEXT PAGE . . . . . . . .