UNIT-3

CHAPTER-8
Automobile Engineering
TH

THEORIES OF FAILURE

PREPARED BY : ER. RAVI KUMAR

(ASSISTANT PROFESSOR )

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 Introduction

Automobile Engineering

• Failure – A part is permanently distorted and will not function properly..

• Failure of truck driveshaft spline due to corrosion fatigue.

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 Failure Examples

• Failure of an overhead-pulley retaining bolt on a weightlifting machine.

• A manufacturing error caused a gap that forced the bolt to take the entire moment load.

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 Maximum Normal (Principal) Stress Theory
• Theory: Yielding begins when the maximum principal stress in a stress element
exceeds the yield strength.
• For any stress element, use Mohr’s circle to find the principal stresses.
• Compare the largest principal stress to the yield strength.
• Often the first theory to be proposed by engineering students.
• Is it a good theory?

• Experimental data shows the theory is unsafe in the 4th quadrant.

• This theory is not safe to use for ductile materials.

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 Maximum Shear Stress Theory (MSS)

• Theory: Yielding begins when the maximum shear stress in a stress element exceeds the
maximum shear stress in a tension test specimen of the same material when that specimen begins
to yield.
• For a tension test specimen, the maximum shear stress is s1 /2.
• At yielding, when s1 = 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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 Maximum Shear Stress Theory (MSS)

• For any stress element, use Mohr’s circle to find the maximum shear
stress. Compare the maximum shear stress to Sy/2.
• Ordering the principal stresses such that s1 ≥ s2 ≥ s3,

• Incorporating a design factor n

• Or solving for factor of safety

Sy / 2
n
 max
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 • Plot three cases on
principal stress axes
• Case 1: sA ≥ sB ≥ 0
• sA ≥ S y
• Case 2: sA ≥ 0 ≥ sB
• s A − s B ≥ Sy
• Case 3: 0 ≥ sA ≥ sB
• sB ≤ −Sy
• Other lines are
symmetric cases
• Inside envelope is
predicted safe zone

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 Distortion Energy (DE) Failure Theory
• Also known as:
• Octahedral Shear Stress
• Shear Energy
• Von Mises
• 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 distortion energy.

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 • Hydrostatic stress is average of principal stresses

• Strain energy per unit volume,

• Substituting Eq. (3–19) for principal strains into strain energy equation,

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 Selection of Failure Criteria
• First determine ductile vs. brittle
• For ductile
• MSS is conservative, often used for design where higher reliability is
desired
• DE is typical, often used for analysis where agreement with
experimental data is desired
• If tensile and compressive strengths differ, use Ductile Coulomb-
Mohr
• For brittle
• Mohr theory is best, but difficult to use
• Brittle Coulomb-Mohr is very conservative in 4th quadrant
• Modified Mohr is still slightly conservative in 4th quadrant, but closer
to typical

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 FREQUENTLY ASKED QUESTIONS:
Q1. What is maxi. Principal stress theory?
Q2. Why the maxi. Shear stress theory is used for ductile material.
Automobile Engineering
Q3. What do you mean by factor of safety?
Q4. Which theory of failure is used for brittle material.
Q5. What do you mean by notch sensitivity?

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 List of References:

1. D.H Shames, Introduction to Solid Mechanics, Prentice Hall Inc.

2. GH Ryder, Strength of Materials – ( MacMillan)
3. Crandall &Dahi, An introduction to MechanicsEngineering
Automobile of Solids – ( McGraw Hill )
4. Gere, Mechanics of Materials (Cengage Learning)
5. Hibler, Mechanics of Materials (Pearson Education)

Reference Links:
http://www.cs.cmu.edu/~rapidproto/mechanisms/
http://www.softintegration.com/chhtml/toolkit/mechanism/fourbar/
fourbar_ani.html

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 Thank-you for listening
Automobile Engineering

Any Questions Please ????????????

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