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Static Failure Theories

Design of Machine Elements

Dr Moudar Zgoul, @zgoul_ju, 2011 [extracted from different sources]

Introduction
Strength is a property or characteristic of a mechanical element. This property results from the material identity, the treatment and processing incidental to creating its geometry, and the loading, and it is at the controlling or critical location. strengths of the mass-produced parts will all be somewhat different from the others in the collection or ensemble because of variations in dimensions, machining, forming, and composition.

Introduction
A static load is a stationary force or couple applied to a member. To be stationary, the force or couple must be unchanging in magnitude, point or points of application, and direction. A static load can produce axial tension or compression, a shear load, a bending load, a torsional load, or any combination of these. To be considered static, the load cannot change in any manner.

Introduction
Failure can mean a part has separated into two or more pieces; has become permanently distorted, thus ruining its geometry; has had its reliability downgraded; or has had its function compromised, whatever the reason. Mechanical components fail, simply because the applied stresses exceeds the materials strength. Under any load combination, there is always a combination of normal and shearing stresses in the material.

Ductile and Brittle Materials


A ductile material deforms significantly before fracturing. Ductility is measured by % elongation at the fracture point. Materials with 5% or more elongation are considered ductile.

Ductile and Brittle Materials


Brittle material yields very little before fracturing, the yield strength is approximately the same as the ultimate strength in tension. The ultimate strength in compression is much larger than the ultimate strength in tension.

Ductile and Brittle Materials

Which stress causes the material to fail?


Usually ductile materials are limited by their shear strengths. While brittle materials(ductility < 5%) are limited by their tensile strengths.

Failure Theories

Failure Theories

Ductile Materials Maximum shear stress theory (Tresca 1886)


Yield strength of a material is used to design components made of ductile material

Failure Theories -

(max )component > ( )obtained from a tension test at the yield point
= Sy

Failure

=
= Sy

Sy 2

To avoid failure

(max )component <

Sy 2

max =
=Sy

Sy 2n

n = Safety factor

Design equation

Ductile Materials Distortion energy theory (von Mises-Hencky)


Yield strength of a material is used to design components made of ductile material Simple tension test (Sy)t Hydrostatic state of stress (Sy)h

Failure Theories -

t (Sy)h >> (Sy)t


Distortion contributes to failure much more than change in volume.

h h h

t
(total strain energy) (strain energy due to hydrostatic stress) = strain energy due to angular distortion > strain energy obtained from a tension test at the yield point failure

Ductile Materials Distortion energy theory (von Mises-Hencky)


The area under the curve in the elastic region is called the Elastic Strain Energy.

Failure Theories -

U =
3D case UT =

11 + 22 + 33
2
E

Stress-strain relationship
Strain energy

1 = 2 = 3 =

1
E

v v v

v v v

3
E

2
E

1
E

3
E

3
E

1
E

2
E

UT =

2E

(12 + 22 + 32) - 2v (12 + 13 + 23)

Ductile Materials Distortion energy theory (von Mises-Hencky)


Distortion strain energy = total strain energy hydrostatic strain energy

Failure Theories -

Ud = UT Uh
UT =
1

2E

(12 + 22 + 32) - 2v (12 + 13 + 23) 1 = 2 = 3 = h (h2 + h2 + h2) - 2v (hh + hh+ hh)

(1)

Substitute

Uh =

2E

Simplify and substitute

1 + 2 + 3 = 3h into the above equation (1 + 2 + 3)2 (1 2v)


6E

Uh =

3h 2E

(1 2 v ) =

Ductile Materials Distortion energy theory (von Mises-Hencky)

Failure Theories -

Subtract the hydrostatic strain energy from the total energy to obtain the distortion energy 1+v Ud = UT Uh = 6E

(1 2)2 + (1 3)2 + (2 3)2

(2)

Ductile Materials Distortion energy theory (von Mises-Hencky)


Strain energy from a tension test at the yield point

Failure Theories -

1= Sy and 2 = 3 = 0
Ud = UT Uh =
1+v

Substitute in equation (2)

6E

(1 2)2 + (1 3)2 + (2 3)2


2

(2)

Utest = (Sy) To avoid failure, Ud < Utest

1+v 3E

(1 2)2 + (1 3)2 + (2 3)2


2

<

Sy

Ductile Materials Distortion energy theory (von Mises-Hencky)


(1 2)2 + (1 3)2 + (2 3)2
2
2D case, 3 = 0

Failure Theories -

<

Sy

(1 12 + 2 ) < Sy =
2 2

Where is von Mises stress

Sy n

Design equation

Design Process
Distortion energy theory Maximum shear stress theory

Sy n

Sy max = 2n Sy , Su

Select material: consider environment, density, availability Choose a safety factor

Size

Weight

Cost

The selection of an appropriate safety factor should be based on the following: Degree of uncertainty about loading (type, magnitude and direction) Degree of uncertainty about material strength Uncertainties related to stress analysis

Design Process
Consequence of failure; human safety and economics Type of manufacturing process Codes and standards Use n = 1.2 to 1.5 for reliable materials subjected to

loads that can be determined with certainty.


Use n = 1.5 to 2.5 for average materials subjected to

loads that can be determined. Also, human safety and economics are not an issue.
Use n = 3.0 to 4.0 for well known materials subjected to

uncertain loads.

Design Process
Consequence of failure; human safety and economics Type of manufacturing process Codes and standards Use n = 1.2 to 1.5 for reliable materials subjected to

loads that can be determined with certainty.


Use n = 1.5 to 2.5 for average materials subjected to

loads that can be determined. Also, human safety and economics are not an issue.
Use n = 3.0 to 4.0 for well known materials subjected to

uncertain loads.

Design Process

Select material, consider environment, density, availability Choose a safety factor

Sy , Su

Formulate the von Mises or maximum shear stress in terms of size. Use appropriate failure theory to calculate the size.

Sy n

Sy max = 2n

Optimize for weight, size, or cost.

Failure Theories

Brittle Materials

One of the characteristics of a brittle material is that the ultimate strength in compression is much larger than ultimate strength in tension.

Suc >> Sut


Mohrs circles for compression and tension tests.

Suc 3
Stress state

Sut

Tension test Compression test

Failure envelope

Failure Theories

Suc

Brittle Materials

Sut

Tension test Compression test

Failure envelope

The component is safe if the state of stress falls inside the failure envelope. 1 > 3 and 2 = 0

Failure Theories
3 or 2
Sut
Safe Safe Safe

Brittle Materials Modified Coulomb-Mohr theory

3 or 2
Sut Sut

Suc -Sut
Safe

1
-Sut

I II III

Sut

Suc

Suc

Cast iron data

Three design zones

Failure Theories
Zone I

Brittle Materials Modified Coulomb-Mohr theory


3
Sut

1 > 0 , 2 > 0 and 1 > 2 1 =


Sut

I II
-Sut

Sut

Design equation

Zone II

III

1 > 0 , 2 < 0 and 2 < Sut 1 =


Zone III Sut
Suc Design equation

1 ( 1 > 0 , 2 < 0 and 2 > Sut

1 1 1 ) 2 = n Suc Sut Suc Design equation

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