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Course Code

Course Name

Contact Hours
L
T
P C
3
0
0
3

FAILURE ANALYSIS AND DESIGN

1. Course objectives:
To impart knowledge about various modes of failure this leads to safe design.
To expose to fracture mechanics and failure analysis tools.
2.

Course pre-requisites

Material Science
Engineering Metallurgy

UNIT - I STRESSES IN BODY


9
State of stress in two dimensions, Mohrs circle of stress in two dimensions, hydrostatic and deviator
components of stress, Elastic stress strain relations .Flow curve, true stress and strain, yielding criteria for
ductile materials, Octahedral shear stress and shear strain, plastic stress-strain relations, two dimensional
plastic flow Slip line field theory.
.
UNIT -II FRACTURE MECHANICS
9
Types of fracture in metals, theoretical cohesive strength of metals, Griffith theory of brittle fracture,
Metallographic aspects of failure, fractography, dislocation theories of brittle fracture, ductile fracture,
notch effects, concept of fracture curve, effect of high hydrostatic pressures on fracture. Strain-energy
release rate, fracture toughness and design, plain-strain toughness testing, plasticity corrections, crack
opening displacement ,J integral, R-curve, Probabilistic aspects of fracture mechanics.
UNIT III FATIUGE OF METALS
9
Stress cycles, the S-N curve, statistical nature of fatigue, cyclic stress-strain curve, low cycle fatigue,
strain life equation, structural features of fatigue, fatigue crack propagation, effects of stress concentration
on fatigue. Fracture analysis diagram, environment sensitive fracture
UNIT IV WEAR AND CORROSION FAILURES
9
Wear- Types of wear , wear models; wear preventions-analysis methods, design details, lubrication and
materials. Corrosion- Corrosion principles-electrochemical aspects, environmental effects, metallurgical
aspects. Forms of corrosion, Corrosion testing.
UNIT V FAILURE ANALYSIS TOOLS
9
Probabilistic approach to design Basic Probability using the Normal Distribution, Sources of statistical
tables, Frequency distributions combining applied stress and material strength, Probabilistic design,
satefy, factor. Design for Reliability-causes of unreliability, minimizing failure, sources of reliability data,
and cost of reliability. Failure mode analysis-Making a FMEA analysis. Defects and failure modes,
industrial case studies / Projects on FMEA.
Total Hours: 45

3. Course outcomes:

Ability to identify potential changes in behavior and properties of materials as they are altered and
influenced by manufacturing processes.
Ability to research concepts, simulate, test working conditions and application of modeling
methods and their impact on the designed systems.
Ability to solve open ended engineering problems in design engineering areas including the
design and realization of such systems.

REFERENCES:
1. George E.Dieter, Linda C.Schmidt, Engineering Design, McGraw Hill Education (India) Private
Ltd, 2012.
2. George E.Dieter, Mechanical Metallurgy, McGraw Hill book company co 2014.
3. Mars G.Fontana Corrosion Engineering, Tata McGraw Hill Education Private Company, New
Delhi, 2010.
4. Richard G Budynas, Keith J Nisbett, Shigley's Mechanical Engineering Design McGraw Hill
Education (India) Private Ltd, 2014.
5. http://www.npd-solutions.com/fmea.html

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