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Failure Resulting from Static
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MEE 311 Machine Design
Kitchanon Ruangjirakit, Ph.D.
Textbook
Shigley's mechanical engineering design 9th edition
Contents
Design?
Stress and Strength
Uncertainty
Reliability
Material Strength and Stiffness
Hardness
Stress and Its Cartesian Components
Morhs Circle
Beam Bending
Torsion
Failure Resulting from Static
Loading
Failure Theories for Ductile
Materials
Design?
Design is an iterative process of creating
something innovative with specified need or
intention to solve a problem.
The products that engineer designs must be
functional, safe, reliable, competitive, usable,
manufacturable, and marketable.
The design process consists of different steps.
4
Design?
The first step in the design process is
identification of need, which may be only a
vague discontent, a feeling of uneasiness, or a
sensing that something is not right.
Design?
Once the specifications are clear, many
schemes connecting possible system elements
are proposed, investigated, and quantified.
This is also called concept design.
Design?
The evaluation step is one of the most
important steps in design process as it is the
final proof of a successful design and often
involves the testing of prototype.
Design?
It is worth noting that the design process discussed earlier is
highly iterative.
Uncertainty
There are 2 techniques to address uncertainties: deterministic and
stochastic methods.
The deterministic approach establishes a design factor based on the
absolute uncertainties of a loss-of-function parameter and a
maximum allowable parameter. The design factor, nd, is defined as
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Uncertainty
After the design is completed, the actual elements used may be offthe-shelf and different from those initially designed; therefore, the
actual design factor may change. This factor is then called the factor
of safety or safety factor, n.
11
Reliability
Reliability, R, is the statistical approach to determine the probability
that a mechanical component will not fail in service. The range of the
reliability is between 0 and 1 (0 R 1).
For example, a reliability of 0.95 (R = 0.95) means that the chance of a
part will work properly without failure is 95 percent.
The failure of 6 parts from 1,000 parts will result in the reliability of
6
R 1
0.994
1000
or
99.4 percent
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Reliability
Reliability, R, in a series system of n components is the multiplication
of reliability of each component. This can be expressed
mathematically by
n
R Ri
i 1
P
A0
A0 14 d 02
Engineering strain
Hooks law
E is called
Youngs modulus
or modulus of
elasticity
14
Hardness
The hardness can be defined as the resistance of a material to
penetration by a tool.
Two most common used measuring systems are Rockwell and Brinell.
For steel
Source: http://classes.mst.edu/ide110/concepts/13/strain/plane_stress_vs_strain.gif
16
Morhs Circle
The two principal stresses can be expressed as
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Morhs Circle
18
Beam Bending
The bending stress varies linearly with the distance from the neutral
axis, y, and can be expressed as
where I is the second moment of area about the z-axis
where
Z=
I
c
19
Torsion
The angle of twist (radians) of a solid round tube is
given by
where T = torque, l = length, G = modulus of
rigidity, J = polar second moment of area
20
Stress Concentration
In many cases, the machine element contains discontinuity, which
affects stress field near the vicinity of the discontinuity. Therefore, the
elementary stress equations can no longer be used to represent the
state of stress in the part at these locations
These discontinuities are also called stress raisers and the areas which
they occur are called areas of stress concentration.
Stress concentrations can also arise from tool marks, holes, notches,
etc.
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Stress Concentration
Stress distribution in a rectangular filleted bar in pure bending obtained through photoelastic procedures. (By
permission of S. P. Timoshenko and J. N. Goodier; the figure was included in, "Theory of Elasticity," Third Edition,
McGraw-Hill, Inc., 1969.)
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Stress Concentration
The maximum normal and shear stresses
near the discontinuity need to be
modified by a factor defined by the
equations
Stress Concentration
If the load is static and the material is considered ductile, the element
can carry loads with no general yielding. In these cases the engineer
who design the part can set the geometric stress concentration factor,
Kt, to unity (this is to set Kt = 1).
However be careful when using this rule for ductile materials with
static loads such that the material must not be susceptible to brittle
fracture in the environment of use.
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Sy
2
1 3
33
1 3 S y
1 3 S y
or
S sy 0.5S y
max
Sy
2n
or
1 3
Sy
n
34
3 0
A Sy
Case 2: A 0 B
1 A 3 B
A B Sy
Case 3: 0 A B
1 0
3 B
B S y
35
36
37
av
1 2 3
3
38
1
u
2
As for the cubic element, the strain energy per unit volume is
1
u 11 2 2 3 3
2
39
1 2
2
2
u
1 2 3 21 2 2 3 31
2E
The strain energy required to only change the volume of the cubic
element (uv) can be derived by substituting 1 = 2 = 3 = av
1 2 2
2
2
uv
1 2 3 21 2 2 2 3 2 31
6E
40
3E
2
41
1/ 2
Sy
S y
42
1/ 2
A B
2
A
2 1/ 2
B
43
44
1
2
2
2
1/ 2
x y 3
2
x
2
y
2 1/ 2
xy
45
46
2 1/ 2
xy
Sy
or
xy
Sy
3
0.577S y
S sy 0.577 S y
which is approximately 15 % greater than 0.5Sy predicted by MSS theory.
47
Compression
Failure envelope
Tension
Pure shear
49
Tension
50
OC 2 OC1
OC 3 OC1
Tension
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1 3 S t
Sc St
2
2 2 2
St 1 3 S c St
2
2
2 2
1 3
1
St Sc
Tension
52
A B 0 1 A
3 0
Case 1
A St
Case 2:
A 0 B
1 A 3 B
A B
1
St S c
Case 3:
0 A B
B Sc
1 0
Case 2
3 B
Case 3
53
S sy
S yt S yc
S yt S yc
1 3 1
St Sc n
Tension
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