Static Loading - Failure

I/C: KALLURI VINAYAK
8/27/2010 kallurivinayak@bits-pilani.ac.in 1
Introduction
• The static load is a stationary force or couple
applied to a member. Stationary means, the
load should be unchanging in…
– magnitude
– point or points of application
– direction
– Or in any other manner
• A stationary force may cause

– axial tension or compression, shear load or
bending moment or a torsional load or any
combination of these
Introduction
• Failure means a part has had:
– separted into two or more pieces
– become permanently distorted and thus ruined its
geometry
– its reliability downgaded
– its function compromised
• Static strength data of various materials may be available
in two forms
– Data obtained in tests conducted in the similar
conditions as the actual service life
– Data collected in tests conducted in certain ideal
conditions that may not necessary simulate the exact
service conditions
• The first type of data is always desirable but difficult to
produce
• When second type of data is used, then the engineer
must be clever enough
8/27/2010
to apply suitable factors
kallurivinayak@bits-pilani.ac.in 3
Introduction
In designing any machine element, the results of a
great many strength tests are very important for a
chosen material and tests should be made under
exactly the same conditions as the part will
experience in service.
Following four design categories:
1) Mass production or the product can endanger human
life: You must generate the strength data in real service
life conditions and use in the design.
2) Medium quantity of production and does not endanger
lives: moderately accurate tests are ok
3) The part is made in very small quantities: no testing is
required; use the published mean data in handbook
4) The part is already designed, manufactured but proved
defective; needs analysis to find the problem
Stress Concentration
• Basic stress equations for tension, compression,
bending, and torsion were developed with
assumption that no geometric irregularities
occurred in the member under consideration
• Difficult to design a machine without permitting
some changes in the cross sections
Ex 1: Rotating shafts must have shoulders to seat bearings
properly and to take thrust loads; and key slots for securing
pulleys and gears
Ex 2: A bolt has a head on one end and screw threads on the

other end
• Any discontinuity in a machine part alters the stress
distribution in the neighborhood of the discontinuity so
that the elementary stress equations no longer describe
the state of stress in the part at these locations
• Such discontinuities are called stress raisers, and the
regions in which they occur are called areas of stress
concentration.
• A theoretical, or geometric, stress-concentration factor Kt
or Kts is used to relate the actual maximum stress at the
discontinuity to the nominal stress
Where
are
Nominal normal and shear
stress respectively
• Stress concentration is a highly localized effect.
• In some instances it may be due to a surface
scratch
• Stress-concentration factor depends for its value
only on the geometry of the part
• The particular material used has no effect on the
value
• If the load is static and material is ductile, then
Stress concentration factor is unity
• Most stress-concentration factors are found by
using experimental techniques like photoelasticity,
grid methods, brittle-coating methods, and
electrical strain-gauge methods
Ex: Thin plate in tension or
simple compression with a
transverse central hole. The net
tensile force is F = σwt,
(t = thickness of the plate)
The nominal stress is given by
Rectangular filleted bar

in tension or simple
compression.
σ0 = F/A, where A = dt
and t is the thickness.
Stress-concentration factors for a variety of geometries

may be found in Table A–13
Failure Theories
• There is no general theory that is sacrosanct and unique;
hence we call them “failure theories”
• Rather it is a choice based on the design requirement and
nature of material, whether ductile or brittle
• Ductile materials (εf ≥ 0.05 and identifiable yield
strength that is often the same in compression as in
tension i.e Syt = Syc = Sy ) are designed based on yield
criteria
Maximum shear stress (MSS) theory
Distortion energy (DE) theory
Ductile Coulomb-Mohr (DCM) theory
• Brittle materials, (εf < 0.05 and typically classified by
ultimate tensile and compressive strengths i.e Sut and
Suc) are designed based on fracture criteria
Maximum normal stress (MNS) theory
8/27/2010 Brittle Coulomb-Mohr (BCM) theory
kallurivinayak@bits-pilani.ac.in 10
Failure Theories
• How do we know that the given material is ductile?
The judgement is based on the fracture strain.
• Ductile materials
Fracture strain, εf ≥ 0.05 and
identifiable yield strength is often the same in
compression as in tension i.e Syt = Syc = Sy
• Brittle materials
Fracture strain ε f < 0.05
and
Sut ≠ Suc
Maximum-Shear-Stress (MSS)
Theory
• Also referred to as the Tresca or Guest theory.
• Theory predicts that “yielding begins whenever the
maximum shear stress in any element equals or
exceeds the maximum shear stress in a tension test
specimen of the same material when that specimen
begins to yield”
• For a general state of stress, the maximum-
shear-stress theory predicts yielding when
Theory
• For design purposes, Equation can be modified to
incorporate a factor of safety, n.
for plane stress (one of the principal stresses is zero)

and Assuming that σA ≥ σB:
Case 1: σA ≥ σB ≥ 0.
For this case, σ1 = σA and σ3 = 0. Equation reduces to a yield condition of σA ≥ Sy
Case 2: σA ≥ 0 ≥ σB .
Here, σ1 = σA and σ3 = σB , and Equation becomes σA − σB ≥ Sy
Case 3: 0 ≥ σA ≥ σB .
For this case, σ1 = 0 and σ3 = σB and Equation gives σB ≤ −Sy
Theory
σ A ≥ σ B ≥ 0,
σ1 = σ A,σ 2 = σ B,σ 3 = 0
σ1 −σ 3 ≥ Sy,σ A ≥ Sy
0 ≥ σ A ≥ σ B,
σ 1 = 0,
σ 2 = σ A,
σ3 =σB σ A ≥ 0 ≥ σ B,
σ1 −σ 3 ≥ Sy, σ 1 = σ A , σ 2 = 0, σ 3 = σ B
− σ B ≥ −S y σ1 −σ 3 ≥ Sy,σ A −σ B ≥ Sy
unmarked lines are cases for σB ≥ σA

Distortion-Energy (DE) Theory
Other names o f distortional energy criterion

• The von Mises or von Mises-Hencky
theory
• The shear energy theory
• The octahedral shear stress theory
σ ij δ ij p Sij orσij'
σ ij = δ ij p + S ij
• The strain energy per unit volume for simple tension
• For tri-axial stress shown in fig (a)., the strain energy per
unit volume is
• Substituting for the principal strains gives
• The strain energy for producing only volume change is
• Substituting σav = (σ1 + σ2 + σ3)/3 gives
• Then the distortion energy is
• Theory predicts that “yielding occurs when the
distortion strain energy per unit volume reaches or
exceeds the distortion strain energy per unit volume
for yield in simple tension or compression of the
same material”
• For a general state of stress, the Distortion-
Energy Theory predicts yielding when
or σ′ ≥ Sy
Where “σ′ “is a single, equivalent, or effective stress called von Mises stress
• For plane stress, let σA and σB be the two
nonzero principal stresses, then the von Mises
stress is
• The above equation is a rotated ellipse in the

σA, σB plane with σ′ = Sy
• Using xyz components of three-dimensional
stress, the von Mises stress can be written as
• and for plane stress
Octahedral shear stress:
Considering the principal directions as the coordinate
axes, a plane whose normal vector makes equal angles
with each of the principal axes (i.e. having direction
1
cosines equal to ) is called an octahedral plane
3
The shear stress acting on the so-called ‘octahedral
planes’ which are the eight planes that are normal to the
equi-inclined directions in the eight quadrants formed by
the principal stresses.
THE OCTAHEDRAL PLANES: Octahedral shear stress
theory
Failure occurs when the octahedral shear stress in the

given state of stress reaches the octahedral shear
stress in simple tension at yield.
SHEAR YIELD STRENGH:
• According to DE (von Mises) criterion,
substituting the pure shear state of stress in the
2-D DE criterion, the two normal stresses being
zero, Sy
2
3τ xy = S y τ xy = = 0.577 S y
3
At yield , S sy = 0.577 S y
According to the MSS criterion,
S sy = 0.5S y
DE criterion predicts the shear yield strength to be 15 percent more than
that predicted by the MSS criterion. Hence MSS is more conservative.
Ductile Coulomb-Mohr Theory or Internal friction
theory
To be applied when the material has unequal strength in tension and
compression, S ≠S yt yc
Examples of such materials are magnesium alloys, for which S yc ≅ 0.5S yt
DCM is a simplification of the old Mohr’s theory of failure.
OR ⇒
where either yield strength or ultimate strength can be used
Ductile Coulomb-Mohr Theory or Internal friction
theory
Maximum-Normal-Stress Theory
• The maximum-normal-stress (MNS) theory
states that failure occurs whenever one of
the three principal stresses equals or
exceeds the strength.
• For the principal stresses for a general
stress state in the ordered form σ1 ≥ σ2 ≥
σ3; This theory then predicts that failure
occurs whenever
σ1 ≥ Sut or σ3 ≤ −Suc
where Sut and Suc are the ultimate tensile and compressive strengths, respectively,
given as positive quantities.
Maximum-Normal-Stress Theory
• For plane stress, with σA ≥ σB,
σA ≥ Sut or σB ≤ −Suc
Brittle-Coulomb-Mohr Theory
• Design equations for a brittle material are
Modified Mohr Theory
Failure theory selection flowchart
Problem
• The figure shows a crank loaded by a force F = 800 N which
causes twisting and bending of the 20 mm-diameter shaft fixed to
a support at the origin of the reference system. In actuality, the
support may be an inertia which we wish to rotate, but for the
purposes of a strength analysis we can consider this to be a statics
problem. The material of the shaft AB is hot-rolled AISI 1018
steel (Table A–18). Using the maximum-shear-stress theory, find
the factor of safety based on the stress at point A.

Static Loading - Failure

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I/C: KALLURI VINAYAK

• A stationary force may cause

Ex 2: A bolt has a head on one end and screw threads on the

Rectangular filleted bar

Stress-concentration factors for a variety of geometries

for plane stress (one of the principal stresses is zero)

unmarked lines are cases for σB ≥ σA

Other names o f distortional energy criterion

• Substituting for the principal strains gives

• Substituting σav = (σ1 + σ2 + σ3)/3 gives

• Then the distortion energy is

• The above equation is a rotated ellipse in the

• and for plane stress

Failure occurs when the octahedral shear stress in the

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