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Introduction
Theories of failure are those theories which help us to determine the safe dimensions of
a machine component when it is subjected to combined stresses due to various loads
acting on it during its functionality.
Theories of failure are employed in the design of a machine component due to the
unavailability of failure stresses under combined loading conditions.
Theories of failure play a key role in establishing the relationship between stresses
induced under combined loading conditions and properties obtained from tension test
like ultimate tensile strength (Sut) and yield strength (Syt).
Examples:
𝜎1 ≤ Syt
4P
πd2 ≤ Syt
P
2.
Member is subjected to both Twisting moment and
uniaxial load, hence combined loading conditions.
Stresses induced under combined loading conditions and (Syt and Sut) obtained using
tension test which are called theories of failure.
According to M.P.S. T
Condition for failure is,
Syt Sut
1 ≤ N or N Eqn (1)
Note:
1. This theory is suitable for the safe design of machine components made of brittle
materials under all loading conditions (tri-axial, biaxial etc.) because brittle materials
are weak in tension.
2. This theory is not suitable for the safe design of machine components made of ductile
materials because ductile materials are weak in shear.
3. This theory can be suitable for the safe design of machine components made of
ductile materials under following state of stress conditions.
1
(i) Uniaxial state of stress (Absolute max = 2 )
1
(ii) Biaxial state of stress when principal stresses are like in nature (Absolute max = 2 )
(iii) Under hydrostatic stress condition (shear stress in all the planes is zero).
2. Maximum Shear Stress theory (M.S.S.T)
Syt
Absolute max (Sys)T.T or 2
where,
(Sys)T.T Syt
Absolute max ≤ N or 2N
σ3 - σ1
larger of [| σ1 2- σ2 |, |σ2 2- σ3 |, | 2 |] ≤
Syt
2N
Syt
larger of [ |σ1 – σ2|, | σ2 – σ3|, | σ3 – σ1|] ≤ N
σ σ1 - σ2 Syt
| 21 | or | 2 |≤ 2N
Syt
|σ1| ≤ N when σ1, σ2 are like in nature Eqn (2)
Syt
|σ1 – σ2| ≤ N when σ1, σ2 are unlike in nature Eqn (3)
Note:
1. M.S.S.T and M.P.S.T will give same results for ductile materials under uniaxial state
of stress and biaxial state of stress when principal stresses are like in nature.
2. M.S.S.T is not suitable under hydrostatic stress condition.
3. This theory is suitable for ductile materials and gives oversafe design i.e. safe and
uneconomic design.
Maximum Principal strain (ε1) Yielding strain under tensile test (ε Y.P.)T.T
Syt
ε1 (ε Y.P.)T.T or E
Syt
ε1 ≤ EN
1 Syt
E [σ1 - µ(σ2 + σ3)] ≤ EN
Syt
σ1 - µ(σ2 + σ3) ≤ N
for biaxial state of stress, σ3 = 0
Syt
σ1 - µ(σ2) ≤ N Eqn (4)
Total Strain Energy per unit volume Strain energy per unit volume at yield point
(T.S.E. /vol) under tension test (S.E /vol) Y.P.] T.T
Total Strain Energy per unit volume ≤ Strain energy per unit volume at yield point
under tension test. Eqn (5)
σE.L
Strain energy per unit volume up
1
to Elastic limit (E.L) = 2 σE.L εE.L
εE.L
1 1 1
Total Strain Energy per unit volume = 2 σ1 ε1 + 2 σ2 ε2 + 2 σ3 ε3 Eqn (6)
(triaxial)
1
ε1 = E [σ1 - µ(σ2 + σ3)]
1
ε2 = E [σ2 - µ(σ1 + σ3)] Eqn (7)
1
ε3 = E [σ3 - µ(σ1 + σ2)]
1 Syt
[(S.E /vol) Y.P.] T.T = 2E ( N )^2 (9)
By Substituting equations (8) and (9) in equation (5), the following equation is obtained
Syt
σ12 + σ22 + σ32 - 2µ (σ1 σ2 + σ2 σ3 +σ3 σ1) ≤ ( N )^2
Syt
σ12 + σ22 - 2µ σ1 σ2 ≤ ( N )^2 (10)
Note:
1. Eqn (10) is an equation of ellipse (x2 + y2 - xy = a2).
1
Volumetric S.E/vol = 2 (Average stress) (Volumetric strain)
1 σ1 + σ2 + σ3 1-2µ
= 2( 3 ) [( E ) (σ1 + σ2 + σ3) ]
1-2µ
Vol S.E/vol = 6E (σ1 + σ2 + σ3)2 (13)
1+µ
D.E/vol = 6E [(σ1 - σ2)2 + (σ2 - σ3)2 + (σ3 - σ1)2] (14)
Substituting equation (14) and (15) in the condition for safe design , the following
equation is obtained
Syt
[(σ1 - σ2)2 + (σ2 - σ3)2 + (σ3 - σ1)2] ≤ 2 ( N )^2
Note:
1. Equation (16) is an equation of ellipse.
3. This theory is best theory of failure for ductile material. It gives safe and economic
design.
4. This theory is not suitable under hydrostatic stress condition.
SYS
Ration of S by using theories of failure
Yt
5. When yielding in shear occurs under pure shear state of stress, τ = Sys.
SYS
(a) S in Maximum Principal stress theory
Yt
According to M.P.S.T,
Considering Factor of safety (N) = 1
σ1 ≤ Syt or
σ1 Syt
τ = Syt
When yielding occurs in shear under pure shear state of stress, τ = Sys
Sys = Syt
SYS
SYt = 1
SYS
(b) S in Maximum shear stress theory
Yt
According to M.S.S.T,
τ – (-τ) = Syt
2 τ = Syt
When yielding occurs in shear under pure shear state of stress, τ = Sys
SYS 1
SYt = 2
SYS
(c) S in Maximum principal strain theory
Yt
According to M.P.St.T,
σ1 - µ(σ2) Syt
τ - µ(-τ) Syt
τ(1+ µ) = Syt
Syt
Sys =
1+ µ
for µ = 0.3
SYS
SYt = 0.77
SYS
(d) S in Total strain energy theory
Yt
According to T.St.E.T,
τ=
√
Sys =
√
for µ = 0.3
SYS
= 0.62
SYt
SYS
(d) S in Maximum distortion energy theory
Yt
According to M.D.E.T,
σ1 2 + σ22 – σ1 σ2 Syt2
τ2 + τ2 + τ2 = Syt2
τ=
√
Sys =
√
SYS
SYt = 0.577
These equations should be used when the component is subjected to both Bending
Moment and Twisting Moment simultaneously.
T T
M M
d
M.P.S.T Me = 1 [ M + √ ] = 32 d3 σper
2
M.S.S.T Te = √ = 16 d3 τper
M.D.E.T Me = √ = d3 σper
32
Normal Stress Equations (σt equations)
τxy
σx σx
τxy
T.O.F σt equations
M.P.S.T Syt
σt = 1 [σx + √ ] = N
2
Syt
M.S.S.T σt = √ = N
Syt
M.D.E.T σt = √ = N
Graphical representation or safe boundaries are used to check whether the given
dimensions of a component are safe or not under given loading conditions.
σ2
Syt
-σ1 σ1
Syc Syt
Syc = -Syt
-σ2
σ2
σ1 -σ2 = -Syt
-σ1 σ1
σ1 -σ2 = Syt
-σ2
(c) M.P.St.T :- Rhombus
σ2
Syt
- σ1 σ1
-Syt Syt
-Syt
-σ2
σ2
M.D.E.T
Syt
M.S.S.T
-Syt
-σ1 σ1
Syt
-Syt
- σ2
Note :-
2. As the area bounded by the curve increases, failure stresses increases thereby
decreases dimensions and hence cost of safety.
In all the quadrants
Area bounded by the MDET curve Aread bounded by MSST curve
Hence
(Dimensions)MDET (Dimensions)MSST
σ2
Syt
-Syt
-σ1 σ1
Syc Syt
Syt
Syc = -Syt
- σ2
Note:
1. All the theories of the failure will give the same result when uniaxial state of stress
Examples –
1. Bar subjected to uniaxial load
2. Beam subjected to pure bending
2. All the theories of the failure will give the same result when one of the principal
stresses is very large as compared to the other principal stresses.
3. For pure shear state of stress, all the theories of failure will give the different result.
(a) MDET and MSST will be used under pure shear state of stress.
(b) MDET will be preferred over MSST.
4. MSST and MDET are not valid for hydrostatic state of stress condition.
5. TSET and MPST will be used for hydrostatic state of stress condition. TSET will be
preferred over MPST.
References
1. Introduction to Machine Design by V.B Bhandari