CAD/CAM A.

ENZI

Failure-Brittle Material
CAD/CAM A. ENZI

1. Maximum-Normal-Stress Theory for Brittle Materials

 The maximum-normal-stress (MNS) theory states that failure occurs

whenever one of the three principal stresses equals or exceeds the
strength.

 Again we arrange the principal stresses for a general stress state in the
ordered form σ1 ≥ σ2 ≥ σ3. This theory then predicts that failure occurs
whenever

where Sut and Suc are the ultimate tensile and compressive strengths,
respectively, given as positive quantities.
CAD/CAM A. ENZI

2. Modifications of the Mohr Theory for Brittle Materials

Written as design equations for a brittle material, they are:

Brittle-Coulomb-Mohr

Failure Criteria Condition

Modified Mohr
CAD/CAM A. ENZI

Shafts and Shaft Components

 A shaft is a rotating member, usually of circular cross section, used to
transmit power or motion. It provides the axis of rotation, or oscillation, of
elements such as gears, pulleys, flywheels, cranks, sprockets, and the like
and controls the geometry of their motion.

 Many shafts are made from low carbon, cold-drawn or hot-rolled steel,
such as ANSI 1020-1050 steels.

 Shafts usually don’t need to be surface hardened unless they serve as the
actual journal of a bearing surface.

 Cold drawn steel is usually used for diameters under about 3 inches.

1. Shaft Layout
 The general layout of a shaft to accommodate shaft elements, e.g., gears,
bearings, and pulleys, must be specified early in the design process in order
to perform a free body force analysis and to obtain shear-moment diagrams.

Important points that the designer must take into account for shaft layout are:
 Axial layout of components
 Supporting axial loads
 Providing for torque transmission
 Assembly and Disassembly
CAD/CAM A. ENZI

2. Shaft Design for Stress

 It is not necessary to evaluate the stresses in a shaft at every point
 Critical locations will usually be on the outer surface, at axial locations
Where the bending moment is large? Where the torque is present? And
where stress concentrations exist?
 Bending, torsion, and axial stresses may be present in both midrange and
alternating components. For analysis, it is simple enough to combine the
different types of stresses into alternating and midrange.

where Mm and Ma are the midrange and alternating bending moments, Tm and Ta
are the midrange and alternating torques, and Kf and Kfs are the fatigue stress-
concentration factors for bending and torsion, respectively, and endurance limit is
Se.
CAD/CAM A. ENZI

For example, DE-Gerber indicates the stresses are combined using the distortion
energy (DE) theory, and the Gerber criteria are used for the fatigue failure.
CAD/CAM A. ENZI

A von Mises maximum stress is calculated for this purpose.

Solution (a) D/d = 1.65/1.100 = 1.50, r/d = 0.11/1.100 = 0.10, Kt = 1.68 (Fig. A–
15–9), Kts = 1.42 (Fig. A–15–8).
CAD/CAM A. ENZI

Note: Kf=1.58, kfs=1.37, Se’=52.5 kpsi, ka=0.787, kb=0.870, kc=kd=kf=1, ke =

0.814, Se= 29.3 kpsi, q= 0.85, and qshear =0.88.
Where
ka = surface condition modification factor
kb = size modification factor
kc = load modification factor
kd = temperature modification factor
ke = reliability factor
Se’= rotary-beam test specimen endurance limit
Se = endurance limit at the critical location of a machine part in the
geometry and condition of use
q= Notch sensitivity