Theories of failure

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.

Some examples of such components are as follows:

1. I.C. engine crankshaft

2. Shaft used in power transmission

3. Spindle of a screw jaw

4. Bolted and welded joints used under eccentric loading

5. Ceiling fan rod

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:

1. Syt = 200 MPa

Sut = 300 MPa

Directly we can get (d) without using any failure

d theory because only uniaxial load (P)

𝜎1 ≤ Syt

4P
πd2 ≤ Syt

P
2.
Member is subjected to both Twisting moment and
uniaxial load, hence combined loading conditions.

We cannot determine (d) directly in this case

d because failure stresses under combined loading
conditions are unknown.

So, different scientists give relationships between

Stresses induced under combined loading conditions and (Syt and Sut) obtained using
tension test which are called theories of failure.

Various Theories of Failure

1. Maximum Principal Stress theory also known as RANKINE’S THEORY

2. Maximum Shear Stress theory or GUEST AND TRESCA’S THEORY
3. Maximum Principal Strain theory also known as St. VENANT’S THEORY
4. Total Strain Energy theory or HAIGH’S THEORY
5. Maximum Distortion Energy theory or VONMISES AND HENCKY’S THEORY

1. Maximum Principal Stress theory (M.P.S.T)

According to M.P.S. T
Condition for failure is,

Maximum principal stress ( 1) failure stresses (Syt or Sut )

and Factor of safety (F.O.S) = 1

If 1 is +ve then Syt or Sut

1 is –ve then Syc or Suc

Condition for safe design,

Factor of safety (F.O.S) > 1

Maximum principal stress ( 1) ≤ Permissible stress ( per)

Failure stress Syt Sut

where permissible stress = = or
Factor of safety N N

Syt Sut
1≤ or Eqn (1)
N N

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 w hen 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)

Condition for failure,

Maximum shear stress induced at a critical Yield strength in shear under tensile
point under triaxial combined stress test

Syt
Absolute max (Sys)T.T or 2

unknown therefore use Syt

Condition for safe design,

Maximum shear stress induced at a critical ≤ Permissible shear stress (τper)

tensile point under triaxial combined stress

where,

Yield strength in shear under tension test (Sys)T.T Syt

Permissible shear stress = Factor of safety = N = 2N

(Sys)T.T Syt
Absolute max ≤ N or 2N

For tri-axial state of stress,

σ1 - σ2 σ3 - σ1 Syt
larger of [| 2
| , | σ2 -2σ3 | , | 2 |] ≤ 2N

Syt
larger of [ | σ1 – σ2|, | σ2 – σ3|, | σ3 – σ1| ] ≤ N

For Biaxial state of stress, σ3 = 0

σ1 σ1- σ Syt
| 2 | or | 2
2
| ≤ 2N
 Syt
| σ1| ≤ N when σ1, σ2 are like in nature Eqn (2)

Syt
| σ 1 – σ2| ≤ N when σ1, σ2 areunlike 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.

3. Maximum Principal Strain theory (M.P.St.T)

Condition for failure,

Maximum Principal strain (ε1) Yielding strain under tensile test (ε

Y.P.)T.T
Syt
ε1 (ε Y.P.)T.T or E

where E is Young’s Modulus of Elasticity

Condition for safe design,

Maximum Principal strain ≤ Permissible strain

Yielding strain under tensile test (ε Y.P.)T.T Syt

where Permissible strain = Factor of safety = N = EN

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)

4. Total Strain Energy theory (T.St.E.T)

Condition for failure,

Total Strain Energy per unit volume Strain energy per unit volume at yield
(T.S.E. /vol) point under tension test (S.E /vol) Y.P.] T.T

Condition for safe design,

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 = σ1 ε1 + σ2 ε2 + σ3 ε3 Eqn (6)
2 2 2
(triaxial)
Condition for failure,

Maximum Distortion Energy/volume Distortion energy/volume at yield point

(M.D.E/vol) under tension test (D.E/vol) Y.P.] T.T

Condition for safe design,

Maximum Distortion Energy/volume ≤ Distortion energy/volume at yield point

under tension test (11)

T.S.E/vol = Volumetric S.E/vol + D.E/vol

D.E/vol = T.S.E/vol - Volumetric S.E /vol (12)
Under hydrostatic stress condition, D.E/vol = 0
and
Under pure shear stress condition, Volumetric S.E/vol = 0

From equation (8)

1
T.S.E/vol = 2E[σ12 + σ22 + σ32 - 2µ (σ1 σ2 + σ2 σ3 +σ3 σ1)]

1
Volumetric S.E/vol = 2 (Average stress) (Volumetric strain)

1 σ1 + σ2 + σ3 1-2µ
=2( ) [( E ) (σ1 + σ2 + σ3) ]
3

1-2µ
Vol S.E/vol = 6E (σ1 + σ2 + σ3)2 (13)

From equation (12) and (13)

1+µ
D.E/vol = 6E [(σ1 - σ2)2 + (σ2 - σ3)2 + (σ3 - σ1)2] (14)

To get [(D.E/vol) Y.P.] T.T ,

Syt
Substitute σ1 = σ = N , σ2 = σ3 = 0in equation (14)