Maximum Strain theory (Saint Venant)

failure condition:

when the maximum strain reaches the strain due to yield stress
(tension)
(or)

Minimum strain reaches the strain due to yield stress

(compression)
Suman Suthari

, &

Principal stresses

Principal strains

Strain due to yield stress in simple tension =

=

X Yield stress in

X Yield stress in

tension

Strain due to yield stress in simple compression =

compression

&
(failure

conditions )
&

&

(safe Deign)

Maximum Strain Energy theory(Haighs)

failure condition:
When the total Strain energy per unit volume in the material reaches the Strain energy per unit
volume of the material at the elastic limit in simple tension.

Strain Energy (U) =

= 1/2 X Stress X Strain X volume
= 1/2 X X X (A X L )
Therefore Strain Energy per Unit volume =
= 1/2 X X

Total Strain energy per unit volume for (tri axial system) =
U = 1/2 XX + 1/2 XX + 1/2 XX

U=

= 1/2 X X
= 1/2 X X
=

U >
U

(failure condition)
(safe Design)

for Bi-axial system

=0

Distortion Energy theory (Von mises &

Hencky)

failure condition:

When the strain energy of distortion per unit volume at any point in the component ,
become equal to the strain energy of distortion per unit volume in the standard specimen
of tension test when yielding starts.

A unit cube subjected to three principal stresses , & .

The total Strain energy U of the cube is given by
U = 1/2 XX + 1/2 XX + 1/2 XX

Principal strains

U=

U=

= change of volume with no distortion of the element

= distortion of the element with no change of volume
Corresponding stresses are also resolved into two components

, & cause distortion of the cube.

= volumetric change

, & do not change the volume of the cube

+ + =0

(1 = 0
(1 0
=0
=1/3

Strain energy corresponding to the change of volume for the cube

is given by

= 3[

=
=

++]

Simple tension test , when the specimen starts yielding

= and = =0
=]

=
Considering the factor of safety

=
Bi-axial stresses (= 0)
=

A component subjected to pure shear

stresses
=0
=
Replacing by
=/

Theory of fatigue and Design

As earlier we have discussed the deigning of machine component

against static loads (or) Dead load

It is difficult to design a machine component by using previous formulas

when the component has discontinuity in cross section.
Dynamic loads are the loads whose magnitude and direction both can
change w.r.t. time.

Dynamic loadS:

Fluctuating stresses
Repeated stresses
Reversed stresses

Fluctuating or Alternating Stresses :

These stresses varies in a sinusoidal manner with respect to time.

maximum stress is the stress highest in magnitude ()

minimum stress is the stress lowest in magnitude ()

Stress range () = -

Mean stress () = (- )

Stress amplitude () = (+ )

Stress ration (R) = /

Amplitude ration (A) = /

Fatigue Failure :
The materials fail under fluctuating stresses at a stress magnitude
which is lower than the ultimate tensile strength of the material.
Sometimes, the magnitude is even lower than the yield strength.
The phenomenon of decreased resistance of the materials to
fluctuating stresses is the main characteristic of fatigue failure.

Fatigue failure are common are transmission shafts, connecting rods , gears , vehicle
suspension springs and ball bearings.

S.NO.

Static Failure

Fatigue Failure

1.

Gradual applied load

2.

Sufficient time to elongation

No noticeable elongation

3.

plastic flow prior to fracture

Begins with crack then after failure takes

place

4.

More life

Less life

5.

Warns before fail

Sudden

6.

Design is simple as compare

Design is complex as many factors are

involved

Cyclic load or Dynamic load

The crack is more likely to occur in the regions are follows:

Regions of discontinuity , such as oil holes , key ways , screw threads etc.

Regions of irregularities in machining operations , such as scratches on the surfaces ,

stamp mark , inspection marks etc.

Internal cracks due to defects in materials like blow holes

 These regions are subjected to stress concentration due to the crack.

Stress Concentration :
Stress concentration is defined as the localization of high stresses due to the
irregularities present in the component and abrupt changes of the cross section.
it is quantified by a factor is called Stress concentration factor ()

The causes of stress concentration are as follows:

variation in properties of materials

ex: internal cracks , blow hole

Load application on machine components at a point ( point load)

Ex: Meshing teeth of driving and driven gears

Ex: Contact between the cam and follower,

Contact between rail and wheel

Contact between balls and races of ball bearings , Contact between crane hook and the
chain

Abrupt changes in section

Ex: Gears, sprockets, pulleys , stepped shafts etc.

Discontinuities in the component

Ex: oil holes, oil grooves, key ways , splines etc.

Machining Scratches

The chart for the stress concentration factor for a rectangular plate with hole

the stress concentration factor for a flat plate with a shoulder fillet

The stress concentration factor for a round shaft with shoulder fillet

(a) tensile force

(b) Bending Moment

(c) Torsional Moment

Theoretical stress concentration factor at the hole is

 as b = 0 , =

A very sharp crack is indicated and the stress at the edge of the crack.

a = b, =
= 1+2
=3
Ductile materials are not affected by stress concentration under static loads.
When the load is fluctuating, the stress at the discontinuities may exceed the endurance
limit results the failure.
The effect of stress concentration is more severe in case of brittle materials hence this
accounts for both static and fluctuating loads.

Reduction in Stress Concentration:

Additional notches and holes in tension member

 Fillet radius undercutting and notch for member in bending

 Drilling additional holes for shaft

Empirical relationship developed by HF Moore for the ratio c of torsional strength of a shaft
having a keyway to torsional strength of a same sized shaft without key way is

 Reduction of stress concentration in threaded members

 Endurance limit () :
a material is defined as the maximum amplitude of completely reversed stress that the
standard specimen can sustain for an unlimited number of cycles without fatigue failure.
It is also called as fatigue life but infinite number of cycles is not possible , so generally we consider
cycles.

Fatige life :

As the number of tress cycles that the standard specimen can complete during the test before the
appearance of the first fatigue crack.

Dd

 Low Cycle and High Cycle Fatigue:

Low Cycle Fatigue

Stress cycles less than 1000

High Cycle Fatigue

Stress cycles more than 1000

Failure of studs on truck wheel, Failure of

setscrews, short lived such as gears etc.
missiles
It involves plastic yielding
localized area of the components

springs,

ball

bearings,

at Involves endurance strength

Can be ignored by taking suitable Must be considered and designed by

factor of safety
using theories of fatigue failure