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Theories of Failure From My SOM Book PDF
Theories of Failure From My SOM Book PDF
Theories of Failure From My SOM Book PDF
Failure Mode
• Yielding: a process of global permanent plastic deformation. Change in the geometry of the
object.
• Fracture: a process in which cracks grow to the extent that the component breaks apart.
• Buckling: the loss of stable equilibrium. Compressive loading can lead to bucking in
columns.
Failure Modes:
Excessive elastic Yielding Fracture
deformation
1. Stretch, twist, or • Plastic deformation at room • Sudden fracture of brittle
bending temperature materials
2. Buckling • Creep at elevated • Fatigue (progressive
temperatures fracture)
3. Vibration • Yield stress is the important • Stress rupture at elevated
design factor temperatures
• Ultimate stress is the
important design factor
2. Maximum Principal Stress Theory
(W. Rankin’s Theory- 1850) – Brittle Material
The maximum principal stress criterion:
• Rankin stated max principal stress theory as follows- a material fails by fracturing when the
largest principal stress exceeds the ultimate strength σu in a simple tension test. That is, at
the onset of fracture, |σ1| = σu OR |σ3| = σu
S K Mondal’s Theories of Failure Page-3
• Crack will start at the most highly stressed point in a brittle material when the largest
principal stress at that point reaches σu
• Criterion has good experimental verification, even though it assumes ultimate strength is
same in compression and tension
• This theory of yielding has very poor agreement with experiment. However, the theory has
been used successfully for brittle materials.
• Used to describe fracture of brittle materials such as cast iron
• Limitations
o Doesn’t distinguish between tension or compression
o Doesn’t depend on orientation of principal planes so only applicable to isotropic
materials
• Generalization to 3-D stress case is easy:
• Failure by slip (yielding) occurs when the maximum shearing stress, τ max exceeds the yield
1 σ2
U= ⎡⎣σ 12 + σ 22 + σ 32 − 2μ (σ 1σ 2 + σ 2σ 3 + σ 3σ 1 ) ⎤⎦ = y
2E 2E
σ 12 + σ 22 + σ 32 − 2μ (σ 1σ 2 + σ 2σ 3 + σ 3σ 1 ) = σ y2 For 3D- stress
σ 12 − σ 1σ 2 + σ 22 = σ y2
• It is often convenient to express this as an equivalent stress, σ e:
S K Mondal’s Theories of Failure Page-5
1 ⎡ 2 ⎤ 1/2
σe = ⎢(σ1 − σ2 ) + (σ2 − σ3 ) + (σ3 − σ1 ) ⎦⎥
⎣
2 2
2
1 ⎡ 2 ⎤ 1/2
or σe = ⎢(σ x − σ y ) + (σ y − σz ) + (σ x − σz ) + 6(τ xy + τ yz + τ zx )⎦⎥
⎣
2 2 2 2 2
2
• In formulating this failure theory we used generalized Hooke's law for an isotropic material
so the theory given is only applicable to those materials but it can be generalized to
anisotropic materials.
• The von Mises theory is a little less conservative than the Tresca theory but in most cases
there is little difference in their predictions of failure. Most experimental results tend to fall
on or between these two theories.
• It gives very good result in ductile material.
Higher shear stresses are to the left of origin, since most brittle materials have higher strength in
compression
8. Comparison
A comparison among the different failure theories can be made by superposing the yield surfaces as
shown in figure
S K Mondal’s Theories of Failure Page-7
GATE-2. Which theory of failure will you use for aluminium components under steady
loading? [GATE-1999]
(a) Principal stress theory (b) Principal strain theory
(c) Strain energy theory (d) Maximum shear stress theory
GATE-2. Ans. (d) Aluminium is a ductile material so use maximum shear stress theory
Vs =
1
12G
{
(σ 1 − σ 2 ) + (σ 2 − σ 3 ) + (σ 3 − σ 1 )
2 2 2
} Where E = 2G(1 + μ ) simplify and get result.
IES-2. From a tension test, the yield strength of steel is found to be 200 N/mm2. Using
a factor of safety of 2 and applying maximum principal stress theory of failure,
the permissible stress in the steel shaft subjected to torque will be: [IES-2000]
(a) 50 N/mm2 (b) 57.7 N/mm2 (c) 86.6. N/mm2 (d) 100 N/mm2
IES-2. Ans. (d) For pure shear τ = ±σ x
IES-3. A circular solid shaft is subjected to a bending moment of 400 kNm and a
twisting moment of 300 kNm. On the basis of the maximum principal stress
theory, the direct stress is σ and according to the maximum shear stress
theory, the shear stress is τ . The ratio σ/ τ is: [IES-2000]
1 3 9 11
(a ) (b) (c) (d)
5 9 5 6
IES-3. Ans. (c) σ =
16
π d3
(M + M2 + T 2 ) and τ =
16
π d3
( M2 + T 2 )
σ M + M2 + T 2 4 + 42 + 32 9
Therefore = = =
τ M2 + T 2 42 + 32 5
IES-4. A transmission shaft subjected to bending loads must be designed on the basis
of [IES-1996]
(a) Maximum normal stress theory
(b) Maximum shear stress theory
(c) Maximum normal stress and maximum shear stress theories
(d) Fatigue strength
IES-4. Ans. (a)
IES-9. A rod having cross-sectional area 100 x 10- 6 m2 is subjected to a tensile load.
Based on the Tresca failure criterion, if the uniaxial yield stress of the material
is 200 MPa, the failure load is: [IES-2001]
(a) 10 kN (b) 20 kN (c) 100 kN (d) 200 kN
IES-9. Ans. (b) Tresca failure criterion is maximum shear stress theory.
P sin 2θ P σ yt
Weknow that,τ = or τ max = = or P = σ yt × A
A 2 2A 2
IES-10. A cold roller steel shaft is designed on the basis of maximum shear stress
theory. The principal stresses induced at its critical section are 60 MPa and - 60
MPa respectively. If the yield stress for the shaft material is 360 MPa, the
factor of safety of the design is: [IES-2002]
(a) 2 (b) 3 (c) 4 (d) 6
IES-10. Ans. (b)
IES-12. For a two-dimensional state stress ( σ 1 > σ 2 , σ 1 > 0, σ 2 < 0 ) the designed values
are most conservative if which one of the following failure theories were used?
[IES-1998]
(a) Maximum principal strain theory (b) Maximum distortion energy theory
(c) Maximum shear stress theory (d) Maximum principal stress theory
IES-12. Ans. (c)
S K Mondal’s Theories of Failure Page-10
IES-15. The maximum distortion energy theory of failure is suitable to predict the
failure of which one of the following types of materials? [IES-2004]
(a) Brittle materials (b) Ductile materials (c) Plastics (d) Composite materials
IES-15. Ans. (b)
IES-16. If σy is the yield strength of a particular material, then the distortion energy
theory is expressed as [IES-1994]
(σ 1 − σ 2 ) + ( σ 2 − σ 3 ) + (σ 3 − σ 1 )
2 2 2
(a) = 2σ y2
(b) (σ 2
1 − σ 22 + σ 32 ) − 2μ (σ 1σ 2 + σ 2σ 3 + σ 3σ 1 ) = σ y2
(σ 1 − σ 2 ) + (σ 2 − σ 3 ) + (σ 3 − σ 1 ) = 3σ y2
2 2 2
(c)
(d) (1 − 2 μ )(σ 1 + σ 2 + σ 3 ) = 2 (1 + μ ) σ y
2 2
IES-17. If a shaft made from ductile material is subjected to combined bending and
twisting moments, calculations based on which one of the following failure
theories would give the most conservative value? [IES-1996]
(a) Maximum principal stress theory (b) Maximum shear stress theory.
(d Maximum strain energy theory (d) Maximum distortion energy theory.
IES-17. Ans. (b)
S K Mondal’s Theories of Failure Page-11
Code: A B C D A B C D
(a) 2 1 3 4 (b) 2 4 3 1
(c) 4 2 3 1 (d) 2 4 1 3
IES-18. Ans. (d)
IAS-4. Which one of the following graphs represents Mises yield criterion? [IAS-
1996]
or
16 ⎡1500 + 15002 + T 2 ⎤ = 210 ×106
3 ⎢ ⎥⎦
π (0.050) ⎣
or T = 3332 Nm = 3.332 kNm
(ii ) According to Maximum shear stress theory
σ1 − σ 2 σ y
τmax = =
2 2
or , σ1 − σ 2 = σ y
16
or , 2× M 2 + T 2 = 210 ×106
πd3
The failure criterion is thus obtained by equating Ed and Edy , which gives
± ⎜⎜⎜ ⎜
⎜⎜⎝ 2 ⎠⎟⎟ ( )
2
σ= ⎟ + τ xy
⎟
2
= ± + 32
2 ⎝⎜ 2 ⎠⎟ 2
= 11745.8 − − − (i )
2σ yt2 = 2 ×(70) = 9800 − − − (ii )
2
and,
Since 11745.8 > 9800 so yielding will occur.
Conventional Question GATE-1995
Question: A thin-walled circular tube of wall thickness t and mean radius r is subjected
to an axial load P and torque T in a combined tension-torsion experiment.
(i) Determine the state of stress existing in the tube in terms of P and T.
(ii) Using Von-Mises - Henky failure criteria show that failure takes place
σ 2 + 3τ 2 = σ0 , where σ0 is the yield stress in uniaxial tension,
when
σ and τ are respectively the axial and torsional stresses in the tube.
π
J=
2
{(r + t ) 4
}
− r 4 = 2πr 3 t -neglecting t 2 higher power of t.
P T
∴ The state of stress in the tube is, σ x = , σ y = 0, τ xy =
2πrt 2πr 3 t
(ii) Von Mises-Henky failure in tension for 2-dimensional stress is
σ02 = σ12 + σ22 − σ1σ2
⎛ σ x − σ y ⎞⎟
2
σx + σy
σ1 = + ⎜⎜⎜ ⎟ + τ xy
2
2 ⎜⎝ 2 ⎠⎟⎟
⎛ σ x − σ y ⎟⎞
2
σx + σy
σ2 = − ⎜⎜⎜ ⎟ + τ xy
2
2 ⎜⎝ 2 ⎟⎟⎠
σx σ x2
In this case, σ1 = + + τ xy
2
, and
2 4
σx σ x2
σ2 =
2
−
4
+ τ xy
2
(∵ σy = 0)
⎡σ ⎤ ⎡σ ⎤ ⎡σ ⎤⎡ ⎤
2 2 2
σ x2 σ x2 σ x2 2 ⎥ ⎢ σx σ x2
∴ σ = ⎢⎢ x +
2
0
2 ⎥
+ τ xy ⎥ + ⎢⎢ x − 2 ⎥
+ τ xy ⎥ − ⎢⎢ x + + τ xy ⎥ ⎢ − 2 ⎥
+ τ xy ⎥
⎢⎣ 2 4 ⎥⎦ ⎢⎣ 2 4 ⎥⎦ ⎢⎣ 2 4 ⎥⎦ ⎢⎣ 2 4 ⎥⎦
⎡ σ2 σ2 σ σ2 ⎤ ⎡σ2 σ2 σ σ2 ⎤
= ⎢⎢ x + x + τ xy
2
+ 2. x . x + τ xy 2 ⎥
⎥ + ⎢⎢ x + x + τ xy 2
+ 2. x . x + τ xy 2 ⎥
⎥
⎢⎣ 4 4 2 4 ⎥⎦ ⎢⎣ 4 4 2 4 ⎥⎦
⎡σ2 σ2 ⎤
− ⎢ x − x − τ xy 2 ⎥
⎢4 4 ⎥
⎣ ⎦
= σ x + 3τ xy
2 2
σ0 = σ x2 + 3τ xy
2
300
Permissible shear stress = = 150MN/m2
2
150
∴ Factor of safety = = 3.085
48.62