3.failures Resulting From Static Loading

MACHINE DESIGN
BML Munjal University
8/6/2019 kalluri.vinayak@bml.edu.in
Introduction
➢ The static load is a stationary force or couple applied to a
member.
➢ Stationary means, the load should be unchanging in
✓ magnitude
✓ point or points of application
✓ direction
✓ or in any other manner
➢ A stationary force may cause axial tension or

compression, shear load or bending moment or a
torsional load or any combination of these
8/6/2019 kalluri.vinayak@bml.edu.in 3
Introduction
Failure means a part has had:
– separated into two or more pieces
– become permanently distorted and thus ruined its
geometry
– its reliability downgraded
– its function compromised
Focus of this chapter is on first two cases i.e. predictability of

permanent distortion or separation
4
Introduction
Static strength data of various materials may be available
in two forms
– Data obtained in tests conducted in the similar conditions as
the actual service life
– Data collected in tests conducted in certain ideal conditions
that may not necessary simulate the exact service conditions
The first type of data is always desirable but difficult to
produce
When second type of data is used, then the engineer must
be clever enough to apply suitable factors
5
8/6/2019
Failure Theories
➢ There is no general theory that is inviolable and unique; hence we
call them “failure theories”
➢ Rather it is a choice based on the design requirement and nature of
material, whether ductile or brittle
Ductile materials are designed based on yield criteria
➢Maximum shear stress (MSS) theory
➢Distortion energy (DE) theory
➢Ductile Coulomb-Mohr (DCM) theory
Brittle materials, are designed based on fracture criteria
➢Maximum normal stress (MNS) theory
➢Brittle Coulomb-Mohr (BCM) theory
Failure Theories
How do we know that the given material is ductile?
7
8/6/2019 kallurivinayak@bits-pilani.ac.in 7
Maximum-Shear-Stress (MSS) Theory
➢ Also referred to as the Tresca or Guest theory.
➢ Theory predicts that “yielding begins whenever the
maximum shear stress in any element equals or exceeds
the maximum shear stress in a tension test specimen of
the same material when that specimen begins to yield”
➢ For a general state of stress, the maximum-shear-stress
theory predicts yielding when
1 − 3 S y
 max =  or  1 −  3  S y
2 2
The yield strength in shear is given by, Ssy = 0.5 S y
For design purposes, Equation can be modified to incorporate a
factor of safety, n.
Sy Sy
 max = or  1 −  3 =
2n n
for plane stress (one of the principal stresses is zero) and assuming
that σA ≥ σB:
Case 1: σA ≥ σB ≥ 0. S
For this case, σ1 = σA and σ3 = 0. Equation reduces to a yield condition of  A  y
n
Case 2: σA ≥ 0 ≥ σB . Sy
Here, σ1 = σA and σ3 = σB , and Equation becomes  A − B 
n
Case 3: 0 ≥ σA ≥ σB .
− Sy
For this case, σ1 = 0 and σ3 = σB and Equation gives  B 
n 9
 A   B  0,
1 =  A ,  2 =  B ,  3 = 0
Sy Sy
1 −  3  ,A 
n n
0   A  B,
 1 = 0,
 2 =  A,
3 =  B
Sy
 A  0  B,
1 −  3  ,  1 =  A ,  2 = 0,  3 =  B
n
− Sy Sy Sy
− B  1 −  3  ,  A − B 
n n n
unmarked lines are cases for σB ≥ σA
Problem
The figure shows a shaft mounted in bearings at A and D and having
pulleys at B and C. The forces shown acting on the pulley surfaces
represent the belt tensions. The shaft is to be made of AISI 1035
CD steel using a factor of Safety 2. Based on Maximum shear
stress theory, What diameter should be used for the shaft?
A ductile hot-rolled steel bar has a minimum yield strength
in tension and compression of 450 MPa. Using the
distortion-energy and maximum-shear-stress theories
determine the factors of safety for the following plane
stress states:
σx =200 MPa; σy = -100 MPa; τxy = −50 MPa
A gear reduction unit uses the countershaft shown in the figure. Gear
A receives power from another gear with the transmitted force F of
4.5 kN and applied at the 200 pressure angle as shown. The shaft is
made from steel with Sy = 420 MPa and Sut = 560 MPa.. Determine
the factor of safety of the shaft based on MSS criteria of failure.
A gear reduction unit uses the countershaft shown in the figure. Gear A receives power from
another gear with the transmitted force FA applied at the 200 pressure angle as shown. The
power is transmitted through the shaft and delivered through gear B through a transmitted
force FB at the pressure angle shown. Assume shaft is running at constant speed under steady
state. For the given data, if the shaft is made of steel with yield strength of 580 MPa with
factor of safety 1.2, find the suitable diameter of the shaft by using maximum shear stress
theory.
D1 =150 mm ;D2 =225mm

;L1= 200 mm; L2=175 mm;
L3= 150 mm; FA= 10 kN
A countershaft carrying two V-belt pulleys is shown in the figure.
Pulley A receives power from a motor through a belt with the belt
tensions shown. The power is transmitted through the shaft and
delivered to the belt on pulley B. For the given data, if the shaft is
made of AISI 1020 HR steel (Table A-20: Page1048) with factor of
safety 1.5, find the suitable diameter of the shaft by using MSS theory.
D1 =200 mm ;D2 =300mm ;L1=

250 mm; L2=200 mm ;L3= 150
mm; T1=2800 N ; T2=400 N ;
T3= 1800N; T4=200N
Distortion-Energy (DE) Theory
➢Other names of distortional energy criterion

• The Hencky von- Mises or von-Mises theory
• The shear energy theory
Theory predicts that “yielding occurs when the distortion

strain energy per unit volume reaches or exceeds the
distortion strain energy per unit volume for yield in
simple tension or compression of the same material”
For a general state of stress, the Distortion-Energy Theory
predicts yielding when
1
 ( 1 −  2 )2 + ( 2 −  3 )2 + ( 3 −  1 )2  2
   S y or  '
 Sy
 2 
σ′ is a single, equivalent, or effective stress called von-Mises stress
 ij  ij p Sij or  ij'
 ij =  ij p + Sij
The strain energy per unit volume for simple tension
1
u = 
2
For tri-axial stress, the strain energy per unit volume is
1
u = [1 1 +  2 2 +  3 3 ]
2
Substituting for the principal strains gives
 
i.e.  1 =
1
 1 −  ( 2 +  3 ) ;  2 =
1
 2 −  ( 3 +  1 ) and  3 =
1
 3 −  ( 1 +  2 ) 
E E E
u=
1 2
2E

 1 +  2 +  3 − 2 ( 1 2 +  2 3 +  3 1 )
2 2

The strain energy for producing only volume change is
3 av
2
uv = (1 − 2 ) [by substituting  av for  1 , 2 and  3 ]
2E
Substituting σav = (σ1 + σ2 + σ3)/3 gives
1 − 2 2
uv =
6E

 1 +  2 +  3 + 2 1 2 + 2 2 3 + 2 3 1
2 2

Then the distortion energy is

u d = u − uv =
1
2E
 
 12 +  22 +  32 − 2 ( 1 2 +  2 3 +  3 1 )
1 − 2 2
−
6E

 1 +  22 +  32 + 2 1 2 + 2 2 3 + 2 3 1 
1 + ( 1 −  2 ) + ( 2 −  3 ) + ( 3 −  1 ) 
 2 2 2
ud =  
3E  2 
For the simple tension test , at yield
 1 = S y and  2 =  3 = 0
1 + 2
the distortion energy , udt = Sy
3E
Theory predicts that “yielding occurs when the distortion

strain energy per unit volume reaches or exceeds the
distortion strain energy per unit volume for yield in
simple tension or compression of the same material”
For a general state of stress, the Distortion-Energy Theory
predicts yielding when
1
 ( 1 −  2 )2 + ( 2 −  3 )2 + ( 3 −  1 )2  2
   S y or  '
 Sy
 2 
σ′ is a single, equivalent, or effective stress called von-Mises stress
For plane stress, let σA and σB be the two nonzero principal

stresses, then the von Mises stress is
 = ( −  A B +  )
1
' 2 2 2
A B
The above equation is a rotated ellipse in the σA, σB plane

with σ′ = Sy
For plane stress, let σA and σB be the two nonzero principal
stresses, then the von Mises stress is
 = ( −  A B +  )
1
' 2 2 2
A B
For plane stress case, using xy components of two-

dimensional stress, the von Mises stress can be written as
 
1
 =  x −  x y +  y + 3
' 2 2 2 2
xy
SHEAR YIELD STRENGH:
According to DE (von Mises) criterion, substituting the pure
shear state of stress in the 2-D DE criterion, the two
normal stresses being zero,
Sy
3 xy = S y  xy =
2
= 0.577 S y
3
At yield , S sy = 0.577 S y
According to the MSS criterion,
S sy = 0.5S y
DE criterion predicts the shear yield strength to be 15 percent more than that
predicted by the MSS criterion. Hence MSS is more conservative.
Problem
represent the belt tensions. The shaft is to be made of AISI 1035
CD steel using a design factor of 2. Based on von-Mises theory,
What diameter should be used for the shaft?
Maximum-Normal-Stress Theory
• The maximum-normal-stress (MNS) theory states that failure
occurs whenever one of the three principal stresses equals or
exceeds the strength.
• For the principal stresses for a general stress state in the ordered
form σ1 ≥ σ2 ≥ σ3; This theory then predicts that failure occurs
whenever
σ1 ≥ Sut or σ3 ≤ −Suc
where Sut and Suc are the ultimate tensile and compressive strengths, respectively, given as
positive quantities.
Maximum-Normal-Stress Theory
For plane stress, with σA ≥ σB,
σA ≥ Sut or σB ≤ −Suc
Problem
The figure shows a crank loaded by a force F = 800 N which causes
twisting and bending of the 20 mm-diameter shaft fixed to a support
at the origin of the reference system. In actuality, the support may be
an inertia which we wish to rotate, but for the purposes of a strength
analysis we can consider this to be a statics problem..
A. The material of the shaft AB is
ASTM grade 40 cast iron. Using the
maximum normal stress theory, find
the factor of safety based on the
stress at point A F
B. The material of the shaft AB is AISI
1040 HR Steel. Using the maximum
shear stress theory, find the factor of
safety based on the stress at point A
Problem
represent the belt tensions. The shaft is to be made of ASTM grade
25 cast iron using a design factor of 2. Based on maximum normal
stress theory, What diameter should be used for the shaft?
Text Book Pages: 1040-1047 ; Table A20-A24 ---Material data

3.failures Resulting From Static Loading

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

3.failures Resulting From Static Loading

Uploaded by

Copyright:

Available Formats

MACHINE DESIGN

BML Munjal University

➢ A stationary force may cause axial tension or

Focus of this chapter is on first two cases i.e. predictability of

D1 =150 mm ;D2 =225mm

D1 =200 mm ;D2 =300mm ;L1=

➢Other names of distortional energy criterion

Theory predicts that “yielding occurs when the distortion

Then the distortion energy is

Theory predicts that “yielding occurs when the distortion

For plane stress, let σA and σB be the two nonzero principal

The above equation is a rotated ellipse in the σA, σB plane

For plane stress case, using xy components of two-

You might also like