Lesson No.

6 in Machine Design 1 Week 7

 Lesson No. 6 in Machine Design 1 – THEORIES OF FAILURE FOR BRITTLE MATERIALS

 THE BRITTLE COULOMB –MOHR THEORY OF FAILURE (BCM).

The Brittle Coulomb- Mohr theory

is used for static loading of Brittle
materials (ϵ f <0.5 ¿ whose
Ultimate strength in Tension is
not equal to its ultimate strength
in Compression.

S ut
Case 1. For σ 1 ≥ σ 3 ≥ 0 , use n = Kσ
1

1 1 Kσ3 Kσ
Case 2. Forσ 1 >0 >σ 3 , use n = S + S
ut uc

S uc
Case 3. For 0 ≥ σ 1 ≥σ 3 , use n = K σ
3

Again, stresses σ 1 ∧σ 3 are all principal stresses.

 THE MODIFIED –MOHR THEORY OF FAILURE (MM).

The Modified Mohr Theory of

Failure for Brittle materials was
based on experimental data plot
on the actual failure of brittle
materials. It is less conservative
than the Brittle Coulomb-Mohr
theory and will predict brittle
failures more closely.

1 K σ1 K σ1+ K σ3
n = S ut
+
Suc

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Lesson No. 6 in Machine Design 1 Week 7

Conditions for the use of Modified Mohr Theory of Failure:

S ut
*** For σ 1> σ 3 >0 , , use n= K σ
1
σ3 1 K σ1 K σ1+ K σ3
||
*** For σ 1 >0 >σ 3 and σ ¿ 1 , use n = S +
1 ut Suc
σ3 Sut
||
*** For σ 1 >0 >σ 3 and σ ≤ 1 , use n= K σ
1 1
Suc
*** For 0> σ 1>σ 3 , use n = Kσ
3

*Important reiterative note: Compressive Stresses and Compressive Strengths, will be treated
as negative quantities. All formulas in this study takes this treatment into consideration.

Example Problem 2. The state of Plane

stresses for an element of a machine member
is shown in the figure:

(a) If the material is 1035 steel in the hot-rolled

condition ( Su=85,000 psi , S y =54,000 psi , ε f =30 % ¿, find the value of the factor of safety by
(1) The Maximum Shear stress theory , (2) The Distortion Energy Theory of Failure.
(b) Find the Factor of Safety if the material is class 30 gray iron (
Sut =30,000 psi , S uc=110,000 psi . ¿ .
1. by the BCM theory of failure
2. by the Modified Mohr theory of Failure.
For both cases (1035 steel and class 30 gray iron materials), there is a stress raiser equal to 2.0.

Solution:
*Known : For (a) An element on the material ϵ f =30 %(or the material is ductile)
subjected to static stresses as in figure.
1045 hot-rolled steel data: Su=85,000 psi ,
S y =54,000 psi
For (b) Sut ≠ S uc ¿ brittle material behavior ,
Class 30 Gray Iron: Sut =30,000 psi ,
Suc =110,000 psi.
For both materials, K f =2.0

*Required: a. For 1030 hot-rolled steel material,

1. Factor of Safety by the MSS theory.

2. Factor of safety by DE theory.

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Lesson No. 6 in Machine Design 1 Week 7

b. For Class 30 Gray Iron material:

1. Factor of Safety by the Brittle Coulomb-Mohr

Theory of failure.
2. Factor of safety by the Modified Mohr Theory.
*Pertinent Sketches:

*Analysis/Evaluation:
- Formulas for the resultant effect of combined stresses will be
used here. However, for the sake of clarity, a Mohr Corcle will
also be presented.

σ x −σ z 2
τ max=
√( 2 ) 2 2
+ τ xz ¿ √ ( 2,500 ) + ( 6,000 )
2

τ max= 6,500 psi

- Calculate the Principal stresses:

σ x +σ z 6,000+1,000
σ1= + τ max = + 6,500 = +10,000 psi
2 2

σ x +σ z 6,000+1,000
σ3= −τ max= −6,500=−3,000 psi
2 2

σ 1−σ 3 10,000−(−3000)
(As a check, τ max= = = 6,500 psi.)
2 2

a. For 1045 Steel, a ductile material, we can ignore the effect of stress
concentration as then load is static.

1. By Maximum Shear stress Theory of Failure,

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Lesson No. 6 in Machine Design 1 Week 7

0.5 S y 0.5(54,000)
n= = =4.15∗( answer)
τ max 6,500

2.By Distortion Energy Theory of Failure,

σ ' =√ σ 12+ σ 23−σ 1 σ 3

2 2
¿ √ ( 10,000 ) + (−3,000 ) −( 10,000 ) (−3000 )

σ ' = 11,790 psi

Sy
54,000
Therefore, n ¿ '
=
=4.58∗¿∗(answer )
σ 11,790
b. For Class 30 Gray Iron, a brittle material in which Sut ≠ S uc we will employ
the stress concentration for the combined static loading.

1. By Brittle Coulomb-Mohr Theory of Failure.

Because σ 1 >0 >σ 3 , use

1 K f σ 1 K f σ 3 ( 2 )( 10,000 ) ( 2 ) (−3,000 )
= + = +
n S ut S uc 30,000 −110,000

n¿ 1.39∗¿∗( answer )

2. By Modified Mohr Theory of Failure,

σ
Because 1 >¿0 >σ ∧ σ =|−3000|<1 ¿
3
|| 3
σ1 10,000

1 K f σ 1 (2)(10,000)
= =
n S ut 30,000

n=1.5 *** Answer

*Comments: 1. For this case of combined loading, the stress concentration
factor is applied to brittle materials even though the load are static.
For ductile material with combined static loading, the effect of stress
raiser is not appled.
2. Maximum Shear Theory of Failure Failure is more conservative than
Distortion Energy Theory as can be seen on the results of the
computations. Both Theories predicts failure applicable to ductile
materials. It is to be noted that although the material is ductile (ε f =¿
30 % ¿, the Ductile Coulomb- Mohr cannot be used here because
S yt =S yc .

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Lesson No. 6 in Machine Design 1 Week 7

3. The Brittle Coulomb-Mohr when employed, will prove to be more

conservative than the Modified Mohr Theory of Failure. Again, both
theories are recommended only for Brittle materials.

4. Data for this problem was supplied to the learner for direct application of
these theories. However, students are encouraged to practice sourcing of
material data necessary for the solution of future practice problems at
the end of each chapter.

*Example Problem 3:
The shaft in the figure is made of Class 20 cast iron ( Sut =20,000 psi , S uc=80,000 psi ¿ . The
ends are simply supported, but are keyed against rotation. The stress concentration factor at
bracket is equal to 2.0. Find the factor of safety for the shaft on either side of the bracket.

*Solution:

 Known: A simply supported beam but is keyed against rotation and loaded as
shown.
Shaft material is Class 20 cast iron with Sut =20,000 psi ,
Suc =80,000 psi. At the bracket , the stress concentration factor is
equal to 2.0.

 Required: Estimate the factor of safety on either side of the bracket. Use the

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Lesson No. 6 in Machine Design 1 Week 7

Modified Mohr Theory.

 Analysis:
The material has a brittle behavior with different values of tensile and
compressive strengths.

 Evaluation/Petinent Sketches:

At topmost fiber of the beam just at the left of the bracket, for a solid circular section:

M L c 32 M L 32(600)
σ TL ≈+ = 3
= 3 = 763.94 psi
I πd π ( 2)
M c 32 M R 32(2,100)
σ TR ≈+ R = = = 2,674 psi
I π d3 π ( 2 )3

Shear stress Analysis:

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Lesson No. 6 in Machine Design 1 Week 7

4 40
4V
For a solid circular section, ( τ tr )NL= = 3 π (2)2 = 25.46 psi located at
3 A
4
the neutral axis of the
beam just left of bracket

4 210
4V
( τ tr )NR = 3 A = 3 π (2)2 = 89.13 psi
4
also located at neutral axis
just right of bracket

T LlL
At Left of Bracket, the angular deformation is θ L =
JG
T R lR
At Right side of the Bracket, the angular deformation is θ R=
JG
Since at this location, θ L=θ R

Therefore,
T L lL T R l R T R l R T R (10) 2
= , or T L = = = TR
JG JG lL 15 3
2
TL = TR
3

At the Bracket, ∑ T =0, or

T - T L- T R = 0
2
(16)(250) −¿ T −¿ T R ¿ 0
3 R
( 16 )( 250 )
T R= =2,400∈∙ lb
2
+1
3
And T L = 16(250) −¿2400 = 1,600¿ ∙ lb
T L c 16 T L 16(1,600)
Therefore, τ L= = =
J π d3 π ¿¿
TRc 16 T R 16 (2,400)
τ R= = 3
= =1,528 psi
J πd π ¿¿

The topmost fiber the bending element just at the left of the bracket
has the following stresses acting on it:

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Lesson No. 6 in Machine Design 1 Week 7

σ x +σ z 763.94+ 0
σ1= + τ max= 2 +1,088¿ 1,470 psi
2

σ x +σ z 763.94+ 0
σ3= −¿ τ max= −¿1,088¿−706 psi
2 2
σ 3 −706
This is a case where σ 1 >0 >σ 3 and | || |
=
σ 1 1,470
=0.48¿ 1

S ut 20,000
Use n = = =6.8∗¿∗.Factor of safety of a point at topmost fiber just left of the bracket.
K f σ 1 2(1,470)

At Topmost fiber just right of the bracket:

σ x −σ z 2 2 2,674−0 2
τ max=
√( 2 )
+ τ xz ¿
= ± 2,030 psi
√( 2 )
+ ( 1,528 )2

σ x +σ z 2,674+ 0
σ1= + τ max= +2,030¿+3,367 psi
2 2

σ x +σ z 2,674+ 0
σ3= −¿ τ max= −¿2,030¿−693 psi
2 2

σ 3 −693
This is also a case of σ 1 >0 >σ 3 and | || |
=
σ 1 3,367
<1

S ut 20,000
Therefore, n = = = 2.97***Factor of Safety at Topmost fiber just right
K f σ 1 2(3,367)

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Lesson No. 6 in Machine Design 1 Week 7

of the bracket.
- Verify the factor of safety at neutral plane just left of the bracket:

τ xz =¿ 25.46+1,019 = 1,045 psi =τ max

And σ 1 =−σ 3
σ3
||
This is a case where σ 1 >0 >¿ σ 3 , and σ =1
1

S ut 20,000
Therefore n = K σ = 2 ( 1,045 ) =9.57
f 1

We chose the Factor of Safety for the weaker

Left Topmost fiber n = 6.8***(answer)

At the neutral plane just right of the bracket:

τ xz =¿89.13 + 1,528 = 1,617 psi =τ max

And σ 1 =−σ 3 ,
σ 3 −1,617
σ 1 >0 >σ 3 ,
| ||
σ1
=
1,617
=1|
S ut 20,000
n¿ K σ = ( =6.18***
f 1 2 1,617 )

-At the neutral plane just left of the bracket:

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Lesson No. 6 in Machine Design 1 Week 7

τ xz =¿25.46 + 1,019 = 1,045 psi =τ max

And σ 1 =−σ 3 ,

σ 3 −1,045
σ 1 >0 >σ 3 ,
| ||
σ1
= |
1,045
=1

S ut
n¿ K σ =¿9.57**
f 1

Summary of Computed Values:

At Topmost fiber of the beam just left of the bracket: n = 6.8

At topmost fiber of the beam just right of the bracket: n = 2.97 *** Answer

At Neutral plane, outermost fiber just left of the bracket: n = 9.57

At Neutral plane, outermost fiber just right of the bracket: n = 6.2

The lower Factor of Safety rules. At the Right topmost fiber threfore,
for the part, Factor of Safety is n = 2.97*** (Answer).

STATIC LOADING FLOWCHART OF FAILURE THEORIES1

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Lesson No. 6 in Machine Design 1 Week 7

Prepared by: RBMAGAY, M. Engr

/rbm

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