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Sample Chapter
Sample Chapter
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2 Theories of Failure
In the previous chapter, we have seen that a member is subjected to any of the simple stresses
tensile, compressive, shear or bending stressthen it is easy to predict the failure of the member.
But in practice machine members will be subjected to more than one type of stress simultaneously
and hence it will be difficult to predict the failure of such machine members using these simple
stress theories.
In order to predict the failure of such members subjected to combined stresses, the following
theories of failure are being suggested by different people:
(i) Rankines theory or maximum normal stress theory.
(ii) Guests theory or maximum shear stress theory.
(iii) Hencky-Von-Mises theory or distortion energy theory or shear energy theory.
(iv) Saint Venant theory or maximum strain theory.
sy
1 LM OP F 5 − 20 I
se =
2 N
(s x + s y ) + (s x - s y )2 + 4 t 2xy
Q ... GH P 5.8 JK
4th_Proof 2/08/08
T HEORIES OF FAILURE ##
PROBLEMS
Problem : A machine element is subjected to the following stresses sx = 60 MPa , sy = 45 MPa,
txy = 30 MPa. Find the factor of safety if it is made of C45 steal having yield stress as 353 MPa, using
the following theories of failure.
(i) Maximum principal stress theory,
(ii) Maximum shear stress theory,
(iii) Shear energy theory, and
(iv) Maximum strain theory taking Poisson ratio as 0.3
Given data: sx = 60 MPa, sy = 45 MPa, txy = 30 MPa yield stress, sys = 353 MPa
Poisson ratio v = 0.3.
(i) According to maximum principal stress or Rankines theory of equivalent stress
LM
1 OP
se =
2N= (s x + s y ) + (s x - s y ) 2 + 4 t 2xy
Q ...(5-20)
FG3 t = s IJ
se = ( s x - s y ) 2 + 4 t 2xy
H 2K
e
or e
s ys
\ FOS = = 353/61.85 = 5.71
se
(iii) According to shear energy theory or Hencky-Von-Mises theory, equivalent stress
se = s 2x + s 2y - s x s y + 3 t 2xy ...(5-22)
se = 60 2 + 45 2 - 60 ´ 45 + 3 ´ 30 2 = 75 MPa
s ys 353
\ FOS = = = 4.71
se 75
(iv) According to Max-Strain theory or Saint-Venant theory. Equivalent stress
4th_Proof 2/08/08
1 LM OP
se =
2 N
(1 - v)(s x + s y ) + (1 + v) (s x - s y ) 2 + 4 t 2xy
Q ...(5-23)
1 LM OP
` se =
2 N
(1 - 0.3)(60 + 45) + (1 + 0.3) (60 - 45) 2 + 4 ( 30) 2
Q
= 76.95 MPa
s ys 353
\ FOS = = = 4.59.
se 76.95
Problem : A M.S. shaft having yield stress as 232 MPa is subjected to the following stresses.
sx = 120 MPa, sy = 60 MPa and txy = 36 MPa. Find the factor of safety using:
(i) Rankines theory of failure,
(ii) Guests theory of failure and
(iii) Von-Mises theory of failure.
Given data: Yield stress, sys = 232 MPa
sx = 120 MPa, sy = 60 MPa and txy = 36 MPa.
According to Rankines theory or maximum normal stress theory of failure
LM
1 OP
se =
2N(s x + s y ) + (s x - s y ) 2 + 4 t 2xy
Q
= L(120 - 60) + OP = 126.93 MPa
1
2 MN Q
se [120 - ( - 60)]2 + 4 ( 36) 2
s ys 232
FOS = = = 1.828
se 126.93
(ii) According to Guests theory or max shear stress theory of failure
1
te = (s x - s y )2 + 4 t xy
2
2
se = s 2x + s 2y - s x s y + 3 t 2xy
s ys 232
\ FOS = = = 1.36
se 170.55
4th_Proof 2/08/08
T HEORIES OF FAILURE #%
Problem 3: A machine member is subjected to the following stresses sx = 150 MPa, txy = 24 MPa.
Find the equivalent stress as per the following theories of failure.
(i) Shear stress theory,
(ii) Normal stress theory,
(iii) Von-Mises theory.
Given data: sx = 150 MPa, txy = 24 MPa
(sy = Not given) (sy = 0, Not given)
se = s 2x + s 2y - s x s y + 4 t xy
2
Problem 4: Find the diameter of a rod subjected to a bending moment of 3 kNm and a twisting
moment of 1.8 kNm according to the following theories of failure, taking normal yield stress as
420 MPa and factor of safety as 3.
(i) Normal stress theory, (ii) Shear stress theory.
Given data: Bending moment, Mb = 3 kNm = 3 ´ 106 N-mm
Twisting moment, Mt = 1.8 kNm = 1.8 ´ 106 N-mm
Yield stress, sys = 420 MPa FOS = 3
s ys 420
\ Allowable stress, s = se = = = 140 MPa
FOS 3
30.56 ´ 106
s = = sx
d3
LM
1 30.56 ´ 10 6 F 30.56 ´ 10 I 6 2
F 9.167 ´ 10 I
6 2 OP
140 =
2 MM
@3
+ GH @ JK3
+ 4G
H @ JK 3 PP
N Q
\ d = 61.834 mm
(ii) According to maximum shear stress theory
se = ( s x - s y ) 2 + 4 t 2xy
F 30.56 ´ 10 I 6 2
F 9.167 ´ 10 I 6 2
140 = GH @ JK 3
H @ JK
+ 4G 3
\ d = 63.376 mm
\ Recommended diameter, d = 63.376 ~ 64 mm. (Take bigger one always).
Problem 5: A bolt is subjected to a tensile load of 18 kN and a shear load of 12 kN. The material
has an yield stress of 328.6 MPa. Taking factor of safety as 2.5, determine the core diameter of bolt
according to the following theories of failure.
(i) Rankines theory,
(ii) Shear stress theory,
(iii) Shear energy theory and
(iv) Saint Venants theory. Take Possion ratio = 0.298
Given data: Tensile load, FT = 18 kN = 18 ´ 103 N
Shear load, FI = 12 kN = 12 ´ 103 N
Yield stress, sys = 328.6 MPa FOS = 2.5
s OI 328.6
\ Allowable stress, se = = = 131.44 MPa.
FOS 2.5
F6 18 ´ 10 3
Tensile stress, s = = = sx
A )
Fs 12 ´ 10 3
Shear stress, t = = = txy
A )
(sy = 0, not given)
4th_Proof 2/08/08
LM
1 OP
se =
Ns + s 2x + 4 t 2xy
2 x Q
L
1 M 18 ´ 10 3
F 18 ´ 10 I3 2
F 12 ´ 10 3
I 2 OP
131.44 =
2M
+ GH ) JK + 4G
H ) JK PP
MN ) Q
pdc2
A = 182.59 =
4
\ Core dia, d? = 15.25 mm
(ii) According to maximum shear stress theory,
se = s 2x + 4 t 2xy
F 18 ´ 10 I 3 2
F 12 ´ 10 I 3 2
131.44 = GH ) JK H ) JK
+ 4G
pdc2
\ A = 228.24 =
4
\ Core dia, d? = 17.05 mm
(iii) According to Von-Mises theory of failure
se = s 2x + 3 t 2xy
F 18 ´ 10 I 3 2
F 12 ´ 10 I 3 2
131.44 = GH ) JK +3 GH ) JK
pdc2
A = 209.19 =
4
\ Core dia, d? = 16.32 mm
(iv) According to Saint Venants theory of failure
1 LM OP
se =
2 N
(1 - v)( s x ) + (1 + v) s 2x + 4 t 2xy
Q
1
LM 18 ´ 10 3 F 18 ´ 10 I 3 2
F 12 ´ 10 I3 2 OP
131.44 =
2 MM
(1 - 0.298) + (1 + 0.298) GH A JK +4 GH A JK PP
N A
Q
pdc2
A = 196.196 =
4
\ Core dia, d? = 15.81 mm.
4th_Proof 2/08/08
Problem 6: A SAE 1045 steel rod (sys = 309.9 MPa) of 80 mm diameter is subjected to a bending
moment of 3 kNm and torque T. Taking Factor of safety as 2.5, find the maximum value of torque T
that can be safely carried by rod according to:
(i) Maximum normal stress theory,
(ii) Maximum shear stress theory.
Given data: Material SAE 1045.
Yield stress, sys = 309.9 MPa
FOS = 2.5 diameter d = 80 mm
s ys 309.9
\ Allowable stress, se = = = 123.96 MPa
FOS 2.5
Bending moment, Mb = 3 kNm = 3 ´ 106 N-mm.
MJ × r 6 ×( 80 /2 )
\ Shear stress, t = = = (9.95 ´ 10 6) MPa
J ( p /32 ´ 80) 4
\ t = txy = (9.95 106) T
(sy = 0, not given)
(i) According to maximum normal stress theory
LM1 OP
se =
N2
s x + s 2x + 4 t 2xy
Q
123.96 = L59.68 + OP
1
2 MN Q
59.68 2 + 4 (9.95 ´ 10 - 6 T )2
1
te = s 2x + 4 t 2xy
2
Assuming, t e = 0.5 se = 0.5 ´ 123.96 = 61.98 MPa
1
61.98 = 59.68 2 + 4 ( 9.95 ´ 10 - 6 6 ) 2
2
Torque, T = 5.46 ´ 106 N-mm = 5.46 kNm.
4th_Proof 2/08/08
T HEORIES OF FAILURE $
Problem 7: A stressed element is loaded as shown in Fig. 2.3. Determine the following:
(i) Von-Mises stress,
(ii) Maximum shear stress, 100 MPa
(iii) Maximum normal stress,
(iv) Octahedral shear stress.
150 MPa 150 MPa
Given data: Arranging in descending order 150 ³ 150 > 100
\ s1 = 150 MPa,
s2 = 150 MPa and s3 = 100 MPa (compressive) Fig. 2.!
(i) Von-Mises stress
(s 1 - s 2 )2 + (s 2 - s 3 )2 + (s 3 - s 1 )2
te =
2
1
te = (s 1 - s2 )2 + (s 2 - s 3 )2 + ( s 3 - s 1 )2
3
1
= (150 - 150)2 + (150 - 100)2 + ( -100 - 150)2 = 117.85 MPa.
3
Problem 8: A material has a yield strength of 600 MPa. Compute the factor of safety for each of
the failure theories for the each of the following stresses:
(i) s1 = 420 MPa, s2 = 410 MPa, s3 = 0,
(ii) s1 = 420 MPa, s2 = 180 MPa, s3 = 0,
4th_Proof 2/08/08
T HEORIES OF FAILURE $!
(s 1 - s 2 )- 2 + (s 2 - s 3 )2 + (s 3 - s 1 )2
(a) Von-mises theory, se =
2
t ys 600
\ FOS = = = 1.644
te 364.97
s ys 600
\ FOS = = = 1.4286
se 420
(c) Max. shear stress theory
s 1 - s2 420 - 180
t 12 = = = 120 MPa
2 2
s2 - s 3 180
t 23 = = = 90 MPa
2 2
s1 - s3 420
t 13 = = = 210 MPa
2 2
\ tmax = 210 MPa = te
s ys 600
\ FOS = = = 1.4286
2t max 2 ´ 210
(iii) s1 = 0, s2 = 180 MPa, s3 = 420 MPa