1.

Maximum Principal stress theory - Problems

Problem 1
In a metallic body the principal stresses are +35 MN/m2 and
-95MN/m2, the third principal stress being zero. The elastic
limit stress in simple tension as well as in simple
compression is equal and is 220 MN/m2. Find the factor of
safety based on the elastic limit if the criterion of failure for
the material is the maximum principal stress theory.
 1. Maximum principal stress theory - Problems
• Solution:
The given principal stresses are:
𝜎1 = +35 MN/m2
𝜎2 = 0
𝜎3 = -95 MN/m2
and 𝜎𝑒𝑡 = 𝜎𝑒𝑐 = 220 MN/m2
• where, 𝜎𝑒𝑡 = Elastic limit stress in tension, and
• 𝜎𝑒𝑐 = Elastic limit stress in compression.
 1. Maximum principal stress theory - Problems
𝜎𝑒𝑡
• 𝜎1 =𝜎𝑡 (working stress in tension), ∴ 𝜎1 =
𝐹.𝑆.
𝜎𝑒𝑡 220
𝐹. 𝑆. = = = 6.28
𝜎1 35
𝜎𝑒𝑐
• 𝜎3 = 𝜎𝑐 ( working stress in compression), ∴ 𝜎3 =
𝐹.𝑆.
𝜎𝑒𝑐
−95 =
𝐹.𝑆.
220
𝐹.S. = = 2.3.
95

• So the material according to the maximum principal stress theory

will fail due to compressive principal stress.
• ∴ 𝐹. 𝑆. = 2.3.
 1. Maximum principal stress theory - Problems

Problem 2
In a cast-iron body the principal stresses are +40 MN/m2 and -100
MN/m2 the third principal stress being zero. The elastic limit
stresses in simple tension and in simple compression are 80
MN/m2 and 400 MN/m2 respectively. Find the factor of safety
based on the elastic limit if the criterion of failure is the maximum
principal stress theory.
1. Maximum principal stress theory - Problems
• Solution:
Given Principal stresses are:
𝜎1 =40 MN/m2
𝜎2 = 0
𝜎3 = -100 MN/m2
𝜎𝑒𝑡 = 80 MN/m2
𝜎𝑒𝑐 = 400 MN/m2
Now, 𝜎1 =𝜎𝑡 (working stress in tension)
𝜎𝑒𝑡
𝜎1 =
𝐹.𝑆.
𝜎 80
𝐹. 𝑆. = 𝑒𝑡 = =2
𝜎1 40
 1. Maximum principal stress theory - Problems
Also 𝜎3 = 𝜎𝑐 ( working stress in compression)
𝜎𝑒𝑐
or 𝜎3 =
𝐹.𝑆.
𝜎𝑒𝑐
−100 =
𝐹.𝑆.
400
𝐹.S. = = 4.
100
• So the material according to the maximum principal stress
theory will fail due to tensile principal stress.
∴ 𝐹. 𝑆. = 2
 2. Maximum shear stress theory - Problems

Problem 1
A mild steel shaft 120 mm diameter is subjected to a maximum
torque of 20 kNm and a maximum bending moment of 12 kNm at
a particular section. Find the factor of safety according to the
maximum shear stress theory if the elastic limit in simple tension
is 220 MN/m2.
 2. Maximum shear stress theory - Problems
Solution
• d = 120 mm = 0.12 m.
• T= 20 kNm
• M= 12 kNm
• 𝜎𝑒𝑡 = 220 MN/m2
• 𝐹. 𝑆. = ?

𝜋
𝑀= 𝑑 3 𝜎𝑏 .
32
32 𝑀 32×20×103
𝜎𝑏 = = × 10−6 𝑀𝑁/𝑚2 = 70.74 MN/m2
𝜋𝑑 3 𝜋𝑑 3
 2. Maximum shear stress theory - Problems
𝜋
• 𝑇= 𝑓𝑠 𝑑3
16
16𝑇 16×20×103
𝑓𝑠 = = × 10−6 𝑀𝑁/𝑚2 = 58.95 N/m2
𝜋𝑑 3 𝜋(0.12)3

𝜎𝑏 𝜎𝑏 2
𝜎= ± + 𝑓𝑠 2
2 2
70.74 70.74 2
= ± + 58.952
2 2
= 35.57± 68.75 = 104.12 MN/m2 or -33.38 MN/m2
 2. Maximum shear stress theory - Problems
• According to maximum shear stress theory
𝜎1 − 𝜎3 = 𝜎𝑡
𝜎1 = 104.12 𝑀𝑁/𝑚2
𝜎2 = 0
𝑀𝑁
𝜎3 = −33.38
𝑚2
104.12 − −33.38 = 𝜎𝑡
𝜎𝑡 = 137.5 𝑀𝑁/𝑚2
𝜎𝑒𝑡 220
• F.S. = = = 1.6
𝜎𝑡 137.5
 2. Maximum shear stress theory - Problems

Problem 2
A shaft is subjected to a maximum torque of 10 kNm and a
maximum bending moment of 7.5 kNm at a particular section. If
the allowable equivalent stress in simple tension is 160 Mn/m2 ,
find the diameter of the shaft according to the maximum shear
stress theory.
 2. Maximum shear stress theory - Problems

Solution:
Maximum torque, T= 10 kNm
Maximum bending moment, M = 7.5 kNm
Allowable equivalent stress in simple tension is, 𝜎𝑡 =
160 𝑀𝑁/𝑚2
Diameter of the shaft is d
𝜋 3 32 𝑀
• M =𝜎𝑏 𝑑 𝜎𝑏 =
32 𝜋𝑑 3

𝜋 16 𝑇
• T= 𝑓𝑠 𝑑3 𝑓𝑠 =
16 𝜋𝑑 3
 2. Maximum shear stress theory - Problems
• Principal stresses are given by,
𝜎𝑏 𝜎𝑏 2
𝜎1,3 = ± + 𝑓𝑠 2
2 2

1 2 2 1 32𝑀 32𝑀 2 32𝑇 2

= 𝜎𝑏 ± 𝜎𝑏 + 4𝑓𝑠 = ± +
2 2 𝜋𝑑 3 𝜋𝑑 3 𝜋𝑑 3

16 2 2
= 𝑀± 𝑀 + 𝑇
𝜋𝑑 3
16 2 2
• 𝜎1 = 𝑀+ 𝑀 + 𝑇
𝜋𝑑 3
• 𝜎2 = 0
16 2 2
• 𝜎3 = 𝑀− 𝑀 + 𝑇
𝜋𝑑 3
 2. Maximum shear stress theory - Problems
• According to maximum shear stress theory,
𝜎𝑡 =𝜎1 − 𝜎3 =
16 2 2 16 2 2
𝑀+ 𝑀 + 𝑇 − 3 𝑀− 𝑀 + 𝑇
𝜋𝑑 3 𝜋𝑑
32 2 2
= 𝑀 + 𝑇
𝜋𝑑 3

32 2 2 32×103 2 2
• d3 = 𝑀 + 𝑇 = 7.5 + 10
𝜋𝜎𝑡 𝜋160×106
=7.957× 10−4
• d= 0.0926 m or 92.6 mm
• ∴ 𝑑 = 92.6 𝑚𝑚
 3. Strain energy theory

Problem 1
A shaft is subjected to a maximum torque of 10 kNm and a
maximum bending moment of 7.5 kNm at a particular section. If the
allowable equivalent stress in simple tension is 160 MN/m2 , find
the diameter of the shaft according to the strain energy theory. Take
1
poisson’s ratio, = 0.24.
𝑚
 3. Strain energy theory
Solution
16 2 2
• 𝜎1 = 𝑀+ 𝑀 + 𝑇 ; 𝜎2 = 0
𝜋𝑑 3
16 2 2
• 𝜎3 = 3 𝑀 − 𝑀 + 𝑇
𝜋𝑑
Now according to strain energy theory,
2 2 2 2 2
• 𝜎𝑡 = 𝜎1 + 𝜎2 + 𝜎3 − 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1
𝑚
2
= 𝜎1 2 + 𝜎3 2 − 𝜎1 𝜎3 (since 𝜎2 = 0)
𝑚
16 2 2
= 2 𝑀2 + 𝑀2 + 𝑇 2 − (𝑀2 − 𝑀2 − 𝑇 2 )
𝜋𝑑 3 𝑚
16 2 1
= 4𝑀2 + 2𝑇 2 (1 + )
𝜋𝑑 3 𝑚
 3. Strain energy theory
16 1
• 𝜎𝑡 = 4𝑀2 + 2 1 + 𝑇2
𝜋𝑑 3 𝑚

1
32 1+𝑚
= 3 𝑀2 + 𝑇2
𝜋𝑑 2
32
= 3 𝑀2 + 0.62𝑇 2
𝜋𝑑

32
d3 = 𝑀2 + 0.62𝑇 2
𝜋𝜎𝑡
32×103
= 6 7.52 + 0.62 × 102
𝜋×160×10

d = 0.0885 m = 88.5 mm
d = 88.5 mm.
 3. Strain energy theory
• A bolt is under an axial thrust of 9.6 kN together with a
transverse force of 4.8 kN. Calculate its diameter according to:
(i) Maximum principal stress theory
(ii) Maximum shear stress theory, and
(iii) Strain energy theory.
Given: Factor of safety =3, yield strength of material of bolt = 270
N/mm2 and Poisson’s ratio = 0.3.
 3. Strain energy theory
• A solid circular shaft is subjected to a bending moment of 60
kNm and a torque of 6 kNm. Design the diameter of the shaft
according to
(i) Maximum principal stress theory
(ii) Maximum shear stress theory
(iii) Maximum strain energy theory
Take 𝜇 = 0.25, stress at elastic limit 250 N/mm2 and factor of
safety =2.5.
4. Shear Strain (Distortion) energy theory - Problem
Problem:
In a steel member, at a point, the major principal stress is 200 MN/m2
and the minor principal stress is compression. If the tensile yield point
of the steel is 235 MN/m2; find the value of minor principal stress at
which yielding will commence, according to each of the following
criteria of failure.
(i) Maximum shear stress
(ii) Maximum total strain energy
(iii) Maximum shear strain energy . Take 𝜇 = 0.26
4. Shear Strain (Distortion) energy theory - Problem
Solution:
𝜎1 = 200 MN/m2
𝜎2 =?
𝜎𝑡 = 235 MN/m2
𝜇 = 0.26
(i) Maximum shear stress criteria:
𝜎1 − 𝜎2 = 𝜎𝑒
200 − 𝜎2 = 235
∴ 𝜎2 = −35MN/m2
(ii) Maximum total strain energy criteria:
2 2 22
𝜎1 + 𝜎2 + 𝜎3 − 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1 = 𝜎𝑒 2
𝑚
Here 𝜎3 = 0
2
𝜎1 2 + 𝜎2 2 − 𝜎1 𝜎2 = 𝜎𝑒 2
𝑚
4. Shear Strain (Distortion) energy theory - Problem
2
𝜎1 + 𝜎2 − 𝜎1 𝜎2 = 𝜎𝑒 2
2 2
𝑚
2002 + 𝜎2 2 − 104𝜎2 − 55225 = 0
𝜎2 2 − 104𝜎2 − 15225 = 0
104 ± 1042 + 4 × 15225
𝜎2 =
2
104 − 267
=
2
= 81.89MN/m2(comp.)
(iii) Maximum shear strain energy criteria:
𝝈𝟏 − 𝝈𝟐 𝟐 + 𝝈𝟐 − 𝝈𝟑 𝟐 + 𝝈𝟑 − 𝝈𝟏 𝟐 = 𝟐𝝈𝒆 𝟐
𝜎3 = 0
𝜎1 2 + 𝜎2 2 − 2𝜎1 𝜎2 + 𝜎2 2 + 𝜎1 2 = 2σe 2
2𝜎1 2 + 2𝜎2 2 − 2𝜎1 𝜎2 = 2σe 2
𝜎1 2 + 𝜎2 2 − 𝜎1 𝜎2 = σe 2
4. Shear Strain (Distortion) energy theory - Problem
𝜎1 2 + 𝜎2 2 − 𝜎1 𝜎2 = σe 2
2002 + 𝜎2 2 − 200𝜎2 = 2352
𝜎2 2 − 200𝜎2 − 15225 = 0
200 ± 2002 + 4 × 15225
𝜎2 =
2
= 58.82MN/m2(comp.)
 Glimpse of theories of failure
(i) Maximum principal stress theory,
𝝈𝒆𝒕
𝝈𝟏 =
𝑭. 𝑺.
𝜎𝑒𝑐
𝜎3 =
𝐹.𝑆.
(ii) Maimum shear stress ( stress difference) theory,
𝝈𝒆𝒕
𝜎1 -𝜎3 =
𝑭.𝑺.
(iii) Maximum strain energy theory,
2 2 2 2 𝜎𝑒𝑡 2
𝜎1 + 𝜎2 + 𝜎3 − 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1 =
𝑚 𝐹.𝑆.
(iv) Maximum shear strain energy (Distortion energy) theory,
2 2 2 𝜎𝑒𝑡 2
𝜎1 − 𝜎2 + 𝜎2 − 𝜎3 + 𝜎3 − 𝜎1 =2
𝐹.𝑆.
 Problems
• A thick steel cylinder with an internal diameter 200 mm has to
withstand an internal fluid pressure of 30 N/mm2, calculate the
thickness of the metal by using,
(i) Maximum principal stress theory
(ii) Maximum shear stress theory
The tensile stress at yield point is 250 N/mm2 use factor of safety
of 2.5.
 Problems
Answers:
(i) Maximum principal stress theory:
b=650000, a=35
𝑟0 = 136.27 mm
t=36.27 mm
(ii) Maximum shear stress theory:
b=50× 104 , a=20
𝑟0 = 158.11 mm
t=58.11 mm
Hence minimum thickness of metal required is 58.11 mm.
∴Provide 60 mm thickness.
 Problems
• A cylindrical shell 1.2 m diameter is to be made of mild steel
plates. It is subjected to an internal pressure of 1.5 MN/m2. If
the material yields at 200 MN/m2, calculate the thickness of the
plate on the basis of following theories of failure assuming a
factor of safety of 3 in each case.
(i) Maximum principal stress theory
(ii) Maximum shear stress theory
(iii) Maximum shear strain energy theory.
 Problems
• At a point , the major principal stress is 120 N/mm2 (tensile)
and the minor principal stress is compressive. If the yield stress
of steel is 250 N/mm2. Find the value of minor principal stress
at which yielding takes place according to each of following
theories of failure.
(i) Maximum shear stress theory
(iii) Maximum principal stress theory
 Problems
• A solid circular shaft is subjected to a bending moment of 60
kNm and a torque of 6 kNm. Design the diameter of the shaft
according to
(i) Maximum principal stress theory
(ii) Maximum shear stress theory
(iii) Maximum strain energy theory
Take 𝜇 = 0.25, stress at elastic limit 250 N/mm2 and factor of
safety =2.5.