Lecture - 2

Machine Design: Failure

Theory, Variable Loading
Machinery Dynamics
(3 Credits)

Course Lecturer:

Dr. Nurhadi Siswantoro, S.T., M.T.

Digital Marine Operation and Maintenance Laboratory
workbook.its@gmail.com
Department of Marine Engineering – Faculty of Marine Technology
nurhadi@ne.its.ac.id Institut Teknologi Sepuluh Nopember, Surabaya, Indonesia
Introduction - Machinery Design

https://marine.pert.com.ph/enginemachinery.php
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Introduction - Machinery Design

ENGINE ROOM SIMPLIFIED PIPING AND ER ARRANGEMENT

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Introduction - Machinery Design

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Introduction - Machinery Design

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Introduction - Machinery Design
Characteristics Affect Design
Etc.
Flexibility Strenght

Corrosion Characteristics Reliability

affect the
design
Safety Wear

Cost Life
Utility

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Introduction - Machinery Design
Codes / Standards
 There are many organizations that impose codes
and standards on the products designed and
manufactured.
 ASME
 ASTM
 ANSI
 API
 AS/NZ Standards
 DIN Standards
 ISO
 etc
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Introduction - Machinery Design
Codes / Standards

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Introduction - Machinery Design
Codes / Standards

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Failure Theory
Mechanism of Failure
First sign of trouble
Point where failure (Potential Failure)
Smooth
starts to occur (not
Operation
necessary related to age
P-F interval
Performance

a P
b
Warning Time

F
c
Time
a = asset works well

b = asset can still work but not within specifications (partial failure)

c = asset does not work or fails to work

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Failure Theory
Evolution of Failure Characteristics

-Now
A growing awareness of
Things got older, they Six Failure Pattern actually occur in
“infant mortality”
more likely to fail practice
(Bathtub curve)

1 2 3

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Failure Theory
Type of Failure Pattern
Age Related = 11% Random = 89%

SIX
1. Bathtub failure rate pattern 4. Best new failure rate pattern FAILURE
PATTERNS

2. Worst old failure rate pattern 5. Constant failure rate pattern

Failure rate

Failure rate

time time
3. Slow aging failure rate pattern 6. Worst new failure rate pattern

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Failure Theory

Today

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Failure Theory
Failure related to Strength
 The material strength could be taken in the
form of
 Yield strength,
 Ultimate strength,
 Shear strength,
 or any appropriate combinations of these
strength values

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Failure Theory
 1. Maximum Normal Stress Theory
 This theory states that if in a component one of
the three principal stresses at any point equals
or exceeds the strength of the material, then
failure is deemed to have occurred. If the three
principal stresses are arranged in an ordered
form such as
then, according to this theory, failure
occurs when: St and Sc are tensile and
compressive strengths (yield
or ultimate strength)
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Failure Theory
 2. Maximum Normal Strain Theory or Saint-
Venant's Theory
 This theory states that when at any point in a
component the largest of the three principal strains
becomes equal to or greater than strain
corresponding to the yield strength of the material,
then the failure is deemed to have occurred.

 This theory is applicable only in the elastic range

of stresses and assumes that the yield strengths in
compression and in tension are equal.
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Failure Theory
 Maximum Normal Strain Theory or Saint-
Venant's Theory
According to this theory, failure occurs when:

 Sy is the yield strength

of the material
 v is Poisson's ratio

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Failure Theory
 Maximum Normal Strain Theory or Saint-
Venant's Theory

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Failure Theory
 3. Maximum Shear Stress Theory
 This theory states that failure begins whenever the
maximum shear stress at any point in the continuum
becomes equal to the maximum shear stress in a
tension test specimen of the same material when that
specimen begins to yield. Failure is predicted when any
one of the following conditions exists:

Sy is the yield strength of

the material
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Failure Theory
 4. Distortion Energy Theory or Von Mises Theory
 According to this theory, failure is predicted whenever
the distortion energy in a unit volume of the
continuum equals the distortion energy in the same
volume when uniaxially stressed to the yield strength.
Thus, failure is predicted when
Commonly is called
Effective Stress

Sy is the yield strength of the

material
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Failure Theory
 5. Coulomb Mohr Theory
 This theory is based on three Mohr's Circles: one for
the uniaxial compression test, one for pure sheer, and
one for the uniaxial tension test. Once again assuming
that , the theory can be expressed as:

St and Sc are tensile and compressive

strengths (yield or ultimate strength)
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Variable Loading
 Fatigue
 Most of the time, these maximum fluctuating stresses
are well below the ultimate stress, and, in some cases,
they may be below the yield stress of the material.
Even then, failure has been observed under those
conditions because of the fluctuating nature of the
stress, the failure is called fatigue failure.

 Fatigue failure starts as a crack at places where there

is a stress concentration or material defect.

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Variable Loading
 Endurance Limit
 To established the fatigue strength of material, test are
conducted with varying amounts of applied stress (S) on to
standard specimen and the number of load cycles (N) at
failure is noted.
Relationship between Endurance
Limit and Tensile Strength

Sut is ultimate tensile strengths

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Design of Stress
 The application of stress calculation on
rotating equipment, such as:
 Design of Shaft and Axies
 Design of Belts
 Design of Flywheel
Read page 20-27 (Handbook of Machinery
Dynamics)

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References
Book: Handbook of Machinery Dynamics; Lynn L Faulkner, et al,
2000.
Book: Dynamics of Machinery: Theory and Applications; H. Dresig,
et al, 2010.
Other references from International Journal, internet, news, etc.

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