L3 - Failure Theories
L3 - Failure Theories
L3 - Failure Theories
INTRODUCTION
• “Failure” is the first word in the chapter title.
= [ − ( + )]
=?
=?
=?
u= [ + + −2 + + ]
Distortion-Energy Theory for Ductile
Materials
3
= (1 − 2 )
2
1+ − + − + −
= − =
3 2
/
− + − + −
≥
2
Von Mises stress
If we had a simple case of tension σ, then yield would occur when σ ≥ .
Thus, the left of equation mentioned in the previous slide can be thought
of as a single, equivalent, or effective stress for the entire general state of
stress given by , , and .
This effective stress is usually called the von Mises stress, σ′, named after
Dr. R. von Mises, who contributed to the theory.
Thus equation mentioned in the previous slide, for yield, can be written as
≥
/
=
Distortion-Energy Theory for Ductile
Materials
For plane stress, let and be the two
nonzero principal stresses. Then from von
Mises stress, we get
= − + /
1 /
= − + − + − + 6( + + )
2
=( − + +3 )
/
Other names of Distortion-Energy
Theory
Von Mises or von Mises–Hencky theory
Shear-energy theory
Octahedral-shear-stress theory
Octahedral shear stress Theory
Understanding octahedral shear stress will shed
some light on why the MSS is conservative.
1
= ( − ) +( − ) +( − )
3
Octahedral shear stress Theory
Statement:
Under the name of the octahedral-shear-stress theory, failure is assumed to
occur whenever the octahedral shear stress for any stress state equals or
exceeds the octahedral shear stress for the simple tension-test specimen at
failure.
As before, on the basis of the tensile test results, yield occurs when =
and = = 0.
From Equation mentioned in the previous slides, the octahedral shear stress
under this condition is
2
=
3
Octahedral shear stress Theory
This reduces to
/
− + − + −
2
≥
Design equation Octahedral shear
stress
This equation can be expressed as a design equation
by
=
Widely used theory
The distortion-energy theory predicts
No failure under hydrostatic stress
Agrees well with all data for ductile behavior
Hence, it is the most widely used theory for ductile materials and is
recommended for design problems unless otherwise specified.
Final note concerns the shear yield
strength
Consider a case of pure shear , where for plane stress = = 0.
For yield,
/
Von Mises stress =( − + +3 )
/
(3 ) =
= =0.577
= 0.577
About 15 percent greater than the 0.5 predicted by the MSS theory.
Final note concerns the shear yield
strength
For pure shear, the principal
stresses from equation of Mohrs circle
are = - = .
/
= [490 −490(490)+490 ] = 490 MPa
700
Answer n= = 490 =1.43
700
Answer n= = 490 =1.43
Example-1
Solution:
(b)
The ordered principal stresses are = = 490, = = 210, =0
MPa.
/
using DE = [490 −490(210)+210 ] = 426 MPa
Answer n= = = 1.64
σ′
MSS Case 1,
Answer n = = = 1.43
Example-1
Solution:
(c)
The ordered principal stresses are = = 490, = 0, = = -210
MPa
/
using DE = [490 −490(−210)+(−210) ] = 622
MPa
Answer n= = = 1.13
σ′
MSS Case 2,
Answer n = = =1
( )
Example-1
Solution:
(d)
The ordered principal stresses are = 0, = = -210, = = -490
MPa.
/
using DE = [(−490) −(−490)(−210)+(−210) ] = 426
MPa
Answer n= = = 1.64
σ′
MSS Case 3,
Answer n = - = - = 1.43
Example-1
Solution:
(e)
The ordered principal stresses are = 210, = 210, = 210 Mpa .
/
using DE = [(210−210) +(210−210) +(210−210) ] =0
Mpa
Answer n= = =∞
σ′
MSS
Answer n = = =∞
Coulomb-Mohr Theory for Ductile
Materials
All materials do not have compressive strengths equal to
their corresponding tensile values.
For example, the yield strength of magnesium alloys in compression
may be as little as 50 percent of their yield strength in tension.
The ultimate strength of gray cast irons in compression varies from 3
to 4 times greater than the ultimate tensile strength.
Focus
Theories that can be used to predict failure for materials whose
strengths in tension and compression are not equal.
Coulomb-Mohr Theory for Ductile
Materials
Historically, the Mohr theory of failure dates to 1900, a date that is
relevant to its presentation.
= , = , =
Coulomb-Mohr Theory for Ductile
Materials
−
− −
2 2 = 2 2
+
− +
2 2 2 2
Cross-multiplying and simplifying reduces
this equation to
− =1
− =1
1
− =
Coulomb-Mohr Theory for Ductile
Materials
• Since for the Coulomb-Mohr theory we do not need the torsional shear
strength circle we can deduce it from equation.
− =1
and simplifying gives
=
+
Example-2
A 25-mm-diameter shaft is statically torqued to 230 N·m. It is made of cast
195-T6 aluminum, with a yield strength in tension of 160 MPa and a yield
strength in compression of 170 MPa. It is machined to final diameter.
Estimate the factor of safety of the shaft.
Example-2
Solution:
The maximum shear stress is given by
( )
= = =75MPa
[ ]
The two nonzero principal stresses are 75 and −75 MPa,
making the ordered principal
Stresses = 75, = 0, = -75 Mpa . For yield,
1
− =
= = =1.1
( ) ( )
Example-2
Solution:
Alternatively
( )
= = =82.4MPa
and = 75 MPa.
= =1.1
Failure of Ductile Materials Summary
• Marin collected data from many sources
• Either the maximum-shear-stress theory
or the distortion-energy theory is
acceptable for design and analysis of
materials that would fail in a ductile
manner.
• For design purposes the maximum-
shear-stress theory is easy, quick to use,
and conservative.
• If the problem is to learn why a part
failed, then the distortion-energy theory
may be the best to use.
• For ductile materials with unequal yield
strengths, in tension and in
compression, the Mohr theory is the best
available.
Example-3
This example illustrates the use of a failure theory
to determine the strength of a mechanical
element or component. The example may also
clear up any confusion existing between the
phrases strength of a machine part, strength of a
material, and strength of a part at a point.
A certain force F applied at D near the end of the
380mm lever shown in the Figure, which is quite
similar to a socket wrench, results in certain
stresses in the cantilevered bar OABC. This bar
(OABC) is of AISI 1035 steel, forged and heat-
treated so that it has a minimum (ASTM) yield
strength of 560 MPa. We presume that this
component would be of no value after yielding.
Thus the force F required to initiate yielding can
be regarded as the strength of the component
part. Find this force.
Example-3
Solution:
We will assume that lever DC is strong enough and
hence not a part of the problem. A 1035 steel, heat-
treated, will have a reduction in area of 50 percent or
more and hence is a ductile material at normal
temperatures. This also means that stress
concentration at shoulder A need not be considered.
A stress element at A on the top surface will be
subjected to a tensile bending stress and a torsional
stress. This point, on the 25 mm diameter section, is
the weakest section, and governs the strength of the
assembly. The two stresses are
Example-4
The cantilevered tube shown in Figure is to be made of
2014 aluminum alloy treated to obtain a specified
minimum yield strength of 276 MPa. We wish to select
a stock-size tube from Table using a design factor =
4. The bending load is = 1.75 , the axial tension
is P = 9.0 kN, and the torsion is T = 72 N·m. What is the
realized factor of safety?
Example-3
.
= = = 4.57
.
Example-4
Solution:
Since the maximum bending moment is M =
120F, the normal stress, for an element on the
top surface of the tube at the origin, is
9 120(1.75)( )
= + = + 2 = 9 + 105
/
where, if millimeters are used for the area
properties, the stress is in giga pascals.
Example-4
Solution:
The torsional stress at the same point is
( )
= = =
For accuracy, we choose the distortion-energy
theory as the design basis. The von Mises
stress, as in the previous example, is
Von Mises stress =( +3 ) /
Example-4
Solution:
On the basis of the given design factor, the goal for
is
.
≤ = =0.0690
where we have used giga pascals in this relation to
agree with Eqs. and .
• Programming first three equation on a spreadsheet
and entering metric sizes from Table reveals that a 42
× 5mm tube is satisfactory. The von Mises stress is
found to be = 0.06043 GPa for this size. Thus the
realized factor of safety is
.
= = = 4.57
.
Example-4
Solution:
For the next size smaller, a 42 × 4mm tube,
= 0.07105 GPa giving a factor of safety of
.
= = = 3.88
.
Maximum-Normal-Stress Theory
for Brittle Materials
Statement:
Failure occurs whenever one of the three principal stresses
equals or exceeds the strength.
= ≥ ≥0 Load Line 1
≥0≥ and ≤1
Case 2: Design equation becomes
( )
− = ≥ 0≥ and >1
( . )
τ =K =K =(1) =123860F
[ . ]
Nonzero principal stresses σ and σ are
σ ,σ
231424F + 0 1
= ± (231424F − 0) +(123860F )
2 4
Example-5
Solution:
, = 285213F, −53789F
This puts us in the fourth-quadrant of the ,
plane.
Example-5
Solution:
(a)
For BCM, with n = 1 for failure.
1
− =
285213F (−53789F )
− = − =1
210 × 10 750 × 10
F=699N
Example-5
Solution:
95