University of Gonder

Institute of Technology (IoT)

Department of Mechanical Engineering
Machine Elements-I MEng 3152
CHAPTER # 2

2.2 Theories of Failure

By: Andebet T.
2.2 Theories of Failure
Brittle materials (fracture criteria)
 Maximum Normal Stress Theory
 Maximum Normal Strain Theory
 Brittle Coulomb-Mohr
 Modified Mohr
Ductile materials (yield criteria)
 Maximum Shear Stress Theory (Tresca Yield Criterion)
 Strain Energy Theory
 Maximum Distortion Energy Theory
 Ductile Coulomb-Mohr

Out of these eight theories of failure, the maximum normal stress theory
and maximum normal strain theory are only applicable for brittle materials,
and the remaining three theories are applicable for ductile materials.
 INTRODUCTION
 Stress-Analysis is performed on a component to determine
 The required “size or geometry” (design)
 an allowable load (service)
 cause of failure (forensic)

 For all of these, a limit stress or allowable stress value for the
component material is required.

 Hence, a Failure-Theory is needed to define the onset or criterion

of failure

 A failure theory is a criterion that is used in an effort to predict

the failure of a given material when subjected to a complex stress
condition.
 Introduction: Failure
•Occurs if a component can no longer function as intended.

•Failure Modes:
•Yielding: a process of global permanent plastic deformation.
•Change in the geometry of the object.
•Low stiffness: excessive elastic deflection.
•Fracture: a process in which cracks grow to the extent that the
component breaks apart.
•Buckling: the loss of stable equilibrium. Compressive loading
can lead to bucking in columns.
Introduction Failure Prediction Failure Prediction
• The failure of a statically loaded member in uni-axial tension or
compression is relatively easy to predict.
• One can simply compare the stress incurred with the strength of the
material.
• When the loading conditions are Complex (i.e. biaxial loading, sheer
stresses) then we must use some method to compare multiple stresses
to a single strength value.
• These methods are known failure theories
 Need for Failure Theories
 To design structural components and calculate margin
of safety.

 To guide in materials development.

 To determine weak and strong directions.

 1. Maximum normal stress theory
• This theory postulates, that failure will occur in the structural component if the
maximum normal stress in that component reaches the ultimate strength, u
obtained from the tensile test of a specimen of the same material.
• Thus, the structural component will be safe as long as the absolute values of the
2
principle stresses 1 and 2 are both less than u:
u
1 = U and 2 = U
1
-u u

-u
• This theory deals with brittle materials only.
• The maximum normal stress theory can be expresses graphically as shown in the
figure. If the point obtained by plotting the values 1 and 2 of the principle stress
fall within the square area shown in the figure, the structural component is safe.
• If it falls outside that area, the component will fail.
 2. Maximum normal strain theory
 This theory also known as Saint-Venant’s Theory
 According to this theory, a given structural component is safe as long
as the maximum value of the normal strain in that component remains
smaller than the value u of the strain at which a tensile test specimen
of the same material will fail.
 As shown in the figure, the strain is maximum along one of the
principle axes of stress if the deformation is elastic and the material
homogenous and isotropic.

 Thus denoting by 1 and 2 the values of the normal strain along the
principle axes in plane of stress, we write

1 = u and 2 = u

 3. Maximum normal strain theory
 Making use of the generalized Hooke’s Law, we could express these
relations in term of the principle stresses 1 and 2 and the ultimate
strength U of the material.

 We would find that, according to the maximum normal strain theory, the
structural component is safe as long as the point obtained by plotting 1
and 2 falls within the area shown in the figure where  is Poisson’s
ration for the given material. 2

U U
U
1 −
1 +
1
-U U

-U
 4. Maximum shearing stress theory
• This theory is based on the observation that yield in
ductile materials is caused by slippage of the material
along oblique surfaces and is due primarily to shearing
stress.
• A given structural component is safe as long as the
maximum value max of the shearing stress in that
component remains smaller than the corresponding
value of the shearing stress in a tensile test specimen of
the same material as the specimen starts to yield.
• For a 3D complex stress system, the max shear stress is given
by:

max = ½ (1-2)
• On the other hand, in the 1D stress system as obtained
in the tensile test, at the yield limit, 1= Y and 2=0, therefore:-

• max= ½ Y
Maximum shearing stress theory
 Thus, Thus, for a general state of stress, the maximum-shear-
stress theory predicts yielding when

 max = (1 -  2 )
1 1
 max = Y and
2 2
 Y = (1 -  2 )
1 1
2 2
1 -  2 =  Y  1 and  2 have opposite signs
1 =  Y 

1 and  2 have same signs
2 = Y 
 Graphically, the maximum shear stress criterion requires that the two
principal stresses be within the green zone as shown in the figure.
 5. Maximum distortion energy theory
 This theory is based on the determination of the distortion energy in a
given material, i.e. of the energy associated with changes in shape in that
material (as opposed to the energy associated with changes in volume in
the same material).

 A given structural component is safe as long as the maximum value of

the distortion energy per unit volume in that material remains smaller
than the distortion energy per unit volume required to cause yield in a
tensile test specimen of the same material.

 The distortion energy per unit volume in an isotropic material under

plane stress is:
Ud =
1
6G
(
1 - 1 2 +  2
2 2
)
 Maximum distortion energy theory
 In the particular case of a tensile test specimen that is starting to
yield, we have:-
1 =  Y ,  2 = 0
 2Y
and (U d )Y =
6G
Thus,
 2Y
6G 6G
=
1
(
1 − 1 2 +  2
2 2
)
 2Y = 1 − 1 2 +  2
2 2

 This equation represents a principal stress ellipse as illustrated in the

figure
 Von Mises criterion also gives a reasonable estimation of fatigue
failure, especially in cases of repeated tensile and tensile-shear
loading
The distortion-energy theory is also called:
 The von Mises or von Mises–Hencky theory
 The shear-energy theory
 • The octahedral-shear-stress theory
 where the von Mises stress is

 &
 For plane stress, the von Mises stress can be represented by the
principal stresses σA, σB, and zero
Problem #1
 The solid shaft shown in Figure has a radius of 0.5 cm and is
made of steel having a yield stress of 360 MPa. Determine if the
loadings cause the shaft to fail according to Tresca and von
misses theories.

 1 cm

15 kN 32.5 Nm
 Solution
 Calculating
P 15 the stresses caused by axial force and torque
 = = = 19.10 kN = 191MPa
A  (0.515) 2
x 2
cm
P
 = Tc = 3.25(0.5 ) = 19.10 kN = 191MPa
P =  (15
0.5 ) = 165.5MPa
2
x 2
cm
 == A = = 19.10 kN = 191MPa
..55))(0.5 )
xy
JA 3((0
2
x
Tc .025 42 cm 165.5 MPa
 = Tc = 23.25(0.5 ) = 165.5MPa
 = J =  (0.5 ) = 165.5MPa
xy
4
xy

J 2 (0.5 )4 191.1MPa
2
 The Principal stresses
 +  +  
2

 1,2 = x y   x y  +  xy2
2

 x2++  y  2 x +  y  2

 1,2 = x  y    x +  y +  xy 2
2

 1,2 = 2   22  +  xy

− 191 + 02  − 191− 0  2 2  2
= − 191 + 0    − 191−+0(165 2 .5 )
= 2   2   + (165.5)
2

− 191 2+ 0  − 191
2 − 0 
== −95.5  191 .1 .1  + (165 . 5 )2

= −952.5  191 2 
−11 95
= ==95
95
.5.6.6
 191.1
 =−−286
 22== 95
286 .6
1 .6.6
Solution
 Applying Maximum Shear stress theory

1 −  2   y
95.6 − ( −286.6)  360
382.2  360
 So shear failure occurs

 Applying Maximum distortion theory

(1
2 2
)
− 12 +  2   y
2

(95.6− (95.6)(−286.6) + (−286.6) 2 )  3602

2

118677.9  129600
 No Failure
 Problem # 2
 The state of plane stress shown occurs
at a critical point of a steel machine 40 MPa

component. As a result of several

tensile tests, it has been found that the
80 MPa
tensile yield strength is Y=250 MPa
for the grade of steel used. Determine
25 MPa
the factor of safety with respect to
yield, using:

(a) the maximum shearing stress theory

(b) the maximum distortion energy

theory
 Solution
Given  x = 80MPa,  y = −40MPa, and  xy = 25MPa
The principle stresses1 and  2 can be determined by using formula
or mohr's circle,
1 = 85MPa and  2 = −45MPa
(a ). Maximum shearing stress theory
Since  Y = 250MPa, the corresponding shearing stress at yield is

 Y =  Y = (250MPa) = 125MPa
1 1
2 2
The maximum shearing stress can be determined by using formula
or mohr's circle: -
 max = 65MPa
Therefore, tha factor of safety with respect to yield is : -
Y 125MPa
F.S = = = 1.92
 max 65MPa
 Solution
(b). Maximum Distortion Energy Criterion
 
2

1 − 1 2 +  2 =  Y 
2 2

 F.S 
2

(85)2 − (85)(− 45) + (− 45)2 =  250 

 F.S 
250
114.3 =
F.S
F.S = 2.19
 Problems # 3
 A ductile hot-rolled steel bar has a minimum yield strength in tension
and compression of 350 MPa. Using the distortion-energy and
maximum-shear-stress theories determine the factors of safety for the
following plane stress states:
(a) σx = 100 MPa, σy = 100 MPa

 (b) σx = 100 MPa, σy = 50 MPa

 (c) σx = 100 MPa, τxy = -75 MPa

 (d) σx = -50 MPa, σy = -75 MPa, τx y = -50 MPa

 (e) σx = 100 MPa, σy = 20 MPa, τx y = -20 MPa

 Problems # 4
 This problem illustrates that the factor of safety for a machine element
depends on the particular point selected for analysis. Here you are to
compute factors of safety, based upon the distortion energy theory, for
stress elements at A and B of the member shown in the figure. This bar is
made of AISI 1006 cold-drawn steel and is loaded by the forces F = 0.55
kN, P = 4.0 kN, and T = 25 N · m.
THANK YOU