Failure resulting from static load

Chapter 5
What is Failure?
What is Static load?
M S Dasgupta BITS Pilani

Stress Concentration
Changes in cross section causes localized stress concentrations and
severity depends on the geometry of the discontinuity and nature of
the material.

Stress concentration factor

Kt = max/ o
max, maximum stress at
discontinuity and o, nominal
stress.

Kt, value depends only on

geometry of the part.

Design improvement to reduce stress concentration

Stress concentration & Notch

Sensitivity factor
Kt = stress concentration factor
Kf = fatigue stress concentration factor
q = notch sensitivity factor
Q. A steel shaft (ultimate strength 600 MPa) with a shoulder fillet
radius 3mm connects a 32mm radius dia side with 38mm dia.
Estimate Kt and Kf .

M S Dasgupta BITS Pilani

Terminologies
1. Failure theory (FT) to use depends on material (ductile or brittle) and type
of loading (static or dynamic).

2. Terminology:

Su (or Sut) = ultimate strength in tension

Suc = ultimate strength in compression

Sy = yield strength in tension

Sys = 0.5*Sy = yield strength in shear

Sus 0.75*Su = ultimate strength in shear

Se = endurance strength 0.5*Su or get from S-N curve

Se = estimated actual endurance strength = Se(ka) (kb) (kc) (kd) - - -

Sse 0.577* Se = estimated actual endurance strength in shear

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Ductile materials - extensive plastic deformation and

energy absorption (toughness) before fracture
Brittle materials - little plastic deformation and low energy
absorption before failure

Ductility and % Elongation

Ductility is the degree to which a material
will deform before ultimate fracture.
Percent elongation is used as a measure
of ductility.
Ductile Materials have %elong. 5%
Brittle Materials have %elong. < 5%
For machine members subject to repeated
or shock or impact loads, materials with
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%elong > 12% are recommended.

DUCTILE VS BRITTLE FAILURE

(a)
Ductile:
warning before
fracture

(b)

(c)
Brittle:
No
warning
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Failure Prediction Methods

Ductile materials are designed based on
yield criteria
Maximum shear stress (MSS) theory
Distortion energy (DE) theory
Ductile Coulomb-Mohr (DCM) theory

Brittle materials are designed based on

fracture criteria
Maximum normal stress (MNS) theory
Brittle Coulomb-Mohr (BCM) theory
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Maximum-Normal-Stress Theory
The maximum-normal-stress theory states that
failure occurs whenever one of the three
principal stresses equals or exceeds the
strength.
For principal stress
1 2 3
1 Sut or 3 Suc
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Maximum-Shear-Stress Theory
A B 0,
1 A , 2 B , 3 0

Failure occurs when

the maximum shear
stress in any element
equals or exceeds the
maximum shear
stress in a tension
test specimen.

1 3

Sy
n

,A

Sy
n

0 A B,

1 0,
2 A,
3 B
1 3
B

Sy

n
Sy

A 0 B,
1 A , 2 0, 3 B

1 3

M S Dasgupta BITS Pilani

Sy
n

, A B

Sy
n
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Distortion-Energy (DE) Theory

Failure occurs when the distortion strain
energy per unit volume reaches or exceeds
the distortion strain energy per unit volume
for yield in simple tension or compression
For a general state of stress, the Distortion-Energy Theory predicts
yielding when Von Mises stress
1
2

1 2 2 2 3 2 3 1 2
'

S
or

Sy

y
2

For 2D:-

A B
'

2
A

1
2 2
B

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SHEAR YIELD STRENGH:

According to DE (von Mises) criterion, substituting the pure

shear state of stress in the 2-D DE criterion, the two
normal stresses being zero,

2
xy

S y xy

Sy

0.577 S y

3
At yield , S sy 0.577 S y
According to the MSS criterion,

S sy 0.5S y

DE criterion predicts the shear yield strength to be 15 percent more than that
predicted by the MSS criterion. Hence MSS is more conservative.
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Yield Strength Method

Uniaxial Static Stress on Ductile Materials
Static
Load

Ductile Material

In tension:
ANALYSIS:
DESIGN:

max d

S yt

N
In compression:
DESIGN:

max d

S yc
N

For most ductile materials, Syt = Syc

S yt

max

ANALYSIS:

S yt

max

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Maximum Shear Stress

Biaxial Static Stress on Ductile Materials
avg, max
DESIGN:

max d

ANALYSIS:

S ys
N

Sy
2N

S ys

max

Ductile materials begin to yield when the maximum shear stress in a load-carrying
component exceeds that in a tensile-test specimen when yielding begins.

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von Mises Stress

Alternate Form

' 2x 2y x y 3 2xy
For uniaxial stress when y = 0,

' 3
2
x

2
xy

(1 > 2 > 3)

Triaxial Distortion Energy

( 1 2 ) ( 1 3 ) ( 2 3 )
'
2
2

2
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Summary Static Failure Theories:

Ductile materials fail on planes of max
shear stress:
Max shear stress theory
Distortion energy theory

Brittle materials fail on planes of max

normal stress:
Max Normal Stress Theory
Modified Mohr Theory
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Brittle failure or ductile failure? Key: is the fracture surface

on a plane of max shear or max normal stress.

TORQUE:

DUCTILE

BRITTLE

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Real Shaft

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The figure shows a shaft mounted in bearings at A and D and

having pulleys at B and C. The forces shown acting on the
pulley surfaces represent the belt tensions. The shaft is to be
made of AISI 1035 CD steel using a design factor of 2.
Based on MSS & DE What diameter should be used for the
shaft?

M S Dasgupta BITS Pilani

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