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Theories of failure
Introduction:
• Due to large numbers of examples of compound stresses met
with in engineering practice, the cause of failure or
permanent set under such conditions has attracted
considerable attention.
• For brittle materials which do not fail by yielding but fail by brittle
fracture, the maximum principal stress theory is considered to be
reasonably satisfactory.
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.
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.
• This theory implies that failure will occur when the maximum
shear stress 𝑞𝑚𝑎𝑥 in the complex system reaches the value of
the maximum shear stress in simple tension at the elastic
limit,
𝜎1 −𝜎3 𝜎𝑒𝑡
i.e., 𝑞𝑚𝑎𝑥 = = in simple tension
2 2
or 𝜎1 -𝜎3 = 𝜎𝑒𝑡 .
• The theory is not applicable in the case where the state of stress
consists of triaxial tensile stress of nearly equal magnitude
reducing the shear stress to a small magnitude, so that failure
would be by brittle fracture rather than by yielding.
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.
𝜋
𝑀= 𝑑 3 𝜎𝑏 .
32
32 𝑀 32×20×103
𝜎𝑏 = = × 10−6 𝑀𝑁/𝑚2 = 70.74 MN/m2
𝜋𝑑 3 𝜋𝑑 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
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.
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
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
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
2
𝜎1 2 + 𝜎2 2 + 𝜎3 2 − 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1 = 𝜎𝑒 2
𝑚
• In actual design 𝜎𝑒 in the above equation is replaced by the
allowable stress obtained by dividing factor of safety.
• Taking two dimensional case (𝜎3 = 0) the equation reduces to
2 2 2
• 𝜎1 + 𝜎2 − 𝜎1 𝜎2 = 𝜎𝑒 2
𝑚
• If 𝜎 is the working stress in the material, the design criteria may
be stated as follows
2
• 𝜎1 2 + 𝜎2 2 − 𝜎1 𝜎2 ≤ 𝜎2
𝑚 Dr.P.Venkateswara Rao, Associate Professor,
25
Dept. of Civil Engg., SVCE
3. Strain energy theory
• Worth noting points:
• The results of this theory are similar to the experimental results
for ductile materials ( i.e., the materials which fail by general
yielding, for which 𝜎𝑒𝑡 = 𝜎𝑒𝑐 approximately. It may be noted that
order of 𝜎1 , 𝜎2 𝑎𝑛𝑑 𝜎3 is immaterial)
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
1
32 1+
= 3 𝑀2 + 𝑚
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.
Dr.P.Venkateswara Rao, Associate Professor,
29
Dept. of Civil Engg., SVCE
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.
𝜎1 𝜎1
Case (i)
𝜎2
𝜎3
𝜎3 − 𝜎𝑎𝑣 𝜎2 − 𝜎𝑎𝑣
𝜎𝑎𝑣 𝜎𝑎𝑣
𝜎1 − 𝜎𝑎𝑣
𝜎𝑎𝑣 𝜎𝑎𝑣
𝜎1 − 𝜎𝑎𝑣
𝜎𝑎𝑣 𝜎2 -𝜎𝑎𝑣
𝜎𝑎𝑣 Case (ii) 𝜎3 − 𝜎𝑎𝑣 Case (iii)
Dr.P.Venkateswara Rao, Associate Professor,
33
Dept. of Civil Engg., SVCE
4. Shear Strain (Distortion) energy theory
𝜎1 +𝜎2 +𝜎3
• 𝜎𝑎𝑣 is average stress and is given by, 𝜎𝑎𝑣 = .
3
• Since, in case (ii) stress in three mutually perpendicular direction is
identical, there will be uniform change in all directions.
𝜎𝑎𝑣 𝜎𝑎𝑣
𝜎𝑎𝑣 𝜎𝑎𝑣
𝜎𝑎𝑣
𝜎𝑎𝑣 Case (ii)
• In case (iii),
𝜎1 − 𝜎𝑎𝑣
𝛿𝑉 𝜎1 − 𝜎𝑎𝑣
= 𝑒1 + 𝑒2 + 𝑒3
𝑣 𝜎2 -𝜎𝑎𝑣
𝜎1 −𝜎𝑎𝑣 𝜇 𝜎3 − 𝜎𝑎𝑣
= − 𝜎2 − 𝜎𝑎𝑣 + 𝜎3 − 𝜎𝑎𝑣 +
𝐸 𝐸
𝜎2 −𝜎𝑎𝑣 𝜇 Case (iii)
− 𝜎3 − 𝜎𝑎𝑣 + 𝜎1 − 𝜎𝑎𝑣 +
𝐸 𝐸
𝜎3 −𝜎𝑎𝑣 𝜇
− 𝜎1 − 𝜎𝑎𝑣 + 𝜎2 − 𝜎𝑎𝑣
𝐸 𝐸
𝜎1 +𝜎2 +𝜎3 −3𝜎𝑎𝑣 𝜇
= − × 2 𝜎1 + 𝜎2 + 𝜎3 − 3𝜎𝑎𝑣
𝐸 𝐸
𝜎 +𝜎 +𝜎 −3𝜎
= 1 2 3 𝑎𝑣 1 − 2μ
𝐸
𝜎 +𝜎 +𝜎
=0 ( since 1 2 3 = 𝜎𝑎𝑣 ).
3
There is no change in volume in case (iii). It causes only distorsion.
Dr.P.Venkateswara Rao, Associate Professor,
35
Dept. of Civil Engg., SVCE
4. Shear Strain (Distortion) energy theory
Strain energy in Case (i) = Strain energy in case (ii)+ strain energy
in case (iii)
=Strain energy in Case (ii) + distortion energy
in case (iii)
∴Distortion energy = Strain energy in case (i) – Strain energy in case (ii)
We know that
Strain energy per unit volume =
1 2 2 2 2
𝜎1 + 𝜎2 + 𝜎3 − 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1
2𝐸 𝑚
Apply the above equation to case (i) and case (ii), we get
1 2
Distortion energy = 𝜎1 2 + 𝜎2 2 + 𝜎3 2 − 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1 −
2𝐸 𝑚
3𝜎𝑎𝑣 2 (1−2𝜇)
2𝐸
Dr.P.Venkateswara Rao, Associate Professor,
36
Dept. of Civil Engg., SVCE
4. Shear Strain (Distortion) energy theory
Distortion energy
1 2 2 2 2
2 1
= 𝜎1 + 𝜎2 + 𝜎3 − 3𝜎𝑎𝑣 − × 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1 − 3𝜎𝑎𝑣 2
2𝐸 𝑚 2𝐸
1 1
= 1+ 𝜎1 2 + 𝜎2 2 + 𝜎3 2 − 3𝜎𝑎𝑣 2
2𝐸 𝑚
2
1 1 𝜎1 + 𝜎2 + 𝜎3
= (1 + ) 𝜎1 2 + 𝜎2 2 + 𝜎3 2 − 3
2𝐸 𝑚 3
1 1 3𝜎1 2 + 3𝜎2 2 + 3𝜎3 2 − 𝜎1 + 𝜎2 + 𝜎3 2
= (1 + )
2𝐸 𝑚 3
1 1
= (1 + ) 3𝜎1 2 + 3𝜎2 2 + 3𝜎3 2 − 𝜎1 + 𝜎2 + 𝜎3 2
6𝐸 𝑚
1 1
= (1 + ) 2𝜎1 2 + 2𝜎2 2 + 2𝜎3 2 − 2𝜎1 𝜎2 − 2𝜎2 𝜎3 − 2𝜎3 𝜎1
6𝐸 𝑚
1 1 2 2 2
= (1 + ) 𝜎1 − 𝜎2 + 𝜎2 − 𝜎3 + 𝜎3 − 𝜎1 ---(i)
6𝐸 𝑚
Dr.P.Venkateswara Rao, Associate Professor,
37
Dept. of Civil Engg., SVCE
4. Shear Strain (Distortion) energy theory
In uniaxial direction, the state of stress at elastic limit is 𝜎1 = 𝜎𝑒 ,
𝜎2 = 𝜎3 = 0.
1 1
Distortion energy at the elastic limit = (1 + ) 𝜎𝑒 2 + 0 + 𝜎𝑒 2
6𝐸 𝑚
1 1
= (1 + ) 2𝜎𝑒 2 ------(ii)
6𝐸 𝑚
∴ 𝝈𝟏 − 𝝈𝟐 𝟐 + 𝝈𝟐 − 𝝈𝟑 𝟐 + 𝝈𝟑 − 𝝈𝟏 𝟐 = 𝟐𝝈𝒆 𝟐