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Failure Theories Static Loads

Static load a stationary load that is gradually applied having an unchanging
magnitude and direction

Failure A part is permanently distorted and will not function properly.

A part has been separated into two or more pieces.

Material Strength
Sy = Yield strength in tension, Syt = Syc
Sys = Yield strength in shear
Su = Ultimate strength in tension, Sut
Suc = Ultimate strength in compression
Sus = Ultimate strength in shear = .67 Su

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Ken Youssefi

Mechanical Engineering Dept., SJSU

Ductile and Brittle Materials

A ductile material deforms significantly before fracturing. Ductility is measured
by % elongation at the fracture point. Materials with 5% or more elongation are
considered ductile.

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Ken Youssefi

Brittle material yields very little before fracturing, the

yield strength is approximately the same as the
ultimate strength in tension. The ultimate strength in
compression is much larger than the ultimate
strength
in tension.
3
Mechanical Engineering
Dept., SJSU

Failure Theories Ductile Materials

Yield strength of a material is used to design components made of
ductile material

Maximum shear stress theory (Tresca 1886)

(max )component > ( )obtained from a tension test at the yield point
= Sy

Failure

Sy
To avoid failure

(max )component <

= Sy

max =

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=S
Ken Youssefi

Sy
2n

Sy
2

n = Safety
factor

Design equation
Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

Distortion energy theory (von Mises-Hencky)
Simple tension test (Sy)t

Hydrostatic state of stress (Sy)h

h
(Sy)h >> (Sy)t
Distortion contributes to
failure much more than
change in volume.

h
h

t
(total strain energy) (strain energy due to hydrostatic stress) = strain energy
due to angular distortion > strain energy obtained from a tension test at the
yield point failure

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Ken Youssefi

Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

The area under the curve in the elastic region is called the Elastic Strain Energy.

U =
3D case
UT =
Strain
energy

Stress-strain relationship

1 =
2 =
3 =
UT =

1
E

2
E

3
E

v
v
v

2
E

1
E

1
E

v
v
v

3
E

3
E

2
E

(12 + 22 + 32) - 2v (12 + 13 + 23)

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2E
Ken Youssefi

11 + 22 + 33

Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

Distortion strain energy = total strain energy hydrostatic strain energy

Ud = UT Uh
UT =

2E

Substitute

Uh =

2E

(12 + 22 + 32) - 2v (12 + 13 + 23)

1 = 2 = 3 = h
(h2 + h2 + h2) - 2v (hh + hh+ hh)

Simplify and substitute

Uh =

3 h
2E

(1)

(1 2v) =

1 + 2 + 3 = 3h into the above equation

(1 + 2 + 3)2 (1 2v)
6E

Subtract the hydrostatic strain energy from the total energy to

obtain the distortion energy
1+v

Ud = UT Uh =
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6E
Ken Youssefi

(1 2)2 + (1 3)2 + (2 3)2

Mechanical Engineering Dept., SJSU

(2)
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Failure Theories Ductile Materials

Strain energy from a tension test at the yield point

1= Sy and 2 = 3 = 0
U d = UT Uh =

1+v

6E

Substitute in equation (2)

(1 2)2 + (1 3)2 + (2 3)2

Utest = (Sy)

(2)

1+v

3E

To avoid failure, Ud < Utest

(1 2)2 + (1 3)2 + (2 3)2

2

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Ken Youssefi

Mechanical Engineering Dept., SJSU

<

Sy

Failure Theories Ductile Materials

(1 2)2 + (1 3)2 + (2 3)2
2

<

Sy

2D case, 3 = 0

(1 12 + 2 ) < Sy =
2

Where is von Mises stress

Sy
n

Design equation

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Ken Youssefi

Mechanical Engineering Dept., SJSU

Failure Theories Ductile Materials

Pure torsion,

= 1 = 2
(12 2 1 + 22) = Sy2

3 = Sy
2

Sys = Sy / 3 Sys = .577 Sy

Relationship between yield strength in
tension and shear

If y = 0, then

1, 2 = x/2

[(x)/2]2 + (xy)2

the design equation can be written in terms of the dominant

component stresses (due to bending and torsion)

(x) + 3(xy)
2

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Ken Youssefi

1/2

Mechanical Engineering Dept., SJSU

Sy
n
10

Design Process
Distortion energy theory

Maximum shear stress theory

Sy
max =
2n

Sy
n

Select material: consider environment, density, availability

Choose a safety factor

Size

Weight

Sy , Su

Cost

The selection of an appropriate safety factor should be based

on the following:
Degree of uncertainty about loading (type, magnitude and direction)
Degree of uncertainty about material strength
Uncertainties related to stress analysis
Consequence of failure; human safety and economics
Type of manufacturing process
Codes and standards
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Ken Youssefi

Mechanical Engineering Dept., SJSU

11

Design Process
Use n = 1.2 to 1.5 for reliable materials subjected to

loads that can be determined with certainty.

Use n = 1.5 to 2.5 for average materials subjected to

loads that can be determined. Also, human safety and

economics are not an issue.
Use n = 3.0 to 4.0 for well known materials subjected to

uncertain loads.

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Ken Youssefi

Mechanical Engineering Dept., SJSU

12

Design Process
Sy , Su

Select material, consider environment, density, availability

Choose a safety factor

Formulate the von Mises or maximum shear stress in terms of size.

Use appropriate failure theory to calculate the size.

Sy
n

Sy
max =
2n

Optimize for weight, size, or cost.

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Ken Youssefi

Mechanical Engineering Dept., SJSU

13

Failure Theories Brittle Materials

One of the characteristics of a brittle material is that the ultimate strength
in compression is much larger than ultimate strength in tension.

Suc >> Sut

Mohrs circles for compression and tension tests.

Suc

Stress
state

Sut

Tension test
Compression test

Failure envelope
The component is safe if the state of stress falls inside the failure envelope.
1 > 3 and 2 = 0

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Ken Youssefi

Mechanical Engineering Dept., SJSU

14

Failure Theories Brittle Materials

Modified Coulomb-Mohr theory
3 or 2

3 or 2

Sut
Safe

Suc

Sut
Safe

Sut

Safe

Sut

II

-Sut

-Sut

Safe

III

Suc

Suc

Cast iron data

Three design zones

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Ken Youssefi

Mechanical Engineering Dept., SJSU

15

Failure Theories Brittle Materials

3

Zone I

Sut

1 > 0 , 2 > 0 and 1 > 2

1 =

Sut

I
Design equation

Sut

II
-Sut

Zone II

III

1 > 0 , 2 < 0 and 2 < Sut

1 =

Sut

Suc

Design equation

Zone III

1 > 0 ,

2 < 0 and 2 > Sut

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Ken Youssefi

Mechanical Engineering Dept., SJSU

1 (

1
1

) 2 =
n
Sut
Suc
Suc
Design equation

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