Lecture 7.

Static failure theories

Important notices:
Revised schedule for next few weeks:
Thurs, 4/27: Static Failure Theories

Tues, 5/2: Static Failure Theories (cont'd)

Thurs, 5/4: Mid-quarter review + HW #4 DUE

Tues, 5/9: MIDTERM EXAM

Thurs, 5/11: Fatigue failure

We'll return to the original course schedule for the week of 5/16
onwards.

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 Lecture 7. Static failure theories

Quiz #3 (10 pts total)

ME174 M.P. Rao 2

 Lecture 7. Static failure theories

Quiz #3 (10 pts total)

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 Lecture 7. Static failure theories

Introduction to failure theories

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 Lecture 7. Static failure theories

Failure
Failure is generally defined as a loss of function of a machine element
However, functional loss is often dependent upon the nature of the
application, thus failure can take many forms. For example, so far,
weve learned that failure can occur when a machine element:
Permanently deforms (i.e. material yielding); or
Separates into one or more pieces (i.e. fracture); or
Instantaneously shortens under compressive loading, due to large
lateral deflection (i.e. buckling)
Failure can also vary depending on the temporal nature of the
loading. For example, failure can occur at different loads under :
Static loading (this lecture & next); or
Fatigue loading (Lectures 11-14)
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 Lecture 7. Static failure theories

Ductile vs. brittle failure

Ductile failure (emphasized in this course)
Failure occurs first by onset of plasticity Brittle materials
(when > SY), followed by fracture (e.g. concrete, glass, etc., but also
many metals under specific loading
(when = Su), often only after significant &/or service conditions)
plasticity has occurred
Graceful failure mode, since large failure
strain produced by plasticity (f > 0.05) SU x
provides warning of impending failure
Brittle failure (not covered in detail) Su x
Minimal to no plasticity prior to failure by SY
fracture (when = Su) Ductile materials
(e.g. metals, plastics, etc.)
Catastrophic failure mode, since minimal
failure strain provides little to no warning
of impending failure (f < 0.05) f f

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 Lecture 7. Static failure theories

Failure theories
Thus far, weve stated that strength-based design seeks to ensure
that stresses in a machine element are kept below the materials
strength
However, we have yet to define exactly what stresses are important
within this context
In simplistic stress states, e.g. uniaxial tension, this could be as
simple as ensuring max principal stress, 1, is less than SY
However, in more complex multiaxial stress states things become less
clear, since failure may be caused by exceeding maximum normal
stress, shear stress, strain energy, or other critical values
Failure theories developed over the years provide means for
consideration of these additional failure modes

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 Lecture 7. Static failure theories

Common static failure theories

Ductile Materials (emphasized in this course)

Maximum-Shear-Stress (MSS)
This lecture

Distortion Energy (DE)

Next lecture

Ductile Coulomb-Mohr (DCM)

Brittle Materials (not covered in detail)

Maximum Normal Stress (MNS)

Brittle Coulomb-Mohr (BCM)

Modified Mohr (MM)

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 Lecture 7. Static failure theories

Maximum-shear-stress theory (MSS)

for ductile materials

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 Lecture 7. Static failure theories

Theoretical basis http://www.doitpoms.ac.uk/tlplib/metal-forming-3/plane_stress.php

In tension tests, onset of yielding

is observed to correspond with
formation of slip lines oriented
45 to tensile axis
Since slip is associated with
shear stress, can define shear-
based failure theory that relates
yield strength measured during
tensile testing to principal
x
stresses in more complex
multiaxial stress states SY

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 Lecture 7. Static failure theories

Maximum-shear-stress (MSS) theory

Predicts that yielding begins
whenever the maximum y

shear stress in any element 2=3=0 1=Sy

equals or exceeds the 1 = Sy

maximum shear stress in a z A

x
tension test specimen of the max

same material, when that
specimen begins to yield 1 3 Sy
max n = Safety Factor
Also referred to as the 2 2n
Sy
Tresca Theory Safe design when : 1 3
Used often in mechanical n
design, despite conservative For uniaxial tension, 3 0
nature Sy
Safe design when 1
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 Lecture 7. Static failure theories

MSS theory for plane stress state

Assumptions:
Principal stress convention of 1 2 3 is maintained; and
Plane stress state (i.e. out-of-plane principal stress is zero)

Case 1: In-plane principal stresses are both tensile (i.e. 1 2 0)

2 Sy
y Safe design when : 1 3
n
3 2 1
Since 3 0,
1
Sy
z A
x Safe design when : 1
max n

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 Lecture 7. Static failure theories

MSS theory for plane stress state (contd)

Assumptions :
Principal stress convention of 1 2 3 is maintained; and
Plane stress state (i.e. out-of-plane principal stress is zero)

Case 2: In-plane principal stresses are tensile & compr. (i.e. 1 0 3)

3 Sy
y Safe design when : 1 3
n
3 2 1
Since 3 0,
1
Sy
z A
x Safe design when : 1 3
max n

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 Lecture 7. Static failure theories

MSS theory for plane stress state (contd)

Assumptions :
Principal stress convention of 1 2 3 is maintained; and
Plane stress state (i.e. out-of-plane principal stress is zero)

Case 3: In-plane principal stresses are both compr. (i.e. 0 2 3)

3
Sy
y Safe design when : 1 3
n
3 2 1
Since 1 0,
2
Sy
z A
x Safe design when : 3
max n

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 Lecture 7. Static failure theories

MSS design envelope for plane stress

Assumptions :
Principal stress convention of 1 2 3 is maintained; and
Plane stress state (i.e. out-of-plane principal stress is zero)
n = 1 & P1 P2
Case 1: In-plane principal stresses are both tensile
P2
Syt
2
y

3 2 1

Syt 1
P1 z A
x
max

Sy
Safe when : 1
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 Lecture 7. Static failure theories

MSS design envelope for plane stress (contd)

Assumptions :
Principal stress convention of 1 2 3 is maintained; and
Plane stress state (i.e. out-of-plane principal stress is zero)
n = 1 & P1 P2
Case 2: In-plane principal stresses are tensile & compr.
P2

3
y

3 2 1

Syt 1
P1 z A
x
max

Sy
-Syc Safe when : 1 3
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 Lecture 7. Static failure theories

MSS design envelope for plane stress (contd)

Assumptions :
Principal stress convention of 1 2 3 is maintained; and
Plane stress state (i.e. out-of-plane principal stress is zero)
n = 1 & P1 P2
Case 3: In-plane principal stresses are both compr.
P2
3

3 2 1

2
-Syc P1 z A
x
max

Sy
-Syc Safe when : - 3
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 Lecture 7. Static failure theories

MSS design envelope for plane stress (contd)

Assumptions :
Principal stress convention of 1 2 3 is maintained; and
Plane stress state (i.e. out-of-plane principal stress is zero)
n = 1 & P1 P2
P2
Syt

Syt
-Syc P1

-Syc
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 Lecture 7. Static failure theories
Solution plan
Example 1 Determine principal stresses
A plate made from ductile, hot- Apply MSS theory to find unknown
rolled steel with tensile & factor of safety
compressive yield strength of 350 Determine principal stresses
MPa is subjected to the state of
plane stress shown below.
Determine the factor of safety
against yield using MSS theory.
y

75 MPa

100 MPa
x

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 Lecture 7. Static failure theories y

Example 1 75 MPa
Apply MSS theory to find unknown FS 100 MPa
From previous page: x

1 = 140 MPa; 2 = 0; 3 = -40 MPa

P2
Syt

Syt
-Syc P1

-Syc
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 Lecture 7. Static failure theories
Solution plan
Example 2 Determine principal stresses
The same plate in the previous Apply MSS theory to find unknown
example is now subjected to a factor of safety
different state of plane stress shown Determine principal stresses
below. Determine the factor of
safety against yield using MSS
theory (Syt = Syc = 350 MPa, as
before). y
75 MPa

50 MPa

50 MPa
x

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 Lecture 7. Static failure theories y
75 MPa

Example 2 50 MPa
Apply MSS theory to find unknown FS 50 MPa
From previous page: x

1 = 0; 2 = -11 MPa; 3 = -114 MPa

P2
Syt

Syt
-Syc P1

-Syc
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