Failure Theories: Static

Failure of ductile
materials
Design 1
Mechanical Engineering Faculty
Engineering Division
Universidad Santo Toms
1
Failure Definition

Failure refers to any action that causes the

member of a structure or machine to cease to
function satisfactorily.
() each failure theory is only an attempt to
model the mechanism of failure for a given
class of material

Urugal, Mechanical Design, pg 266

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Types of Mechanical Failures

Ductile yielding
Fragile fracture
Excessive elastic deflection
Buckling
Fatigue
Impact

3
Types of Mechanical Failures

Creep
Relaxation
Thermal shock
Wear
Corrosion
Environmental Stress cracking
Corrosion Stress cracking

4
 Factor of Safety

The actual failure mechanism in an element

can be quite complicated; () In each case a
factor of safety is employed to provide the
required safety and reliability
Urugal, Mechanical Design, pg 266

Engineers employ a factor of safety to ensure

against the foregoing unknown uncertainties
Urugal, Mechanical Design, pg 266

5
Types of Uncertainties
Assumptions made in stress-strain analysis

Assumptions made in load analysis

Nature of failure and failure consequences

Material composition and properties

6
Types of Uncertainties
Effects of manufacturing process

Effects of heat treatment

Effects of wear and/or corrosion

The number of existing uncertainties

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 Choosing a Factor of Safety
failure load
N N material N stress N geoemtry N failure analysis N reliability
allowable load

Nmaterial Description
1.0 Material properties are well known, experimentally obtained from tests on
a specimen known to be identical to the component being designed and
from test representing the loading to be applied
1.1 Material properties are known from a handbook or are manufacturers
values

1.2-1.4 Material properties are not well known

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 Choosing a Factor of Safety
failure load
N N material N stress N geoemtry N failure analysis N reliability
allowable load

Nstress Description
1.0-1.1 Load is well defined as static or fluctuating; there are no anticipated
overloads or shock loads; an accurate stress analysis method has been
used.
1.2-1.3 The nature of the load is defined in an average manner; overloads of 20-
50 percent; stress analysis method with errors less than 50 percent.

1.4-1.7 Load is not well known or the stress analysis method is of doubtful
accuracy.

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 Choosing a Factor of Safety
failure load
N N material N stress N geoemtry N failure analysis N reliability
allowable load

Ngeometry Description
1.0 Manufacturing tolerances are tight and held well

1.0 Manufacturing tolerances are average

1.1-1.2 Dimensions are not closely held

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 Choosing a Factor of Safety
failure load
N N material N stress N geoemtry N failure analysis N reliability
allowable load

Nfailure Description
1.0-1.1 Failure analysis is derived from the stress state, as for uniaxial or
multiaxial static stresses, or fully reversed uniaxial fatigue stresses.

1.2 Failure analysis is a simple extension of the above theories, such as for
multiaxial, fully reversed fatigue stresses or uniaxial nonzero mean fatigue
stresses.
1.3-1.5 Failure analysis is not well developed, as with cumulative damage or
multiaxial nonzero mean fatigue stresses

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Choosing a Factor of Safety
failure load
N N material N stress N geoemtry N failure analysis N reliability
allowable load

Nreliability Description
1.1 Reliability for the part does not need to be high (less than 90 percent)

1.2-1.3 Reliability is an average of 92-98 percent

1.4-1.6 Reliability must be high (greater than 99 percent)

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Static Loading

An ideal static load is one that is applied

slowly and never removed. Some loads that
are applied slowly and removed and replaced
very infrequently can also be considered to be
static.
Mott, Mechanical Elements in Mechanical Design, pg 164

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Static Loading

A static load is a stationary force or couple

applied to a member. () To be considered
static, the load cannot change in any matter.
Budynas-Nisbett, Shigleys Mechanical Engineering Design, pg 206

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Static Failure
The part fails when the maximum value of
stress or strain in a multi-axial state equals
or exceeds the static strength of the
material.

Ideally, engineers should have available

extensive data of strength tests. More
often, it is necessary to design using only
published strength values.
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Static Failure
Frequently, mechanical designers choose
metallic materials.

Structural metal behavior is typically classified

as being ductile of brittle:

Ductile: f 0.05; S yc S yt S y

Brittle: f 0.05; Suc Sut

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Ductile vs Brittle Materials

Ductile Brittle

From MatWeb Website

From NSW HSC Online Website
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Ductile vs Brittle Materials

From Urugal, pg 107

From Missouri S&T IDE120 Website

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Static Ductile Theories

MSS: Maximum-Shear-Stress Theory

(Tresca Yield Criterion): yielding begins
whenever the maximum shear stress at
any point of the body becomes equal to
the maximum shear stress at yielding in an
uniaxial tensile test.

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MSS Theory

When yielding begins:

1 S y
1 Sy
max
2 2
Adapted from Urugal, pg 106
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 MSS Theory

xy

Adapted from Budynas-Nisbett, pgs 76, 83, 213.

triaxial Principal Sy
state of state of max 1/ 3
stress stress
2N
MSS
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 MSS Theory
For plane stress: FAILURE
ZONE
N<1 SAFETY
ZONE
N>1

x y
2
1 2 S
max xy2 y
2 2 2N
A 1; B 2 ; 3 0
Adapted from Budynas-Nisbett, pgs 76, 213
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Static Ductile Theories

DE: Distortion-Energy Theory (VonMises

Yield Criterion): yielding occurs when, at
any point in the body, the distortion energy
per unit volume in a state of combined
stress becomes equal to that associated
with yielding in an uniaxial tensile test.

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DE Theory
Principal Hidrostatic stress Deviatoric stress
stress (dilatational) (distortional)

= +

Adapted from Budynas-Nisbett, pg 213

u uv ud
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 DE Theory
1 2
u
1
2E

12 22 32 2 1 2 2 3 3 1 uv
6E
1 2 3 2

+ -

1 1 2 2 3 3 1
2 2 2 1 2
u d u uv ud Sy
3E
3E 2
For tensile test
(at yielding)

1 2 2 2 3 2 3 1 2
12
Sy
'
2 N

DE 25
 DE Theory
For Plane Stress: FAILURE
ZONE
N<1
SAFETY
ZONE
N>1

1 2
' 2
1 2
2 12

x y 3
' 2
x
2
y
2 12
xy
A 1; B 2 ; 3 0
Adapted from Budynas-Nisbett, pgs 76, 215
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Comparison of the yielding
theories

Adapted from Budynas-Nisbett, pg 215

27
Comparison of the yielding
theories

From Urugal, pg 282

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Resume
Failure cease to function
Factor of safety ensure against
uncertainties
Static Failure stress exceeds static
strength
Static strength for ductile materials yield
stress

29
Resume
Failure theories for ductile materials: MSS
and DE.

DE is more suitable for ductile materials

(experimental results).

MSS is conservative compared to DE

(difference in results is not very great).
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References

Norton, R.L. Machine Design: an integrated

approach. 3rd ed, 2006.
Budynas and Nisbett. Shigleys Mechanical
Engineering Design. 8th ed, 2006.
Mott, R.L. Machine Elements in Mechanical
Design. 4th ed, 2004.
Urugal, A.C. Mechanical Design. 2004.

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References
MatWeb Tensile Strength website:
http://www.matweb.com/reference/tensilestrength
.aspx
HSC Online Tensile Testing website:
http://hsc.csu.edu.au/engineering_studies/lifting/3
210/index.html
Missouri University of Science and Technology
Materials Testing IDE120 website:
http://classes.mst.edu/ide120/lessons/torsion/frac
ture/index.html
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any questions?

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