Design of Machine Elements

Dr. G.Praveen Kumar

Assistant Professor
Mechanical Engineering Department
IIITDM Kurnool
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 Design
of
Machine
Elements

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Theories of failure
• Introduction to failure

• Failure of various types of materials

• Theories of failure

• Comparison of failure theories

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Theories of failure
What is Failure?
Anything that might cause a component to lose its structural tolerances,
preventing it from serving its intended purpose

• This means
– Fracture
– or plastic deformation
– or excessive elastic deformation

• For this course, plastic deformation is considered as failure

Failure and fracture are not the same

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Theories of failure
• Machine parts fail when the stresses induced by external forces exceed
their strength
• Strength
• Property of the machine element
• Property of the material

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Theories of failure
• Design
• Selection of optimum materials and dimensions to withstand failure due to applied load
• Failure
• Mechanical failure in materials
• Type of applied loads

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Theories of failure
• When designing using a specific material, an upper limit on the
state of stress needs to be defined
• Ductile Material
– Failure is usually specified by the initiation of yielding
• Brittle Material
– Failure is usually specified by fracture

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Theories of failure

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Theories of failure
• Brittle material: If percentage elongation at fracture is less than 5%

• Ductile material: If percentage elongation at fracture is more than 5%

• Ductile materials may fail by fracture if there is:
• Cyclic loading
• Long term static loading at elevated temperature (creep loading)
• Impact loading
• Work hardening
• Severe quenching

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Design for Strength
• Type of applied loads
• Static load:
• Does not change in magnitude and direction and normally increases gradually
to a steady value
• Point of application of load is also not changing

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Design for Strength
• Type of applied loads
• Variable load:
• Change in magnitude
• E.g. traffic of varying weight passing a bridge
• Change in direction
• E.g. load on piston rod of a double acting cylinder

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Allowable Stresses: Factor of Safety
Working Stress
When designing machine parts, it is desirable to keep the stress lower than the
maximum or ultimate stress at which failure of the material takes place. This stress is
known as the working stress or design stress. It is also known as safe or allowable
stress.

Factor of Safety

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Allowable Stresses: Factor of Safety
• For ductile materials, the yield strength and for brittle materials the ultimate
strength are taken as the critical stress
• An allowable stress is set considerably lower than the ultimate strength
• The ratio of ultimate to allowable load or stress is known as factor of safety
• For ductile materials
• Allowable stress = yield stress/F.S.
For brittle materials
• Allowable stress = ultimate stress/F.S.
 F.S ≥ 1
• The ratio must always be greater than unity

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Allowable Stresses: Factor of Safety
Why Failure Theories are Required?
• Modes of failure are readily defined if the member is
subjected to a uniaxial state of stress e.g. simple tension

• In case of biaxial or triaxial stress, the criterion for failure

becomes more difficult to establish

• Various failure theories are used to predict the failure of a

material subjected to a multiaxial state of stress

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Theories of failure
• Machine element is subjected to a system of complex stress system
• It is important to predict the mode of failure of a machine element
• Design methodology will be based on a particular failure criterion
• Theories of failure are essentially a set of failure criteria developed for
the ease of design
• In machine design an element is said to have failed if it ceases to
perform its function

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Theories of failure

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Theories of failure
• There are basically two types of mechanical failure:
• Yielding- This is due to excessive inelastic deformation rendering the
machine
• part unsuitable to perform its function. This mostly occurs in ductile materials.
• Fracture- in this case the component tears apart in two or more parts.
This mostly occurs in brittle materials.

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Theories of failure
 Static failure theories
• Predicting failure in members subjected to uni-axial stress is both simple and straight-
forward. But, predicating the failure stresses for members subjected to bi-axial or tri-
axial stresses is much more complicated.

• A large numbers of different theories have been formulated. The principal theories of
failure for a member subjected to bi- axial stress are as follows:
I. Maximum principal (or normal) stress theory (Rankine’s th.)
II. Maximum shear stress theory (Guest’s theory)
III. Maximum strain energy theory (Haigh’s theory)
IV. Maximum distortion energy theory (Hencky&Von Mises th.)
V. Maximum principal (or normal) strain theory (Saint’s theory)

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Maximum Principal or Normal Stress Theory
(Rankine’s Theory)
According to this theory, the failure or yielding occurs at a point in a member when the
maximum principal or normal stress in a bi-axial stress system reaches the limiting
strength of the material in a simple tension test.
σ Max = σ Yield Point
σ Max ≤ σ Allowable - Safe Condition
Suppose we arrange the three principle stresses for any stress state in the ordered form
σ1 > σ2 > σ3 then this theory predicts the failure occurs. Whenever σ 1 = σ yt or σ 1 = σ ut
which ever is applicable.
This theory considers only the maximum of principal stresses and disregards the
influence of the other principal stresses. the dimensions of the component are
determined by using a factor of safety.
For Tensile Stress σ 1 = σ Yield Ten.Point /F.S or σ Ultimate Ten. Strength / F.S
For Compressive Stress σ 1 = σ Yield Comp. Point / F.S or σ Ultimate Comp. Strength / F.S
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Theories of failure
This theory assume that when the maximum principal stress in a complex
stress system reaches the elastic limit stress in a simple tension,
failure will occur.
Therefore the criterion for failure would be
s1 = syp
For a two dimensional complex stress system s1 is expressed as
Where sx, sy and txy are the stresses in the any given complex stress
system.

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Theories of failure
Maximum Principal or Normal Stress Theory
(Rankine’s Theory)

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Theories of failure
Maximum Shear Stress Theory
(Guest’s or Tresca’s Theory)
According to this theory, the failure or yielding occurs at a point in a member when the
maximum shear stress in a bi-axial stress system reaches a value equal to the shear stress
at yield point in a simple tension test.

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Theories of failure
Maximum Shear Stress Theory
(Guest’s or Tresca’s Theory)

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Theories of failure
Maximum Shear Stress Theory
(Guest’s or Tresca’s Theory)

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Theories of failure
Maximum Shear Stress Theory
(Guest’s or Tresca’s Theory)

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Theories of failure
Maximum Strain Energy Theory
(Haigh’s Theory)
According to this theory, the failure or yielding occurs at a point in a member when the
strain energy per unit volume in a bi-axial stress system reaches the limiting strain
energy (i.e. strain energy at the yield point ) per unit volume as determined from simple
tension test.

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Theories of failure
Maximum Strain Energy Theory
(Haigh’s Theory)

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Theories of failure
Distortion Energy Theory
(Von misesTheory)

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Theories of failure
Maximum Distortion Energy Theory
(Hencky and Von Mises Theory)
According to this theory, the failure or yielding occurs at a point in a member when the
distortion strain energy (also called shear strain energy) per unit volume in a bi-axial
stress system reaches the limiting distortion energy (i.e. distortion energy at yield point)
per unit volume as determined from a simple tension test.

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Theories of failure

We know that distortion energy at yield point in a tension test specimen

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Theories of failure

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Theories of failure

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Theories of failure
Maximum Principal Strain Theory
(Saint Venant’s Theory)
According to this theory the yielding occurs at a point when the
maximum principal strain at any point reaches a value equal to the
elastic strain as computed in simple tension test. Thus the criteria for
failure is
ϵmax = ϵ Allowable, ϵ max ≤ ϵ Allowable
ϵ1 =
We know the three principle strains are

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Theories of failure
Maximum Principal Strain Theory
(Saint Venant’s Theory)

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Theories of failure
Comparison of all failure of theories

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Theories of failure

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Theories of failure
Example :1
• The load on a bolt consists of an axial pull of 10kN together with a
transverse shear force of 5kN. Find the diameter of bolt required
according to
1. Maximum principal stress theory
2. Maximum shear stress theory
3. Maximum principal strain theory
4. Maximum strain energy theory
5. Maximum distortion energy theory
Permissible tensile stress at elastic limit =100MPa and Poisson’s ratio
=0.3
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Theories of failure
Solution 1
• Cross – sectional area of the bolt,
 2
A  d  0.7854d 2
4
• Axial stress,
P 10 12.73
1    kN / mm 2

A 0.7854d 2 d2

• And transverse shear stress,

Ps 5
   6.365kN / mm 2

A 0.7854d 2

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Theories of failure
According to maximum principal stress theory
• Maximum principal stress,
   
2

1   x    x    2xy
 2   2 
 x   y   x   y 
2

1         2xy
 2   2 

 12 .73    12 .73
2
  6.365  
2

1   2 
  2 
 2  
 2 d   2 d   d  
15365
1  N / mm 2

d2
• According to maximum principal stress theory, Syt = σ1
15365
100  2
 d  12.4mm
d
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Theories of failure
According to maximum shear stress theory
• Maximum shear stress,
 x   y 
2

 max      2xy
 2 
 x 
2

 max      2xy
 2 
 12.73  2  6.365  2  9 9000
  2    2    2 kN / mm 2  2 N / mm 2
 d   d   d d
• According to maximum shear stress,
S yt
9000 100
 max   2 
2 d 2
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Theories of failure
• According to maximum strain energy
theory
21  2
1   2   S yt
2 2 2

m
15365    2635  15365  2635
2 2


 d 2   d 2   2    0.3  100 2

d2 d2
d  12.78mm
• According to maximum distortion theory
S yt  1
2
  2  1  2
2

 15365  2   2635  2 15365  2635 
100    2       
 d   d  2
d 2
d 2 
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 41
Theories of failure
According to maximum principal strain theory
• The maximum principal stress,
 x   y  x   y
2
 
1         2xy
 2   2 

  x 
2
 15365
1   x       2
xy 
 2   2  d2
• And minimum principal stress,

 x   y  x   y
2
 
 2         2xy
 2   2 

 x   x 
2 2 2
12.73  12.73   6.365 
2        xy 
2
  2 
 
 2   2   2d   d 
2 2
d
 2635
2 
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2
N / mm 2
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Theories of failure
• And according to maximum principal strain theory,

σ1 σ 2 Syt
 
E mE E
σ2 15365 2635  0.3
σ1   Syt  2
 2
 100
m d d
d  12.7mm

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