Machine Design - I

Tutor:
Dr. Owaisur Rahman Shah
 Module – IIA
Week 3 – 4
Chapter 5: Mechanical Engineering Design
by Joseph Shigley, Charles Mischke, Richard Budynas
10th Edition.

• Failure Resulting From Static Loading

– Static Strength
– Stress Concentration
– Failure Theories
– Maximum Shear Stress Theory
– Distortion-Energy Theory
– Coulomb-Mohr Theory
– Maximum Normal Stress Theory
– Mohr Theory for Brittle Materials
– Selection of Failure Criteria
 Static Strength
• A static load is a stationary force or couple applied to
a member. To be stationary, the force or couple must
be unchanging in magnitude, point or points of
application, and direction
 Static Strength
• Failure of the part would endanger human life, or the
part is made in extremely large quantities; consequently,
an elaborate testing program is justified during design.
• The part is made in large enough quantities that a
moderate series of tests is feasible.
• The part is made in such small quantities that testing is
not justified at all; or the design must be completed so
rapidly that there is not enough time for testing.
• The part has already been designed, manufactured, and
tested and found to be unsatisfactory. Analysis is
required to understand why the part is unsatisfactory
and what to do to improve it.
 Static Strength
• Stress Concentration
– A load of 20 kip induces a nominal
tensile stress of 20 kpsi in the shank as
depicted at point A in. At the critical
location in the fillet the stress is 40
kpsi, and the SCF is K is 2.
– A load of 30 kip induces a nominal
tensile stress of 30 kpsi in the shank at
point B. The fillet stress is still 40 kpsi
(point D), and the SCF K is 1.33.
– At a load of 40 kip the induced tensile
stress (point C) is 40 kpsi in the shank.
At the critical location in the fillet, the
stress (at point E) is 40 kpsi. The SCF K
is 1.
 Static Strength
• Failure Theories
– Ductile materials are normally classified such that εf > 0.05 and have an
identifiable yield strength that is often the same in compression as in tension (Syt
= Syc = Sy). Brittle materials, εf < 0.05, do not exhibit an identifiable yield strength,
and are typically classified by ultimate tensile and compressive strengths, Sut and
Suc, respectively

• Ductile materials (yield criteria)

– Maximum shear stress (MSS)
– Distortion energy (DE)
– Ductile Coulomb-Mohr (DCM)

• Brittle materials (fracture criteria)

– Maximum normal stress (MNS)
– Brittle Coulomb-Mohr (BCM)
– Modified Mohr (MM)
 Static Strength
• Maximum-Shear-Stress Theory for Ductile
Materials
– The maximum-shear-stress (MSS) theory predicts that
yielding begins whenever the maximum shear stress in
any element equals or exceeds the maximum shear stress
in a tension-test specimen of the same material when
that specimen begins to yield. The MSS theory is also
referred to as the Tresca or Guest theory.
 Static Strength
• Maximum-Shear-Stress Theory for Ductile
Materials
– Including factor of safety
 Static Strength
• Distortion Energy Theory for Ductile Materials
– The distortion-energy theory predicts that yielding occurs
when the distortion strain energy per unit volume reaches or
exceeds the distortion strain energy per unit volume for yield
in simple tension or compression of the same material.
 Static Strength
• Distortion Energy Theory for Ductile Materials
 Static Strength
• Distortion Energy Theory for Ductile Materials
 Static Strength
• Distortion Energy Theory for Ductile Materials
 Static Strength
• Maximum-Normal-Stress
Theory for Brittle Materials
– The maximum-normal-stress (MNS)
theory states that failure occurs
whenever one of the three principal
stresses equals or exceeds the
strength. Again we arrange the
principal stresses for a general stress
state in the ordered form σ1 > σ2 >
σ3. This theory then predicts that
failure occurs whenever
 Static Strength
• Coulomb Mohr Theory for
Ductile Materials
– Not all materials have compressive
strengths equal to their
corresponding tensile values. For
example, the yield strength of
magnesium alloys in compression
may be as little as 50 percent of their
yield strength in tension. The ultimate
strength of gray cast irons in
compression varies from 3 to 4 times
greater than the ultimate tensile Three Mohr circles, one for the
uniaxial compression test, one for
strength. So, in this section, we are the test in pure shear, and one for
primarily interested in those theories the uniaxial tension test, are used
that can be used to predict failure for to define failure by the Mohr
materials whose strengths in tension hypothesis. The strengths Sc and St
and compression are not equal. are the compressive and tensile
strengths, respectively; they can be
used for yield or ultimate strength.
 Static Strength
• Coulomb Mohr Theory for Ductile
Materials
– A variation of Mohr’s theory, called the
Coulomb-Mohr theory or the internal
friction theory, assumes that the boundary
BCD in Fig. is straight. With this assumption
only the tensile and compressive strengths
are necessary. Consider the conventional
ordering of the principal stresses such that
σ1 > σ2 > σ3. The largest circle connects σ1
and σ3, as shown in Fig. The centers of the
circles in Fig. are C1, C2, and C3. Triangles
OBiCi are similar, therefore
Three Mohr circles, one for the
uniaxial compression test, one for
the test in pure shear, and one for
the uniaxial tension test, are used
to define failure by the Mohr
hypothesis. The strengths Sc and St
are the compressive and tensile
strengths, respectively; they can be
used for yield or ultimate strength.
 Static Strength
• Coulomb Mohr Theory for
Ductile Materials
– where B1C1 5 St/2, B2C2 = (σ1 – σ3)/2,
and B3C3 = Sc/2, are the radii of the
right, center, and left circles,
respectively. The distance from the
origin to C1 is St/2, to C3 is Sc/2, and to
C2 (in the positive s direction) is
(σ1+σ3)/2. Thus Canceling the 2 in each
term, cross-multiplying,
and simplifying reduces
this equation to
 Static Strength
• Coulomb Mohr Theory for Ductile Materials
 Static Strength
• Coulomb Mohr Theory for Ductile Materials