Static Failure

Sami Salama Hussen Hajjaj - May 2014 1
MACHINE DESIGN
Static Failure – Summary
Sami Salama Hussen Hajjaj - Oct 2013 2
Contents
• Introduction to Static Failure
• Stress Analysis
• The Safety Factor
• Strain Analysis
• Static Failure Theories
• For Ductile Materials
• For Brittle Materials
• Examples
INTRODUCTION
Static Failure – Introduction
Introduction
“Design a bridge that can take a maximum of 100 people at a
time, withstand average wind speed of 40 Km/hr, and a water
pressure of about 40N/m”
Referring to the design problem above. The first task of the

designer is to insure that the part/machine/component
performs its function without failure with a certain degree of
safety and reliability.
As such, it is important for us to understand how does failure

occurs, and that understanding will help us avoid it.
Introduction
We begin by performing Mechanics; which is simplifying the
applied loading. Next, knowing (or defining) the geometry of
the part, we can determine the stress the material is under,
𝐹
𝜎=
𝐴
Next, we can select a material, of a Strength 𝑆. Then ..
If 𝑆 ≥ σ, or if the material’s Strength is created that than the

applied stresses, then we can say that the material is SAFE.
Otherwise, we can say that the material has FAILED.
The Safety Factor.

𝑆
Let us define the term Safety Factor, 𝑛 = which defines the
𝜎
degree of safety, as follows:
𝑆
If 𝑛 = = 1 ⇒ The part is barely safe
𝜎
𝑆
If 𝑛 = > 1 ⇒ The part is safe
𝜎
𝑆
If 𝑛 = ≫ 1 ⇒ The part is very safe (and expensive)
𝜎
𝑆
If 𝑛 = < 1 ⇒ The part has failed.
𝜎
The Safety Factor.

𝑆
Let us define the term Safety Factor, 𝑛 = which defines the
𝜎
degree of safety, as follows:
The choice of safety factor depends on you as a designer. In

general, the higher the value of n, the safer the design gets.
But also, the more expensive/complex the design gets.
As such, the decision/choice of the value of n depends on how

critical the design is. If you are designing a plastic toy, then
perhaps you can go for n = 1. However, if you are designing a
component of spaceship, then you might go for n = 5 or higher
Strain Analysis
In strain analysis, we calculate the maximum deflection that
will occur due to loading, such as 𝑦𝑚𝑎𝑥
Next, we compare this limit to the available spacing and

tolerance given or allowed in the design, If it’s OK, then the
design can proceed, if not, then changes need to be made.
This is important, because material deflect in the elastic range

even before yielding, and this deflection could cause problems.
As such, it is possible the material is SAFE from the point of

view of Stress, but still fails due to Strain and deflection.
Fatigue Failure
The principle of fatigue failure is the same, we need to find the

safety factor for fatigue loading, and ensure is it also greater
than 1.
However, the process to finding fatigue stress is different

because the loading is different, we will discuss that in the next
chapter
Failure of Brittle Materials
The principle is the same, we need to find stress limit for brittle
material, and then compare it to strength of the brittle material
and use that to find the safety factor, and ensure is it also
greater than 1.
But because the behavior of Brittle material is different than

Ductile material, the process is slightly different, we will see
that next.
STATIC FAILURE THEORIES
Introduction
Ductile vs. Brittle Material

Before we talk about failure, let’s differentiate between these
two types of materials.
Ductile Materials
Ductile materials are normally classified such that εf ≥ 0.05
and have an identifiable yield strength, be it in compression or
in tension (Syt = Syc = Sy ).
Brittle Materials
Brittle materials, with εf < 0.05, and do not exhibit an
identifiable yield strength, and are typically classified by the
Ultimate Tensile and Compressive strengths, Sut and Suc,
respectively (where Suc is given as a positive quantity)
Failure Theories
Due to varying types of loading and material, (Static vs.
Fatigue stress), (Ductile vs. Brittle Material), there is no
universal theory of failure for all.
Instead, we will need consider these situations individually.

Over the years several hypotheses have been formulated and
tested, leading to today’s accepted practices.
Being accepted, these “practices” are referred to as theories

as most designers do.
Failure Theories
Many theories attempted to explain what causes failure during the
Tensile Stress, which is used to measure the Yield Strength. The
following are some of the theories that attempted to do so:
• Failure of Ductile Materials
• Maximum Shear Stress Theory (MSS Theory)
• Distortion Energy theory (DE Theory)
• The Coloumb-Mohr Theory (CM Theory)
• Failure of Brittle Materials
• Brittle-Coloumb-Mohr Theory
• Modified Brittle-Coloumb-Mohr Theory

Ductile Materials
Maximum Sheer Stress Theory

The MSS Theory predicts that yielding begins whenever the
maximum shear stress equals or exceeds the maximum shear
stress in a tension-test specimen of the same material.
Remember that:
𝑃 𝜎
•𝜎= , and 𝜏𝑚𝑎𝑥 = (on a surface 45° from the tensile surface)
𝐴 2
• Yielding begins with Applied stress equals Material Strength, therefore ..
𝑆𝑦
𝜏𝑚𝑎𝑥 =
2

This can be expanded to incorporate Principle Stresses ..
σ1 −σ3 σ1 −σ3 Sy
τmax = therefore, τmax = ≥ , or simply ..
2 2 2
σ1 − σ3 ≥ Sy
Also, if we want to set a safety factor greater than 1, then,
𝑆𝑦 𝑆𝑦
𝜏𝑚𝑎𝑥 = or σ1 − σ3 ≥
2𝑛 𝑛

To narrow the discussion to 2D principle stresses, we refer to
them as σA , σB (refer to section 5.4).
As such, there are now three Possibilities:
Case 1: σA ≥ σB ≥ 0 => σA ≥ Sy
Case 2: σA ≥ 0 ≥ σB => σA − σB ≥ Sy
Case 3: 0 ≥ σA ≥ σB => σB ≤ −Sy

Distortion Energy Theory

The DE 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.
Following the process in section 5.5 in the book, the above statement can
be represented mathematically as:
, , or,
𝜎 ′ ≥ 𝑆𝑦

The ’ stress is called the von Mises stress, named after Dr.
R. von Mises, who contributed this theory.
The main advantage of the von Mises stress is that it

encompasses ALL applied stresses into a singular form and
therefore simplifies the analysis.
The formula derived above is using principle stresses in 3D,

the equation can be simplified when considering only 2D, or

Principle stress can be found in terms of applied stresses. So,
the last expression can be re-written as
Where:
𝜎𝑥 is the applied tensile stress in the x - direction
𝜎𝑦 is the applied tensile stress in the y – direction
𝜏𝑥𝑦 is the applied shear stress on the by – plane
Understanding the expression and how to use it is vital.

Single Axis vs. Multi Axis Tensile Stress
Most of the time, applied loadings, and therefore the applied

stresses, come along one axis. That is why 𝜎𝑦 is set to zero
most of the time.
In the event that loading is applied from multiple Axis, then the
problem becomes (Multi-Axial Design Case), which we will
discuss in greater details later.
Pure Tensile Stress (in single Axis)
In the event that the applied stress is ONLY a pure tensile

stress, 𝜎𝑥 , then what happens?
Simple. Just set everything else to zero and solve. We find that
𝜎 ′ = 𝜎𝑥
Pure Shear Stress

If the applied stress is pure sheer stress, 𝜏𝑥𝑦 , then we can't
compare the applied stress to the Material strength. Why?
If we set all tensile stresses to zero, we get
Or, according to the DE theory, the Sheer yield Strength is,

Coulomb Mohr Theory

Not all materials have compressive strengths, SC, equal to
their tensile strength, St . Following the procedure outline in
section 5-6, the following can be summarized.
𝑆𝑡 NOTE:
Case 1: σA ≥ σB ≥ 0 => σA ≥ If you set the safety
𝑛
factor, n = 1, then
1
these equations will
Case 2: σA ≥ 0 ≥ σB => look exactly like the
𝑛
ones in the book
𝑆
Case 3: 0 ≥ σA ≥ σB => σB ≤ − 𝑛𝑐
Furthermore, , and
Brittle Materials
Brittle-Coloumb-Mohr Theory
Brittle Material, by definition, have compressive strengths
different from their tensile strengths. So, following the outlined
process in section 5-9, the following can be summarized.
𝑆𝑡
Case 1: σA ≥ σB ≥ 0 => σA ≥
𝑛
1
Case 2: σA ≥ 0 ≥ σB =>
𝑛
𝑆
Case 3: 0 ≥ σA ≥ σB => σB ≤ − 𝑛𝑐
Modified Brittle-Coloumb-Mohr Theory
To enhance the validity of the findings of the BCM Theory, the

process has been slightly modified. Following the outlined
process in section 5-9, the following can be summarized.
Case 1: =>
Case 2: =>
Case 3: =>
Case 4: =>
EXAMPLES
Recommended Examples
Solved Problem
Sami Salama Hussen Hajjaj - Oct 2013 30
Examples
It is highly recommended that you study and learn the following
Solved examples from the textbook:
Example 5.1 (MSS Theory vs. DE Theory)
Example 5.2 (Columb Mohr Theory)
Examples 5.3 & 5.4 (Applied loading question)
Example 5.5 (Brittle Material example)

Problem 5-36
• This problem illustrates that
the factor of safety for a
machine element depends
on the particular point
selected for analysis.
• Given the loading, F, T, and

P, and the geometry of the
Object … Calculate the
safety factors at Points A
This bar is made of AISI 1006 and B
cold-drawn steel and is loaded
by the forces F = 0.55 kN,
P = 4.0 kN, and T = 25 N m.
Problem 5-36
What the question wants ?
Safety factors at A and B,
or 𝑛𝐴 and 𝑛𝐵
What is the formula for 𝒏 ?

𝑆𝑦
𝑛= ′
𝜎
Where do we get 𝑺𝒚 ?
Go to Table A-20, and look for
Where do we get 𝝈�′? “of AISI 1006 cold-drawn Steel”
From the formulas we learnt
𝑆𝑦 = 280 MPa
last week
Problem 5-36
Which equations for 𝝈�′ ?
Even though this is a 3D
object, we are only interested
in points A and B, which are on
plane. Therefore, we can still
consider it as 2D problem.
The question did NOT ask us

to find the principle stresses,
Therefore the formula is: so we will bother finding them.
We will focus on applied
stresses, or 𝜎𝑥 , 𝜎𝑥 and 𝜏𝑥𝑦
Problem 5-36
For Point A
At point A the following
stresses are acting:
𝜎𝐴𝑥𝑖𝑎𝑙 (𝐹𝑜𝑟𝑐𝑒 𝑃)
𝜏 𝑇𝑜𝑟𝑠𝑖𝑜𝑛 (𝑇𝑜𝑟𝑞𝑢𝑒 𝑇)
𝜏 𝑇𝑟𝑎𝑛𝑠𝑣𝑒𝑟𝑠𝑒 (𝐹𝑜𝑟𝑐𝑒 𝐹)
Therefore …
Finding 𝝈′ : 𝜎𝑥 = 𝜎𝐴𝑥𝑖𝑎𝑙
𝜎𝑦 = 0
𝜏𝑥𝑦 = 𝜏 𝑇𝑜𝑟𝑠𝑖𝑜𝑛 + 𝜏 𝑇𝑟𝑎𝑛𝑠𝑣𝑒𝑟𝑠𝑒
Problem 5-36
For Point B
At point B the following
stresses are acting:
𝜎𝐴𝑥𝑖𝑎𝑙 (𝐹𝑜𝑟𝑐𝑒 𝑃)
𝜎𝐵𝑒𝑛𝑑𝑖𝑛𝑔 (𝑀𝑜𝑚𝑒𝑛𝑡 𝐹𝑙)
𝜏 𝑇𝑜𝑟𝑠𝑖𝑜𝑛 (𝑇𝑜𝑟𝑞𝑢𝑒 𝑇)
Therefore …
Finding 𝝈′ : 𝜎𝑥 = 𝜎𝐴𝑥𝑖𝑎𝑙 + 𝜎𝐵𝑒𝑛𝑑𝑖𝑛𝑔
𝜎𝑦 = 0
𝜏𝑥𝑦 = 𝜏 𝑇𝑜𝑟𝑠𝑖𝑜𝑛
Problem 5-36
𝝈𝑨𝒙𝒊𝒂𝒍 (𝑭𝒐𝒓𝒄𝒆 𝑷)
𝐹
𝜎𝐴𝑥𝑖𝑎𝑙 =
𝐴
𝑃
= 𝜋 2
𝑑
4
Finding 𝝈′ : 4𝑃
=
𝜋𝑑 2
Problem 5-36
𝝈𝑩𝒆𝒏𝒅𝒊𝒏𝒈 (𝑴𝒐𝒎𝒆𝒏𝒕 𝑭𝒍)
𝑀𝑐
𝜎𝐵𝑒𝑛𝑑𝑖𝑛𝑔 =
𝐼
𝑑
𝐹𝑙 𝑐 𝐹𝑙
2
= 𝜋 4 = 𝜋 4
𝑑 𝑑
64 64
Finding 𝝈′ :
32 𝐹𝑙
= =
𝜋𝑑 3
Problem 5-36
𝝉𝑻𝒐𝒓𝒔𝒊𝒐𝒏 (𝑻𝒐𝒓𝒒𝒖𝒆 𝑻)
𝑇𝑟
𝜏 𝑇𝑜𝑟𝑠𝑖𝑜𝑛 =
𝐽
𝑑
𝑇𝑟 𝑇
2
= 𝜋 4 = 𝜋 4
𝑑 𝑑
32 32
Finding 𝝈′ :
16 𝑇
= =
𝜋𝑑 3
Problem 5-36
𝝉𝑻𝒓𝒂𝒏𝒔𝒗𝒆𝒓𝒔𝒆 (𝑭𝒐𝒓𝒄𝒆 𝑭)
4𝑉
𝜏 𝑇𝑟𝑎𝑛𝑠𝑣𝑒𝑟𝑠𝑒 =
3𝐴
4𝐹
= 𝜋 2
3 𝑑
4
16𝐹
Finding 𝝈′ : =
3𝜋𝑑 2
Problem 5-36
Next, we calculate the
value of 𝜎 ′ from the
equation below for A
and B
Workout !
Finding 𝝈′ :

Static Failure

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Sami Salama Hussen Hajjaj - May 2014 1

• The Safety Factor

• Static Failure Theories

• For Ductile Materials

• For Brittle Materials

Referring to the design problem above. The first task of the

As such, it is important for us to understand how does failure

Next, we can select a material, of a Strength 𝑆. Then ..

If 𝑆 ≥ σ, or if the material’s Strength is created that than the

The Safety Factor.

The Safety Factor.

The choice of safety factor depends on you as a designer. In

As such, the decision/choice of the value of n depends on how

Next, we compare this limit to the available spacing and

This is important, because material deflect in the elastic range

As such, it is possible the material is SAFE from the point of

The principle of fatigue failure is the same, we need to find the

However, the process to finding fatigue stress is different

Failure of Brittle Materials

But because the behavior of Brittle material is different than

STATIC FAILURE THEORIES

Ductile vs. Brittle Material

Instead, we will need consider these situations individually.

Being accepted, these “practices” are referred to as theories

• Maximum Shear Stress Theory (MSS Theory)

• Distortion Energy theory (DE Theory)

• The Coloumb-Mohr Theory (CM Theory)

• Failure of Brittle Materials

• Modified Brittle-Coloumb-Mohr Theory

STATIC FAILURE THEORIES

Maximum Sheer Stress Theory

• Yielding begins with Applied stress equals Material Strength, therefore ..

Maximum Sheer Stress Theory

Also, if we want to set a safety factor greater than 1, then,

Maximum Sheer Stress Theory

As such, there are now three Possibilities:

Case 3: 0 ≥ σA ≥ σB => σB ≤ −Sy

Distortion Energy Theory

Distortion Energy Theory

The main advantage of the von Mises stress is that it

The formula derived above is using principle stresses in 3D,

Distortion Energy Theory

Understanding the expression and how to use it is vital.

Distortion Energy Theory

Single Axis vs. Multi Axis Tensile Stress

Most of the time, applied loadings, and therefore the applied

Distortion Energy Theory

Pure Tensile Stress (in single Axis)

In the event that the applied stress is ONLY a pure tensile

Distortion Energy Theory

Pure Shear Stress

If we set all tensile stresses to zero, we get

Or, according to the DE theory, the Sheer yield Strength is,

Coulomb Mohr Theory

STATIC FAILURE THEORIES

Modified Brittle-Coloumb-Mohr Theory

To enhance the validity of the findings of the BCM Theory, the

Example 5.1 (MSS Theory vs. DE Theory)

Example 5.2 (Columb Mohr Theory)