VIT University

Design of Machine Element (MEE302)

Semester:- Fall, 2010-2011
Unit-I

Presented by
Prof.E.RAJ KUMAR
Prof.E.Raj kumar,

Design Division, SMBS

Prof.E.Raj kumar,

Design division, SMBS

WHY STUDY Failure?

The engineer has to minimize the
possibility of failure since the design step.
Understand the mechanics of the various
failure modes
fracture, fatigue, and creep

Be familiar with appropriate design principles

to prevent in-service failures.

Prof.E.Raj kumar,

Design division, SMBS

Fracture
In response to an imposed stress, any
fracture process involves two steps:
crack formation
and propagation.

The mechanism of crack propagation

determine the mode of fracture.

Prof.E.Raj kumar,

Design division, SMBS

Ductile Fracture
Ductile fracture:
extensive plastic deformation in the vicinity of an
advancing crack.
proceeds relatively slowly as the crack length is
extended.
often said as stable crack.
it resists any further extension unless there is an increase in
the applied stress.

Normally there will be evidence of appreciable

gross deformation at the fracture surfaces (e.g.,
twisting and tearing).
Prof.E.Raj kumar,

Design division, SMBS

Ductile Fracture

Highly ductile fracture in

which the specimen necks
down to a point.

Prof.E.Raj kumar,

Moderately ductile
fracture after some
necking.

Design division, SMBS

Brittle fracture
without any
plastic deformation.

Ductile Fracture
Normal fracture process stages:
necking
formation of small cavities (microvoids) in the interior of the cross
section,
as deformation continues, these microvoids enlarge, come
together, and to form an elliptical crack,
which has its long axis perpendicular to the stress direction.

The crack continues to grow in a direction parallel to its major

axis by this microvoid coalescence process.
Finally, fracture occurs by the rapid propagation of a crack
around the outer perimeter of the neck, by shear deformation at
an angle of about 45 with the tensile axis
this is the angle at which the shear stress is a maximum.

Prof.E.Raj kumar,

Design division, SMBS

(a) Initial necking.

(b) Small cavity
formation.

(c) Coalescence
of cavities to
form a crack.

(d) Crack
propagation.

(e) Final shear fracture at

a 45 angle relative to the
tensile direction.

Prof.E.Raj kumar,

Design division, SMBS

 The magnitude of the

localized stress
diminishes with distance
away from the crack tip.
At positions far removed,
the stress is just the
nominal stress.
Due to their ability to
amplify an applied stress
in their locale, these flaws
are sometimes called
stress raisers.

Prof.E.Raj kumar,

Design division, SMBS

Concept of Stress Concentration

In a machine element, if there is a discontinuity such as sudden change in cross
section, a fillet Hole,groove or notch;highly localised stresses are induced at such
places. Such discontinuities are called stress raisers and the localised stress
effect they produce is termed as stress concentration.

Theoretical stress
concentration factor, Kt
Maximum stress at the discontinuity

Nominal stress, max stress

with no discontinuity

Prof.E.Raj kumar,

Design division, SMBS

Kt is used for normal

stresses and Kts for
shear stresses.

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Concept of Stress Concentration

Consider an elliptical hole in an infinitely large plate loaded in uniform
tension. Using the theory of elasticity the theoretical stress concentration
factor is given by the equation below.

2b
2a

Elliptical hole

For a circular hole Kt = 3

The equation can be applied to a longitudinal crack where b << a

Prof.E.Raj kumar,

Design division, SMBS

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Stress Concentration Factor

Stress concentration factor is found using experimental methods.

Photoelasticity a plane polarized light is passed thru a

photelastic material (all transparent plastics) resulting in a
colorful fringe pattern indicating the intensity of the stress.

Prof.E.Raj kumar,

Design division, SMBS

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Stress Concentration Factor

Brittle Coating a specially
prepared lacquers are usually
applied by spraying on the actual
part. After air drying, the part is
subjected to stress. A pattern of
small cracks appear on the surface.
Data could be used to locate strain
gages for precise measurement of
the stress. The method is sensitive
to temperature and humidity.

Prof.E.Raj kumar,

Design division, SMBS

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Stress Concentration Factor

Electrical strain gauges
The method is the most popular and widely accepted for strain measurements and
stress analysis. The strain gauge consists of a grid of strain-sensitive metal foil
bonded to a plastic backing material. When the gauge is subjected to a mechanical
deformation, its electrical resistance changes proportionally. The change in voltage
is converted to strain and the stress is calculated from the strain.

Prof.E.Raj kumar,

Design division, SMBS

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Stress Concentration Factor

Finite Element method
The CAD model is subdivided into many small pieces of simple

shapes called elements.

FEA program writes the equations governing the behavior of each

element taking into consideration its connectivity to other elements.

These equations relate the unknowns, for example displacements in

stress analysis, to known material properties, restraints and loads.

The program assembles the

equations into a large set of

simultaneous algebraic
equations (thousands or even
millions).
These equations are then

solved by the program to

obtain the stress distribution
for the entire model.
Prof.E.Raj kumar,

Design division, SMBS

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Stress Concentration Factor

Prof.E.Raj kumar,

Design division, SMBS

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Stress Concentration Factor

Round section
with a fillet

Prof.E.Raj kumar,

Design division, SMBS

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Stress Concentration Factor

Flat plate
with a hole

Prof.E.Raj kumar,

Design division, SMBS

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IMPACT FRACTURE TESTING

Two standardized tests were designed to
measure the impact energy (notch toughness):
Charpy (commonly used in the USA)
Izod.

One of the primary functions is to determine

whether or not a material experiences a ductileto-brittle transition with decreasing
temperature.
If so, what is the range of temperatures over which it
occurs.

Prof.E.Raj kumar,

Design division, SMBS

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Prof.E.Raj kumar,

Design division, SMBS

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 , =Impact stress induced

d = xl =

s
E

1
W (h + d ) = Fl
2
F=

dAE
l

F = s A
Prof.E.Raj kumar,

Design division, SMBS

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Impact Tension

2
UE
s =
AL
Impact Torsion

4 EG
t=
Al
Temperature dependence of the Charpy V-notch impact energy
(curve A) and percent shear fracture (curve B) for an A283 steel.
Prof.E.Raj kumar,

Design division, SMBS

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IMPACT FRACTURE TESTING

Prof.E.Raj kumar,

Design division, SMBS

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Prof.E.Raj kumar,

Design division, SMBS

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