Failure Prediction for Static Loading

crack

Image: The Liberty Bell,

a classic case of brittle fracture.

Bow portion of the Titanic.(Painting by Ken Marschall, based on photographs

taken aboard Alvin, Angus, and Argo research vessels. (Courtesey Dr. Robert D.
Ballard, The Discovery of the Titanic.)

FAILURE PREDICTION OF MACHINE COMPONENT

BASED ON TYPE OF LOADING :
1. STATIC LOADING
2. CYCLIC LOADING
3. IMPACT LOADING
BASED ON SCOPE OF ITS ANALYSIS :
1. MACROMECHANIC (STRESS, STRAIN, STRAIN RATE, STRESS RATE)
2. MICROMECHANIC (FRACTURE SURFACE ANALYSIS, DISLOCATION,).
3. MESOMECHANICS
4. NANOMECHANICS
BASED ON FAILURE CRITERIA :
1. CONVENTIONAL METHOD (STATIC LOADING) ( Stress < Strength )
2. FATIGUE FRACTURE CONCEPT(S N diagram )
3. DAMAGE TOLERANCE APPROACH ( KIC )
( FRACTURE MECHANICS CONCEPT )

DEFINISION OF FAILURE:
Failure is a general term for a condition in which a member is
subjected to plastic deformation; in other words, where
irreversible traces are observed in a member.
CLASIFICATION OF FAILURE (BROADLY) :
1. Damage
2. Fracture
3. Break
4. Rupture.

85 90 % of failure are generally caused directly by fatigue.

Losses of failure are classified as :
1.

Direct losses.

2.

Indirect losses.

FAILURE AND LOSSES

CLASSIFICATION OF FAILURE ACCORDING TO FAILED

MEMBERS.

CLASSIFICATION OF FAILURES ACCORDING TO CAUSE

CLASSIFICATION OF FAILURES ACCORDING TO FACTOR

COMMONLY OBSERVED
MODES OF
MECHANICAL FAILYRE
IN MACHINE
COMPONENT

Stress Concentration

Axial Load on
Plate with Hole

Rectangular plate with hole subjected to axial load. (a) Plate with
cross-sectional plane. (b) Half of plate with stress distribution.
Stress concentration is the
region in which stress raisers
are present.
Kc is stress concentration factor

Kc

Actual Maximum Stress

Average Stress

Stress Concentrations for Plate with Hole

Stress concentration factor for rectangular plate with central hole. (a)
Axial Load. [Adapted from Collins (1981).]

Stress Concentrations for Plate with Hole (cont.)

Stress concentration factor for rectangular plate with central hole. (b)
Bending. [Adapted from Collins (1981).]

Stress Concentrations for Plate with Fillet

Stress concentration factor for rectangular plate with fillet. (a) Axial
Load. [Adapted from Collins (1981).]

Stress Concentrations for Plate with Fillet

(cont.)

Stress concentration factor for rectangular plate with fillet. (b)

Bending Load. [Adapted from Collins (1981).]

Stress Concentrations for Plate with Groove

Stress concentration factor for rectangular plate with groove. (a) Axial
Load. [Adapted from Collins (1981).]

Stress Concentrations for Plate with Groove (cont.)

Stress concentration factor for rectangular plate with groove. (b)

Bending. [Adapted from Collins (1981).]

Stress Concentrations for Bar with Fillet

Stress concentration factor for round bar with fillet. (a) Axial load. [Adapted from
Collins (1981).]

Stress Concentrations for Bar with Fillet (cont.)

Stress concentration factor for round bar with fillet. (b) Bending. [Adapted from
Collins (1981).]

Stress Concentrations for Bar with Fillet (cont.)

Stress concentration factor for round bar with fillet. (c) Torsion. [Adapted from
Collins (1981).]

Stress Concentrations for Bar with Groove

Stress concentration factor for round bar with groove. (a) Axial load. [Adapted from
Collins (1981).]

Stress Concentrations for Bar with Groove (cont.)

Stress concentration factor for round bar with groove. (b) Bending. [Adapted from
Collins (1981).]

Stress Concentrations for Bar with Groove (cont.)

Stress concentration factor for round bar with groove. (c) Torsion. [Adapted from
Collins (1981).]

FLOW ANALOGY
-To reduce stress concentration as much as possible.
-To observe similarity understanding the flow
velocity of fluid in a channel and the stress
distribution of an axially loaded plate.
- The analogy is accurate, since equation of flow
q stress potential in solid
potential in fluid mech. and
mechanics are of the same form.
the volume flow is :

q udA

From solid mechanics, the force must be constant at

any point :

P dA

Stress Contours in Bar

Bar with fillet axially loaded showing stress contours through a flat
plate for (a) square corners, (b) rounded corners (c) small groove, and
(d) small holes.

FRACTURE MECHANICS
Modes of Crack Displacement

Three modes of crack displacement. (a) Mode I, opening; (b) mode II,
sliding; (c) mode III, tearing.

K ci Y nom a

KcI = stress intensity factor

Critical stress intensity = fracture toughness (fracture resistance)

Y = dimensionless correction factor that accounts for geometry of part
containing crack
nom Nominal stress at fracture, MPa
a = Half of crack length, m

FRACTURE MECHANICS
Structural studies that consider crack extension as a function of
applied load are performed in fracture mechanics.
Fracture failure occur when stress intensity is greater that critical
stress intensity factor, as shown in equation below :
KI

KIC or

KII

KIIC or KIII

KIIIC

or combination of each mode.

The broad field of fracture mechanics

Yield Stress and Fracture Toughness Data

Material
Metals
Aluminum alloy
2024-T351
Aluminum alloy
7075-T651
Alloy steel 4340
tempered at 260C
Alloy steel 4340
tempered at 425C
Titanium alloy
Ti-6Al-4V

Yield Stress , S y
ks i
Mpa

Fracture Toughness , K ci
ksi in1 /2
Mpa m1 /2

47

325

33

36

73

505

26

29

238

1640

45.8

50.0

206

1420

80.0

87.4

130

910

40-60

44-66

Ceramics
Aluminum oxide
Soda-lime glass
Concrete

2.7-4.8
0.64-0.73
0.18-1.27

3.0-5.3
0.7-0.8
0.2-1.4

Polymers
Polymethyl methacrylate
Polystyrene

0.9
0.73-1.0

1.0
0.8-1.1

Yield stress and fracture toughness data for selected engineering

materials at room temperature [From ASM International (1989)].