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CHAPTER04THEORIES OF FAILURE
CollegeofEngineering&ComputerScience CECS
Ch05FailureTheories
ChapterHighlightsRoadmap
Introduction
WhatisFailure
SimpleTensionvs.Multiaxial Failure
BrittleFailureTheories
MaximumNormalStressTheory
MohrCoulombTheory
DuctilefailureTheories
MaximumShearStressTheory
DistortionEnergyTheory
ExperimentalverificationsandComparisons
ExperimentalStudies
Comparisons&Conclusions
Failureunderfatigueloading
Variousfailuretheories
Example
Warm-up Quiz
Acriticalsectioninashaftwithcircularsolidcrosssectionissubjectedto
torque,T,bendingmoment,MandnormalforceN.
Sketchthestressdistributiononthesection(useappropriatesymbolstomatch
withgivenaxes)andidentifycriticalpoint(s)fordesign.
xx
Fails(Yields)when:
xx Sy
Fails(Yields)when:
F(xx ,yy ,zz ,xy ,xy,xy)f(Sy,Su,)
Brittlematerialstypicallyhavesignificantlydifferentcompressiveandtensilestrengths.
TheInternalFriction(MohrCoulomb)Theorymaybeusedtoestimatethefailure
state.
ForsomematerialstheMohrCoulombTheorymayprovideaslightlymoreaccurate
estimate.
PLANESTRESSCASE
Wheneverthestressstateiswithinthe
polygon,thematerialwillnotfail.
NotethattheInternalFrictiontheory(IFT)isageneralizationofthe
MaximumShearStressTheory(MSST).TheMaximumMSSTislimitedto
materialsinwhichthetensileandcompressiveyieldstrengthsare
approximatelyequal.
Schematic presentation of
the yield surface
Postulated by:
Gadala et. al (1980) for slightly porous material that were initially ductile and for
materials made from powder compacts
, and dimensionless constants dependent on the material porosity, . The
above equation requires testing for only one material property, the yield strength
while the other parameters , and are only function of
in tension
porosity. Based on finite element simulation of the problem, Gadala et al.
suggested the following values for these parameters , and as function of
the material porosity, , for 0.95
0.60:
25
22 , 10
0.51
0.417
10
1.46
1.65
Example
Consider a thin-walled steel cylinder vessel shown in Figure (a). The ends of the cylinder
are closed with spherical caps, and it is subjected to an internal pressure p. Determine
the pressure under which vessel begins to yield. The material is made of SAE-1018 annealed
steel with yield strength Sy 225 MPa. (Note: consider only the vessel wall stresses).
t=6.35 mm
D=508 mm
Solution:
For an element at the thin walled pressure vessel, the state of stress
is biaxial with circumferential and axial stresses,
c
pD
,
2t
pD
4t
11 c ,
22 a ,
11 33 Y S y
3 0
py
2 t y
D
5.625MPa
c2 a2 c a S yt2
Which gives,
6.495
Comparing the two criteria, the Tresca is more conservative by approximately 14%.
Discussion Problem
(a) FindthebendingandtransverseshearstressatpointsAandBinthe
figure.
(b)Findthemaximumnormalstressandmaximumshearstressatboth
points.
(c)Forayieldpointof50,000psi,findthefactorofsafetybasedonthe
maximumnormalstresstheoryandthemaximumshearstresstheory.
Thedistortionalstresscomponentsareoftencalledthedeviatoricstress
components.
Theseunequalstressesacttodeformordistortthe
materialelement.
Thereisnochangeinvolume,butthereisachangein
shape.
Thesestressestrytoelongateorcompressthematerial
moreinonedirectionthaninanother.
TheeffectivestressiscommonlyreferredtoasthevonMises
stresswhocontributedtothetheoryafterDr.R.vonMises
Aslongasthestressstatefallswithintheshadedarea,thematerialwillnotyield.
Thesurface,blueline,atwhichthematerialjustbeginstoyieldiscalledtheyield
surface.
BoththeDistortionEnergyTheoryandtheMaximum
ShearStressTheoryprovidereasonableestimatesfor
theonsetofyieldinginthecaseofstaticloadingof
ductile,homogeneous,isotropicmaterialswhose
compressiveandtensilestrengthsareapproximately
thesame.
BoththeDistortionEnergyTheoryandtheMaximum
ShearStressTheory predictthattheonsetofyieldis
independentofthehydrostaticstress.Thisagrees
reasonablywellwithexperimentaldataformoderate
hydrostaticpressures.
NotethatR=1fora
completelyreversed
stressstatewithzero
meanstress.
Wearfailure: broadrangeofrelativelycomplex,surfacerelateddamage
phenomena.
Liquiderosionfailure: typeofwearfailureinwhichliquidisresponsible
forremovalofmaterial.
Liquidmetalembrittlement: involvesthemateriallosingsomedegreeof
ductilitybelowitsyieldstrengthduetoitssurfacebeingwettedbya
lowermeltingpointliquidmetal.
Hydrogenembrittlement: notoriouscauseofcatastrophicfailureinhigh
strengthsteelsexposedtohydrogenenvironmentwhichleadstoloseof
ductility(fewpartspermillionofhydrogenisenough).
Creepandstressrupturefailures: failureduetocontinuedstraingrowth
understeadyload.
Allofthesemechanismsareassociatedwiththefailureofthematerial.
Theydonotincludeoneofthemostimportantstructuralfailure
mechanismsthatmustbeconsideredincompressivestress
environments,Buckling.
Fatigue failure
initiating at
mismatched grease
holes
Sharp corners (at
arrows) provided
stress concentrations
Fatigue Failure:
Practical Examples
(Cont.)
Fatigue Failure:
Shaft Failures: You could be rich?? (Cont.)
FatigueLifeMethods
Threemajorfatiguelifemodels
Methodspredictlifeinnumberofcyclestofailure,N,fora
specificlevelofloading
Stresslifemethod
Leastaccurate,particularlyforlowcycleapplications
Mosttraditional,easiesttoimplement
Strainlifemethod
Detailedanalysisofplasticdeformationatlocalizedregions
Severalidealizationsarecompounded,leadingtouncertaintiesinresults
Linearelasticfracturemechanicsmethod
Assumescrackexists
Predictscrackgrowthwithrespecttostressintensity
Strain-Life Method
Strain-Life Method
StrainLifeMethod:Relation
Fig. 613
StrainLifeMethod:RelationofFatigueLifetoStrain
Fig. 613
StrainLifeMethod:RelationofFatigueLifetoStrain
StrainLifeMethod:RelationofFatigueLifetoStrain
StrainLifeMethod:TypicalvaluesforMansonCoffinrelationship
TypicalvaluesforMansonCoffinrelationship(Cont.)
FatigueLifeMethods:StressLifeMethod
Testspecimensaresubjectedtorepeatedstresswhilecounting
cyclestofailure
MostcommontestmachineisR.R.Moorehighspeedrotating
beammachine
Subjectsspecimentopurebendingwithnotransverseshear
Asspecimenrotates,stressfluctuatesbetweenequal
magnitudesoftensionandcompression,knownascompletely
reversedstresscycling
Specimeniscarefullymachinedandpolished
FatigueLifeMethods:StressLifeMethod,SNDiagram
Numberofcyclestofailureatvaryingstresslevelsisplottedonlog
logscale
Forsteels,akneeoccursnear106 cycles
Strengthcorrespondingtothekneeiscalledendurancelimit Se
StressLifeMethod: SNDiagramforSteel
StresslevelsbelowSe predictinfinitelife
Between103 and106 cycles,finitelifeispredicted
Below103 cyclesisknownaslowcycle,andisoftenconsidered
quasistatic.Yieldingusuallyoccursbeforefatigueinthiszone.
StressLifeMethod: SNDiagramforNonferrousMetals
Nonferrousmetalsoftendonothaveanendurancelimit.
FatiguestrengthSf isreportedataspecificnumberofcycles
FigureshowstypicalSN diagramforaluminums
Fig. 617
StressLifeMethod: FiniteLifeCalculation
StressLifeMethod: FiniteLifeCalculation
At 103 cycles,
f is the fraction of Sut represented by ( S f ) 3
10
Solving for f,
Eqs. (611) and (612) can be substituted into Eqs. (69) and
(610) to obtain expressions for S'f and f
Plot Eq. (610) for the fatigue strength fraction f of Sut at 103
cycles
Use f from plot for S'f = f Sut at 103 cycles on S-N diagram
Assumes Se = S'e= 0.5Sut at 106 cycles
Fig. 618
StressLifeMethod: FiniteLifeCalculation
At N =103 cycles,
Sf = f Sut
At N =106 cycles,
Sf = Se
Fig. 610
StressLifeMethod: FiniteLifeCalculation
For parts that are not round and rotating, an equivalent round
rotating diameter is obtained.
Equate the volume of material stressed at and above 95% of the
maximum stress to the same volume in the rotating-beam
specimen.
Lengths cancel, so equate the areas.
For a rotating round section, the 95% stress area is the area of a
ring,
Equate 95% stress area for other conditions to Eq. (622) and
solve for d as the equivalent round rotating diameter
From Fig. 617, S'e = 0.5 Sut is typical of the data and represents
50% reliability.
Reliability factor adjusts to other reliabilities.
Only adjusts Fig. 617 assumption. Does not imply overall
reliability.
Fig. 617
Table 65
For q = 0, Kf = 1
For q = 1, Kf = Kt
Fig. 620
Fig. 621
Alternatively, can use curve fit equations for Figs. 620 and 621
to get notch sensitivity, or go directly to Kf .
Bending or axial:
Torsion:
Se
nf
K f
Fig. 622
Fig. 622
Whenthemeanstressis
zero,thealternating
componentisequaltothe
endurancelimit.
Theinteractioncurvesare
forinfinitelifeoralarge
numberofcycles.
FactorofSafetyFormat
Notethatthefatiguestress
concentrationfactorisapplied
onlytothealternating
component.
Nf: factorofsafety
kf: fatiguestressconcentration
factor
Notethat:
Thefatiguestressconcentration
factorisappliedonlytothe
alternatingcomponent.
Anycombinationofmeanand
alternatingstressthatliesonor
belowtheGerberlinewillhave
infinitelife.
Nf : factorofsafety
kf :
fatiguestressconcentration
factor
Fivecommonlyusedfailurecriteriaareshown
Gerberpassesthroughthedata
ASMEellipticpassesthroughdataandincorporatesroughyieldingcheck
ModifiedGoodmanislinear,sosimpletouse.ItismoreconservativethanGerber.
Soderbergprovidesaveryconservativesingle
Langerlinerepresentsstandardyieldcheck.
Itisequivalenttocomparingmaximumstresstoyieldstrength
Fig. 627
Intersectingaconstantslopeloadlinewitheachfailurecriteriaproduces
designequations
nisthedesignfactororfactorofsafetyforinfinitefatiguelife
Example610
Example610
Example610
Fig. 628
Example610
Fig. 628
Example610
Example610
Fig. 629
Example610
Example
1.0
1.0
Alternating Stress
(Cont.)
1.0
1.0
1.0
to fail
(Cont.)