4th_Proof 2/08/08

+0)26-4

2 Theories of Failure

In the previous chapter, we have seen that a member is subjected to any of the simple stresses
tensile, compressive, shear or bending stressthen it is easy to predict the failure of the member.
But in practice machine members will be subjected to more than one type of stress simultaneously
and hence it will be difficult to predict the failure of such machine members using these simple
stress theories.
In order to predict the failure of such members subjected to combined stresses, the following
theories of failure are being suggested by different people:
(i) Rankines theory or maximum normal stress theory.
(ii) Guests theory or maximum shear stress theory.
(iii) Hencky-Von-Mises theory or distortion energy theory or shear energy theory.
(iv) Saint Venant theory or maximum strain theory.
sy

BIAXIAL STRESSES WITH SHEAR STRESS

sx sx
2.1 RANKINES THEORY OR MAXIMUM NORMAL STRESS THEORY
s
Figure 2.1 shows an element subjected to stresses, sx action along N-direction y

(tensile or compressive), sy acting along O-direction ^ lr to N (tensile or Fig. 2.1

compressive) combined with shear stress, txy.
According to the maximum normal stress theory or Rankines theory of failure, equivalent
stress

1 LM OP F 5 20 I
se =
2 N
(s x + s y ) + (s x - s y )2 + 4 t 2xy
Q ... GH P 5.8 JK
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T HEORIES OF FAILURE ##

PROBLEMS
Problem : A machine element is subjected to the following stresses sx = 60 MPa , sy = 45 MPa,
txy = 30 MPa. Find the factor of safety if it is made of C45 steal having yield stress as 353 MPa, using
the following theories of failure.
(i) Maximum principal stress theory,
(ii) Maximum shear stress theory,
(iii) Shear energy theory, and
(iv) Maximum strain theory taking Poisson ratio as 0.3
Given data: sx = 60 MPa, sy = 45 MPa, txy = 30 MPa yield stress, sys = 353 MPa
Poisson ratio v = 0.3.
(i) According to maximum principal stress or Rankines theory of equivalent stress

LM
1 OP
se =
2N= (s x + s y ) + (s x - s y ) 2 + 4 t 2xy
Q ...(5-20)

= = L(60 + 45) + OP = 83.42 MPa

1
se
2 MN (60 - 45) 2 + 4 ( 30) 2
Q
s ys 353
\ FOS = = = 4.23
se 83.42
(ii) According to max. shear stress theory or Guests theory equivalent stress
1
te = (s x - s y )2 + 4 t 2xy ...(5-21)
2

FG3 t = s IJ
se = ( s x - s y ) 2 + 4 t 2xy
H 2K
e
or e

= ( 60 - 45) 2 + 4 ( 30 ) 2 = 61.85 MPa

s ys
\ FOS = = 353/61.85 = 5.71
se
(iii) According to shear energy theory or Hencky-Von-Mises theory, equivalent stress

se = s 2x + s 2y - s x s y + 3 t 2xy ...(5-22)

se = 60 2 + 45 2 - 60 45 + 3 30 2 = 75 MPa

s ys 353
\ FOS = = = 4.71
se 75
(iv) According to Max-Strain theory or Saint-Venant theory. Equivalent stress
 4th_Proof 2/08/08

#$ DESIGN OF MACHINE ELEMENTS

1 LM OP
se =
2 N
(1 - v)(s x + s y ) + (1 + v) (s x - s y ) 2 + 4 t 2xy
Q ...(5-23)

1 LM OP
` se =
2 N
(1 - 0.3)(60 + 45) + (1 + 0.3) (60 - 45) 2 + 4 ( 30) 2
Q
= 76.95 MPa
s ys 353
\ FOS = = = 4.59.
se 76.95
Problem : A M.S. shaft having yield stress as 232 MPa is subjected to the following stresses.
sx = 120 MPa, sy = 60 MPa and txy = 36 MPa. Find the factor of safety using:
(i) Rankines theory of failure,
(ii) Guests theory of failure and
(iii) Von-Mises theory of failure.
Given data: Yield stress, sys = 232 MPa
sx = 120 MPa, sy = 60 MPa and txy = 36 MPa.
According to Rankines theory or maximum normal stress theory of failure
LM
1 OP
se =
2N(s x + s y ) + (s x - s y ) 2 + 4 t 2xy
Q
= L(120 - 60) + OP = 126.93 MPa
1
2 MN Q
se [120 - ( - 60)]2 + 4 ( 36) 2

s ys 232
FOS = = = 1.828
se 126.93
(ii) According to Guests theory or max shear stress theory of failure
1
te = (s x - s y )2 + 4 t xy
2
2

or se = (s x - s y )2 + 4 t 2xy = [120 - ( - 60)]4 + 4( 36)2

se = 193.87 MPa
s ys 232
\ FOS = = = 1.197
se 193.87
(ii) According to Hencky-Von-Mises theory or shear energy theory of failure

se = s 2x + s 2y - s x s y + 3 t 2xy

= 120 2 + ( - 60) 2 - 120 ( - 60 ) + 3( 36) 2 = 170.55 MPa

s ys 232
\ FOS = = = 1.36
se 170.55
 4th_Proof 2/08/08

T HEORIES OF FAILURE #%

Problem 3: A machine member is subjected to the following stresses sx = 150 MPa, txy = 24 MPa.
Find the equivalent stress as per the following theories of failure.
(i) Shear stress theory,
(ii) Normal stress theory,
(iii) Von-Mises theory.
Given data: sx = 150 MPa, txy = 24 MPa
(sy = Not given) (sy = 0, Not given)

(i) According to maximum shear stress theory, equivalent stress se = (s x - s y )2 + 4 t 2xy

se = 150 2 + 4 24 2 = 157.49 MPa

(ii) According to maximum normal stress theory, equivalent stress
1LM OP
se =
2 N
(s x + s y ) + (s x - s y )2 + 4 t 2xy
Q
= L150 + OP = 153.75 MPa
1
2 MN Q
se 1502 + 4(24 )2

(iii) According to Von-Mises theory, equivalent stress

se = s 2x + s 2y - s x s y + 4 t xy
2

se = 150 2 + 3( 24 ) 2 = 155.65 MPa.

Problem 4: Find the diameter of a rod subjected to a bending moment of 3 kNm and a twisting
moment of 1.8 kNm according to the following theories of failure, taking normal yield stress as
420 MPa and factor of safety as 3.
(i) Normal stress theory, (ii) Shear stress theory.
Given data: Bending moment, Mb = 3 kNm = 3 106 N-mm
Twisting moment, Mt = 1.8 kNm = 1.8 106 N-mm
Yield stress, sys = 420 MPa FOS = 3
s ys 420
\ Allowable stress, s = se = = = 140 MPa
FOS 3

M> C 3 106 d /2 30.56 10 6

Bending stress, s = = =
I ( pd 4 /64 ) d3

30.56 106
s = = sx
d3

MJ r 1.8 106 d /2 9.167 10 6

Shear stress, t = = = = txy
J ( pd 4 /32) d3
 4th_Proof 2/08/08

#& DESIGN OF MACHINE ELEMENTS

(i) According to maximum normal stress theory,

1 LM OP
N
(s x + s y + ( s x - s y ) 2 + 4 t xy
Q
2
se =
2
(Here sy = 0, no stress in ^lr direction)

LM
1 30.56 10 6 F 30.56 10 I 6 2
F 9.167 10 I
6 2 OP
140 =
2 MM
@3
+ GH @ JK3
+ 4G
H @ JK 3 PP
N Q
\ d = 61.834 mm
(ii) According to maximum shear stress theory

se = ( s x - s y ) 2 + 4 t 2xy

F 30.56 10 I 6 2
F 9.167 10 I 6 2

140 = GH @ JK 3
H @ JK
+ 4G 3

\ d = 63.376 mm
\ Recommended diameter, d = 63.376 ~ 64 mm. (Take bigger one always).

Problem 5: A bolt is subjected to a tensile load of 18 kN and a shear load of 12 kN. The material
has an yield stress of 328.6 MPa. Taking factor of safety as 2.5, determine the core diameter of bolt
according to the following theories of failure.
(i) Rankines theory,
(ii) Shear stress theory,
(iii) Shear energy theory and
(iv) Saint Venants theory. Take Possion ratio = 0.298
Given data: Tensile load, FT = 18 kN = 18 103 N
Shear load, FI = 12 kN = 12 103 N
Yield stress, sys = 328.6 MPa FOS = 2.5

s OI 328.6
\ Allowable stress, se = = = 131.44 MPa.
FOS 2.5

F6 18 10 3
Tensile stress, s = = = sx
A )

Fs 12 10 3
Shear stress, t = = = txy
A )
(sy = 0, not given)
 4th_Proof 2/08/08

T HEORIES OF FAILURE #'

(i) According to Rankines theory of failure

LM
1 OP
se =
Ns + s 2x + 4 t 2xy
2 x Q
L
1 M 18 10 3
F 18 10 I3 2
F 12 10 3
I 2 OP
131.44 =
2M
+ GH ) JK + 4G
H ) JK PP
MN ) Q
pdc2
A = 182.59 =
4
\ Core dia, d? = 15.25 mm
(ii) According to maximum shear stress theory,

se = s 2x + 4 t 2xy

F 18 10 I 3 2
F 12 10 I 3 2

131.44 = GH ) JK H ) JK
+ 4G

pdc2
\ A = 228.24 =
4
\ Core dia, d? = 17.05 mm
(iii) According to Von-Mises theory of failure

se = s 2x + 3 t 2xy

F 18 10 I 3 2
F 12 10 I 3 2

131.44 = GH ) JK +3 GH ) JK
pdc2
A = 209.19 =
4
\ Core dia, d? = 16.32 mm
(iv) According to Saint Venants theory of failure
1 LM OP
se =
2 N
(1 - v)( s x ) + (1 + v) s 2x + 4 t 2xy
Q
1
LM 18 10 3 F 18 10 I 3 2
F 12 10 I3 2 OP
131.44 =
2 MM
(1 - 0.298) + (1 + 0.298) GH A JK +4 GH A JK PP
N A
Q
pdc2
A = 196.196 =
4
\ Core dia, d? = 15.81 mm.
 4th_Proof 2/08/08

$ DESIGN OF MACHINE ELEMENTS

Problem 6: A SAE 1045 steel rod (sys = 309.9 MPa) of 80 mm diameter is subjected to a bending
moment of 3 kNm and torque T. Taking Factor of safety as 2.5, find the maximum value of torque T
that can be safely carried by rod according to:
(i) Maximum normal stress theory,
(ii) Maximum shear stress theory.
Given data: Material SAE 1045.
Yield stress, sys = 309.9 MPa
FOS = 2.5 diameter d = 80 mm

s ys 309.9
\ Allowable stress, se = = = 123.96 MPa
FOS 2.5
Bending moment, Mb = 3 kNm = 3 106 N-mm.

M> C 3 106 (80 /2)

\ Bending stress, s = = = 59.68 MPa = sx
I ( p / 64 80 4 )
Torque, Mt = T

MJ r 6 ( 80 /2 )
\ Shear stress, t = = = (9.95 10 6) MPa
J ( p /32 80) 4
\ t = txy = (9.95 106) T
(sy = 0, not given)
(i) According to maximum normal stress theory

LM1 OP
se =
N2
s x + s 2x + 4 t 2xy
Q
123.96 = L59.68 + OP
1
2 MN Q
59.68 2 + 4 (9.95 10 - 6 T )2

\ Torque, T = 8.971 106 N-mm = 8.971 kNm

(ii) According to maximum shear stress theory

1
te = s 2x + 4 t 2xy
2
Assuming, t e = 0.5 se = 0.5 123.96 = 61.98 MPa

1
61.98 = 59.68 2 + 4 ( 9.95 10 - 6 6 ) 2
2
Torque, T = 5.46 106 N-mm = 5.46 kNm.
 4th_Proof 2/08/08

T HEORIES OF FAILURE $

Problem 7: A stressed element is loaded as shown in Fig. 2.3. Determine the following:
(i) Von-Mises stress,
(ii) Maximum shear stress, 100 MPa
(iii) Maximum normal stress,
(iv) Octahedral shear stress.
150 MPa 150 MPa
Given data: Arranging in descending order 150 150 > 100
\ s1 = 150 MPa,
s2 = 150 MPa and s3 = 100 MPa (compressive) Fig. 2.!
(i) Von-Mises stress

(s 1 - s 2 )2 + (s 2 - s 3 )2 + (s 3 - s 1 )2
te =
2

(150 - 150)2 + (150 + 100)2 + ( - 100 - 150)2

= = 250 MPa
2
(ii) Maximum shear stress
s 1 - s 2 150 - 150
t12 = = =0
2 2
s 2 - s 3 150 - ( - 100)
t23 = = = 125 MPa
2 2
s 1 - s 3 150 - ( - 100)
t13 = = = 125 MPa
2 2
\ tmax = 125 MPa (max of these 3 values)
(iii) Maximum normal stress
s1 > s2 > s3
then smax = s1 = 150 MPa.
(iv) Octahedral shear stress

1
te = (s 1 - s2 )2 + (s 2 - s 3 )2 + ( s 3 - s 1 )2
3

1
= (150 - 150)2 + (150 - 100)2 + ( -100 - 150)2 = 117.85 MPa.
3
Problem 8: A material has a yield strength of 600 MPa. Compute the factor of safety for each of
the failure theories for the each of the following stresses:
(i) s1 = 420 MPa, s2 = 410 MPa, s3 = 0,
(ii) s1 = 420 MPa, s2 = 180 MPa, s3 = 0,
 4th_Proof 2/08/08

T HEORIES OF FAILURE $!

(s 1 - s 2 )- 2 + (s 2 - s 3 )2 + (s 3 - s 1 )2
(a) Von-mises theory, se =
2

( 420 - 180)2 + (180 - 0)2 + ( 420 - 0)2

se = = 364.97 MPa
2

t ys 600
\ FOS = = = 1.644
te 364.97

(b) Max. normal stress theory, se = s1 = 420 MPa

s ys 600
\ FOS = = = 1.4286
se 420
(c) Max. shear stress theory

s 1 - s2 420 - 180
t 12 = = = 120 MPa
2 2

s2 - s 3 180
t 23 = = = 90 MPa
2 2

s1 - s3 420
t 13 = = = 210 MPa
2 2
\ tmax = 210 MPa = te

s ys 600
\ FOS = = = 1.4286
2t max 2 210
(iii) s1 = 0, s2 = 180 MPa, s3 = 420 MPa

(0 + 180)2 + ( -180 + 420)2 + (0 + 420)2

(a) Von-Mises theory, se = = 364.96
2
s ys 600
\ FOS = = = 1.644
se 364.93
(b) Max. normal stress theory, se = s1 = 0
600
\ FOS = =
0
600
But, in compression FOS = = 1.4286
420
 4th_Proof 2/08/08

$" DESIGN OF MACHINE ELEMENTS

(c) Max. shear stress theory

s 1 - s2 0 + 180
t 12 = = = 90 MPa
2 2
s2 - s 3 -180 + 4.20
t 23 = = = + 120 MPa
2 2
s 1 - s 3 0 + 420
t 13 = = = 210 MPa \ tmax = 210 MPa
2 2
s ys 600
FOS = = = 1.4286.
2t max 2 210
Problem 9: A hot rolled bar has yield stress of 390 MPa. Compute the factor of safety for the
following theories of failure:
(i) Maximum normal stress theory,
(ii) Maximum shear stress theory and
(iii) Distortion energy theory for the following states of stress.
(a) s1 = 225 MPa, s2 = 225 MPa, s3 = 0
(b) s1 = 225 MPa, s2 = 120 MPa, s3 = 0
(c) s1 = 225 MPa, s2 = 0, s3 = 120 MPa.
Given data: Yield stress, sys = 390 MPa
s ys
FOS =
se
(a) s1 = 225 MPa, s2 = 225 MPa, s3 = 0
s1 > s2 > s3
(i) Maximum normal stress theory, se = s1 = 225 MPa
390
\ FOS = = 1.733
225
(ii) Maximum shear stress theory
s 1 - s2 225 - 225
t 12 = = =0
2 2
s2 - s 3 225 - 0
t 23 = = = 112.5 MPa
2 2
s1 - s3 225 - 0
t 13 = = = 112.5 MPa
2 2
\ t e = tmax = 112.5 MPa
s ys 390
and FOS = = = 1.733
2t max 2 112.5