Chapter 6: Failure Prediction for Static Loading

The concept of failure is central to the design process, and it is by thinking in terms of obviating failure that successful designs are achieved. Henry Petroski Design Paradigms

Hamrock Fundamentals of Machine Elements

Rectangular Plate with Hole

Figure 6.1 Rectangular plate with hole subjected to axial load. (a) Plate with cross-sectional plane; (b) one-half of plate with stress distribution; (c) plate with elliptical hole subjected to axial load. Hamrock Fundamentals of Machine Elements

Rectangular Plate with Hole

Figure 6.1 Stress concentration factors for rectangular plate with central hole. (a) Uniform tension. Hamrock Fundamentals of Machine Elements

Rectangular Plate with Pin-Loaded Hole

Figure 6.2 Stress concentration factors for rectangular plate with central hole. (b) pin-loaded hole. Hamrock Fundamentals of Machine Elements

Rectangular Plate with Hole in Bending

Figure 6.2 Stress concentration factors for rectangular plate with central hole. (c) Bending. Hamrock Fundamentals of Machine Elements

Axially Loaded Rectangular Plate with Fillet

Figure 6.3 Stress concentration factors for rectangular plate with fillet. (a) Axial load. Hamrock Fundamentals of Machine Elements

Rectangular Plate with Fillet in Bending

Figure 6.3 Stress concentration factors for rectangular plate with fillet. (b) Bending. Hamrock Fundamentals of Machine Elements

Axially Loaded Rectangular Plate with Groove

Figure 6.4 Stress concentration factors for rectangular plate with groove. (a) Axial load. Hamrock Fundamentals of Machine Elements

Rectangular Plate with Groove in Bending

Figure 6.4 Stress concentration factors for rectangular plate with groove. (b) Bending. Hamrock Fundamentals of Machine Elements

Axially Loaded Round Bar with Fillet

Figure 6.5 Stress concentration factors for round bar with fillet. (a) Axial load. Hamrock Fundamentals of Machine Elements

Round Bar with Fillet in Bending

Figure 6.5 Stress concentration factors for round bar with fillet. (b) Bending. Hamrock Fundamentals of Machine Elements

Round Bar with Fillet in Torsion

Figure 6.5 Stress concentration factors for round bar with fillet. (c) Torsion. Hamrock Fundamentals of Machine Elements

Axially Loaded Round Bar with Groove

Figure 6.6 Stress concentration factors for round bar with groove. (a) Axial load. Hamrock Fundamentals of Machine Elements

Round Bar with Groove in Bending

Figure 6.6 Stress concentration factors for round bar with groove. (b) Bending. Hamrock Fundamentals of Machine Elements

Round Bar with Groove in Torsion

Figure 6.6 Stress concentration factors for round bar with groove. (c) Torsion. Hamrock Fundamentals of Machine Elements

Round Bar with Hole

Figure 6.7 Stress concentration factors for round bar with hole. Hamrock Fundamentals of Machine Elements

Stress Contours

Figure 6.8 Flat plate with fillet axially loaded showing stress contours for (a) square corners; (b) rounded corners; (c) small grooves; and (d) small holes. Hamrock Fundamentals of Machine Elements

Modes of Fracture

Figure 6.9 Three modes of crack displacement. (a) Mode I, opening; (b) mode II, sliding; (c) Mode III, tearing. Hamrock Fundamentals of Machine Elements

Fracture Toughness

Table 6.1 Yield stress and fracture toughness data for selected engineering materials at room temperature. Hamrock Fundamentals of Machine Elements

Failure Prediction for Multiaxial Stresses I. Ductile Materials

Maximum Shear Stress Theory (MSST):

Distortion-Energy Theory (DET)

Hamrock Fundamentals of Machine Elements

Failure Prediction for Multiaxial Stresses II. Brittle Materials

Maximum Normal Stress Theory (MNST)

Internal Friction Theory (IFT)

Modified Mohr Theory

Hamrock Fundamentals of Machine Elements

Three-Dimensional Yield Locus

Figure 6.10 Three-dimensional yield locus for MSST and DET. Hamrock Fundamentals of Machine Elements

MSST and DET for Biaxial Stress State

Figure 6.11 Graphical representation of maximum-shearstress theory for biaxial stress state.

Figure 6.12 Graphical representation of distortion energy theory for biaxial stress state.

Hamrock Fundamentals of Machine Elements

Example 6.6

Figure 6.13 Rear wheel suspension used in Example 6.6

Hamrock Fundamentals of Machine Elements

Examples 6.7 and 6.8

Figure 6.14 Cantilevered round bar with torsion applied to free end used in Example 6.7.

Figure 6.15 Cantilevered round bar with torsion and transverse force applied to free end used in Example 6.8. Hamrock Fundamentals of Machine Elements

Maximum Normal Stress Theory

Most suitable for fibrous brittle materials, glasses, and brittle materials in general.

Figure 6.16 Graphical representation of maximumnormal-stress theory (MNST) for biaxial stress state. Hamrock Fundamentals of Machine Elements

Internal Friction and Modified Mohr Theories

Figure 6.17 Internal friction theory and modified Mohr theory for failure prediction of brittle materials. Hamrock Fundamentals of Machine Elements

Experimental Verification

Figure 6.18 Experimental verification of yield and fracture criteria for several materials. (a) Brittle fracture; (b) ductile yielding. Hamrock Fundamentals of Machine Elements

Stress Analysis of Artificial Hip

Figure 6.19 Inserted total hip replacement.

Figure 6.20 Dimension of femoral implant (in inches).

Figure 6.21 Sections of femoral stem analyzed for static failure.

Hamrock Fundamentals of Machine Elements