Shigley’s Mechanical Engineering Design

11th Edition in SI units

Richard G. Budynas and J. Keith Nisbett

Chapter 5
Failures Resulting from Static Loading
Prepared by:
Dr. Nader Ghareeb
Dr. Adel Younis
Chapter Outline
5-1 Static Strength
5-2 Stress Concentration
5-3 Failure Theories
5-4 Maximum-Shear-Stress Theory for Ductile Materials
5-5 Distortion-Energy Theory for Ductile Materials
5-6 Coulomb-Mohr Theory for Ductile Materials
5-7 Failure of Ductile Materials Summary
5-8 Maximum-Normal-Stress Theory for Brittle Materials
5-9 Modifications of the Mohr Theory for Brittle Materials
5-10 Failure of Brittle Materials Summary
5-11 Selection of Failure Criteria
5-12 Introduction to Fracture Mechanics
5-13 Important Design Equations
Failure Examples
Failure Examples
Failure Examples
Failure Examples
Failure Examples
Static Strength
• A static load is a stationary force, or couple applied to a member.

• Failure can mean a part has separated into two or more pieces; has
become permanently distorted, thus ruining its geometry; has had its
reliability downgraded; or has had its function compromised, whatever
the reason.
Static Strength
• When a material is subjected to uniaxial stress, it will fail when the
stress reaches the failure strength (Solid Mechanics)

• What about if it is subjected to biaxial or triaxial stress, when would it

fail?

• Is there a difference in the failure mechanisms of ductile and brittle

materials?

• Should stress concentrations be considered?

Static Strength (ductile and brittle materials)

Ductile materials Brittle materials

Static Strength (ductile and brittle materials)
• Ductility is the degree to which a material will deform before
ultimate fracture.
• Percent elongation (% Ɛ) is used as a measure of ductility.
- Ductile Materials have % Ɛ ≥ 5%
- Brittle Materials have % Ɛ < 5%
Static Strength (ductile vs brittle failure)
Static Strength (ductile failure)
Stress Concentration
• Localized increase of stress near discontinuities
• Kt is Theoretical (Geometric) Stress Concentration Factor
 Theoretical Stress Concentration Factor

- Stress concentration effect is commonly ignored (set to unity) for static

loads on ductile materials or cast iron
- Stress concentration must be included for dynamic loading (See Ch. 6)
- Stress concentration must be included for brittle materials, since localized
yielding may reach brittle failure rather than coldworking and sharing the
load.
 Failure Theories (why???)
• Ideally, When designing a machine element, the best way to determine its strength is to test the
part under exactly the same loading conditions the part will experience in service.

• Thus, in most cases it is necessary to design using the

published material properties (yield strength,
ultimate strength, percentage elongation, etc.)
obtained from testing under uniaxial stress.

• How to deal with 2D and 3D states of stress?

→ Use failure theories
(Source: Hibbeler’s Solid Mechanics)
 Failure Theories (Principal Stresses)
• Some failure theories are function of principal stresses:

• σA and σB in plane (2-D) can be calculated using Mohr Circle or Eq. (3-13):

• σ1, σ2 and σ3 in space (3-D): These can be calculated by setting principal stresses
in plane and in space identical according to the following convention:
σ1 ≥ σ2 ≥ σ3
σA ≥ σB
Failure Theories
There is no universal theory of failure for the general case of material properties and stress state.
Instead, over the years several hypotheses have been formulated and tested, leading to today’s
accepted practices most designers do.

The generally accepted theories are:

Ductile materials (yield criteria)

✓ Maximum shear stress (MSS)
✓ Distortion energy (DE)
✓ Ductile Coulomb-Mohr (DCM)

Brittle materials (fracture criteria)

➢ Maximum normal stress (MNS)
➢ Brittle Coulomb-Mohr (BCM)
➢ Modified Mohr (MM)
Maximum Shear Stress Theory (MSS)
• The MSS theory predicts that yielding begins whenever the maximum
shear stress in any element equals or exceeds the maximum shear
stress in a tension test specimen of the same material when the
specimen begins to yield.

• The MSS is referred to as Tresca or Guest theory

• Incorporating the factor of safety n gives:

• Note: In case of pure shear, Sy is replaced by Ssy, where:

Maximum Shear Stress Theory (MSS)
• Let σA and σB represent the two non-zero principal stresses, then
order them with the zero principal stress such that σ1 ≥ σ2 ≥ σ3

• Assuming σA ≥ σB , there are three cases to consider:

◦ Case 1: σA ≥ σB ≥ 0
◦ Case 2: σA ≥ 0 ≥ σB
◦ Case 3: 0 ≥ σA ≥ σB
Maximum Shear Stress Theory (MSS)
• Case 1: σA ≥ σB ≥ 0
◦ For this case, σ1 = σA and σ3 = 0
𝑆𝑦
◦ Eq. (5–3) reduces to n =
σA

• Case 2: σA ≥ 0 ≥ σB
◦ For this case, σ1 = σA and σ3 = σB
𝑆𝑦
◦ Eq. (5–3) reduces to n =
σ A − σB

• Case 3: 0 ≥ σA ≥ σB
◦ For this case, σ1 = 0 and σ3 = σB
𝑆𝑦
◦ Eq. (5–3) reduces to n = -
σB
 Distortion Energy Theory (DE)
• The DE theory (also called Von Mises theory) predicts that yielding occurs
when the distortion strain energy per unit volume reaches or exceeds the
distortion strain energy per unit volume for yield in simple tension or
compression of the same material.
• Incorporating the factor of safety in the theory gives the DE stress as:

• Similar to MSS theory, and in case of pure shear, Sy is replaced by Ssy,

where:
 Distortion Energy Theory
• The DE or Von Mises stress 𝜎 ′ can be calculated depending on the problem:

• If the xyz components of the stress in 3-D (space) are given:

• If the principal stresses in space are given:

Distortion Energy Theory
• If the xy components of the stress in 2-D (plane) are given:

• If the principal stresses in plane are given:

 Ductile Coulomb-Mohr Theory (DCM)
• Some materials have compressive strengths different from tensile strengths
• Mohr theory is based on three simple tests: tension, compression, and shear
• Coulomb-Mohr theory simplifies to linear failure envelope using only tension
and compression tests (dashed circles)
 Ductile Coulomb-Mohr Theory (DCM)
• Incorporating n in the DCM theory gives:

where either yield strength or ultimate strength (preferred) can be used

• As Eq. (5-26) is function of principal stresses in space and these can‘t be

calculated directly, the principal plane stresses σA and σB must be calculated
first.
• For plane stress, when the two nonzero principal stresses are σA ≥ σB , there
is a situation similar to the three cases given for the MSS theory.
Ductile Coulomb-Mohr Theory (DCM)
• Case 1: σA ≥ σB ≥ 0, For this case, σ1 = σA and σ3 = 0

Eq. (5-26) becomes:

• Case 2: σA ≥ 0 ≥ σB, For this case, σ1 = σA and σ3 = σB

Eq. (5-26) becomes:

• Case 3: 0 ≥ σA ≥ σB, For this case, σ1 = 0 and σA = σB

Eq. (5-26) becomes:

Maximum Normal Stress Theroy (MNS)
• The maximum-normal-stress (MNS) theory states that failure occurs
whenever one of the three principal stresses equals or exceeds the
ultimate strength.

• Incorporating design factor:

Brittle Coulomb Mohr Theory (BCM)
Modified Mohr Theory
Example 5-1
Example 5-1
Example 5-1
Example 5-2
 Example 5-3
A certain force F applied at D near the end of the 15-in lever shown in Figure 5–16, which is quite
similar to a socket wrench, results in certain stresses in the cantilevered bar OABC. This bar
(OABC) is of AISI 1035 steel, forged and heat-treated so that it has a minimum (ASTM) yield
strength of 550 MPa. We presume that this component would be of no value after yielding. Thus
the force F required to initiate yielding can be regarded as the strength of the component part.
Find this force.
 Example 5-3

• Employing the distortion-energy theory, we find, from Equation (5–15), that

• Equating the von Mises stress to Sy, we solve for F and get
Example 5-3
Example 5-4

(Please check only the equations

of stresses. The rest is
incomplete and not relevant)
Example 5-4
Example 5-5
Example 5-5
Example 5-5
THANK YOU