Concordia University

Department of Mechanical, Industrial and Aerospace

Engineering

MECH 344 – Machine Element Design

(Design of Load-Carrying Components under Static Load )

 Objective

To learn theoretical techniques based on the type of material to predict failures under static loading and
effectively utilize these techniques to deign load-carrying components that are safe and reasonably light-
weight.
 Rationale for the Need of Failure Theories
Assume as a design engineer, you are engaged with the design of a machine element made of ductile steel which is under
multi-axial stresses. Assume that for a particular application, the combination of static loads have produced at a critical
location in the machine member , the principal stresses 𝜎1 =400 Mpa; 𝜎3 = −200 Mpa; 𝜎2 =0. The member is made of
material SAE 1040 cold drawn which yields under standard tensile test at a stress of 𝑆𝑦 =490 Mpa (Appendix 3).

Will this structural member fail in the proposed application?

𝜎𝑥 = 𝑆𝑦
+𝜏 𝜏𝑚𝑎𝑥 =300 Mpa SAE 1040

𝜎𝑦 +𝜏
𝜎2 = 𝜎3 =0 𝜏𝑚𝑎𝑥 = 𝜎1 /2=245 Mpa

𝜏𝑦𝑥 𝜎1 = 𝜎𝑥 =
𝑆𝑦 = 490 Mpa
𝜎3 = −200 Mpa 𝜎2 =0
SAE 1040 𝜎2 = 𝜎3 =0
+𝜎
cold drawn 𝜎𝑥
+𝜎
𝜏𝑥𝑦
𝜎1 =400 Mpa

Standard tensile stress of the material.

Loads at the critical location have induced principal Yield strength 𝑆𝑦 =490 Mpa
stresses 𝜎1 =400 Mpa; 𝜎3 = −200 Mpa; 𝜎2 =0
 Static Failure Theories

1- Maximum Shear Stress Theory (MSST)-

Also known as Tresca Theory
Ductile
2- Maximum Distortion Energy Theory (MDET)-
Also known as von Mises Theory or Maximum-
Octahedral Shear Stress Theory

Material
3- Maximum Normal Stress Theory (MNST)

Brittle 4- Coulomb-Mohr Theory (CMT)

5- Modified Mohr Theory (MMT)

 Ductile vs Brittle Materials

Under static load, the failure in ductile material means “yielding” thus design is based
on yield strength, 𝑆𝑦 , or shear yield strength , 𝑆𝑠𝑦 . For brittle materials, failure means
“fracture” thus design is based on the ultimate tensile strength, 𝑆𝑢𝑡 , or ultimate
compressible strength, 𝑆𝑢𝑐 .

Ductile materials are considered to be “Even” materials. This means their strength
properties under tension and compression are the same. 𝑆𝑦 = 𝑆𝑦𝑡 = 𝑆𝑦𝑐 .

Brittle materials are considered to be “Un-even” materials. This means their strength
properties under tension and compression are different. Typically in brittle materials:
𝑆𝑢𝑐 ≫ 𝑆𝑢𝑡
 Some Experimental Observations

It breaks nearly at 0o . It breaks at about 45o .

Why? Why?

Pure shear
Pure shear condition
condition

Machine Design-An Integrated Approach by R. Norton. 5th Edition, 2013, Copyright, Pearson
 Static Failure Theories-Ductile Materials

Maximum Shear Stress Theory (MSST):

Based on experimental observations, it has been realized that the cause of failure (yielding) in ductile
materials under static loading is mainly due to shear. “According to MSST, a ductile material begins to
yield when the maximum shear stress at a critical location in a load-carrying component exceeds that in a
tensile-test specimen when yielding begins.” Thus to apply this theory, we only need to find the maximum
shear stress developed at the critical location and compare it with the shear yield strength of the material.
Under uniaxial tensile testing the maximum shear stress is one-half of the applied tensile stress, thus
shear yield strength can be estimated as: 𝑆𝑠𝑦 = 𝑆𝑦 /2.
These are basically
effective stress
Stress element at the location according to MSST
Safety factor
of interest is safe when:

For example for the case of 𝜎1 > 𝜎2 = 0 > 𝜎3 Or

For the case in which all principal stresses are in tension 𝜎1 > 𝜎2 > 𝜎3 = 0

For the case in which all principal stresses are in compression 0 = 𝜎1 > 𝜎2 > 𝜎3 −𝜎3 ≤ 𝑆𝑦 /N Or 𝜎3 ≥ −𝑆𝑦 /N
 Static Failure Theories-Ductile Materials
Maximum Distortion Energy Theory (MDET) (Maximum-Octahedral-Shear-Stress Theory):
When the ductile material under stress deforms (change in shape, volume or both), the energy required to
produce the deformation is stored in the material as the elastic energy. Some part of the elastic energy is
associated with the distortion (change in shape) and the remaining part is associated with volumetric change .
It has been realized that ductile materials could withstand very large hydrostatic pressure (i.e. 𝜎1 = 𝜎2 = 𝜎3 =
large compression) causing volumetric change without yielding while they have a definite limited capacity to
absorb energy associated with distortion. According to MDET the distortion energy is the cause of failure.
MDET postulates that yielding occurs when the maximum distortion energy in the stressed material reaches to
that in the same material under tensile-test at yield.

When using this theory, it is convenient to use an effective stress, 𝜎𝑒 , also known as von-Mises stress . 𝜎𝑒 is
defined as the value of equivalent uniaxial stress that would cause the same level of distortion energy as the
actual stresses involved. In terms of principal stresses, von-Mise stress can be described as:
 Static Failure Theories-Ductile Materials

Maximum Distortion Energy Theory (MDET):

According to MDET, a stress element is considered safe when:

In 2D cased, when :

It is interesting to note that for the case of pure shear :

and thus for N=1

Note that MSST predict failures at 0.5 𝑆𝑦 ,

thus it is more conservative
 Graphical Representation of MSST and MDET Theories
𝜎2
The stress state that lies inside the =1
𝑆𝑦
von-Mises ellipse is safe with
Von Mises Ellipse
respect to both MSST and MDET, the
stress state that lies outside of the 𝜎12 + 𝜎22 − 𝜎1 𝜎2 = 𝑆𝑦2
von-Mises ellipse is failure with
respect to both MSST and MDET. The 2 2
𝜎1 /𝑆𝑦 + 𝜎2 /𝑆𝑦 − 𝜎1 𝜎2 /𝑆𝑦2 = 1
stress state that lies between the
Tresca hexagon and von-Mises
ellipse is safe with respect to MDET
while failure with respect to MSST.

𝜎1
=1
𝑆𝑦

Note: Numerical scales in the graph are normalized to the yield strength
 Static Failure Theories-Brittle Materials
Maximum Normal Stress Theory (MNST):
The MNST states that a material will fracture when the maximum normal stress (either tension or compression) exceeds
the ultimate strength of the material as obtained from a standard tensile or compressive test. MNST provides satisfactory
prediction for brittle materials under pure static tension or compression (first and third quadrants) in figure below.
Uniaxial +𝜏 𝜎3 If: 𝜎1 > 𝜎2 > 𝜎3 = 0
compression 𝜎1 ≤ 𝑆𝑢𝑡 /N
Uniaxial
tension
𝑆𝑢𝑡 If: 0 = 𝜎1 > 𝜎2 > 𝜎3
−𝜎3 ≤ −𝑆𝑢𝑐 /N

𝑆𝑢𝑐
𝜎1
𝑆𝑢𝑐 +𝜎 𝑆𝑢𝑡
𝑆𝑢𝑡

𝑆𝑢𝑐
Principal Mohr Circle must be within
these bounds to prevent failure
2D Graphical representation of MNST. Inside the square is safe
 Static Failure Theories-Brittle Materials
Coulomb Mohr-Theory (CMP):
Compared with MNST, CMT provides better prediction of failure of brittle materials subjected to biaxial tension-
compression stress (4th quadrant). The 2D graphical representation of CM is shown below which is an uneven hexagon.
First and third quadrant is exactly similar to MNST.
𝜎3
𝑆𝑢𝑡
For the state of stress in 4th quadrant:

Graphical: 𝑁 = 𝑂𝐴𝑓 /𝑂𝐴 𝑆𝑢𝑐 𝜎1

𝑜
𝑆𝑢𝑡
Stress state 𝐴
𝑆𝑢𝑡 𝑆𝑢𝑐 𝐴𝑓
Analytical: 𝑁=
𝜎1 𝑆𝑢𝑐 + 𝜎3 𝑆𝑢𝑡
Load line

Note that 𝑆𝑢𝑐 and 𝜎3 are negative.

𝑆𝑢𝑐
 Static Failure Theories-Brittle Materials
Modified Mohr-Theory (MMP):

MMP is a semi-empirical data fitting method that best predicts fracture of brittle material under static load, particularly
for the stress state in the 4th quadrant. 𝜎 3

−𝑆𝑢𝑡
For the state of stress in 4th quadrant:

Graphical: 𝑁 = 𝑂𝐴𝑓 /𝑂𝐴 𝑆𝑢𝑐 𝜎1

𝑜 𝑆𝑢𝑡
𝐴
𝑆𝑢𝑡 𝑆𝑢𝑐
Analytical: 𝑁= −𝑆𝑢𝑡
𝜎1 𝑆𝑢𝑐 + 𝑆𝑢𝑡 (𝜎1 +𝜎3 )
𝑆𝑢𝑡 𝐴𝑓 Load line
Note that 𝑆𝑢𝑐 and 𝜎3 are negative.

𝑆𝑢𝑐
 Static Failure Theories for Ductile Materials-Comparison with Experiment

Machine Design-An Integrated Approach by R. Norton. 5th Edition, 2013,

Copyright, Pearson
 Static Failure Theories for Brittle Materials-Comparison with Experiment

o Illustrate
experimental results

Machine Design-An Integrated Approach by R. Norton. 5th Edition, 2013,

Copyright, Pearson
 Example-Ductile Material
A bracket is made by welding a rectangular bar to a circular rod, as shown below. Design the bar and the rod to carry a
static load of 250 lb.
Use SAE 1340 annealed steel having 𝑆𝑦 = 63 ksi and 𝑆𝑢 = 102 ksi Appendix 3 .
The steel is highly ductile.

The design process involves two parts:

1- Design of the rectangular bar. 2-Design of the circular bar.
Assume safety factor of N=2 for both.

1-Rectangular bar:
The stresses at A are:

The minimum required

section modulus:
Design stress:

For rectangular cross-

section

As a design decision, let

F.B.D of the rectangular bar us assume: ℎ = 3𝑡

In the fractional-inch system, preferred sizes are selected to be t=3/8=0.375 in

𝑡ℎ2 1.252
and h=11/4=1.25 in. We must check if the resulting value for S is satisfactory. 𝑆 = = 0.375 × = 0.0977 > 0.095. 𝑇ℎ𝑢𝑠 𝑖𝑡 𝑖𝑠 𝑜𝑘.
6 6
 Example-Ductile Material

2-Circular rod:
Let us use equivalent torque method explained before as:

Then the shear stress in the bar is:

Polar section modulus for the circular rod:

Using MSST, design shear stress can be expressed as:

F.B.D of the circular rod
Minimum acceptable diameter
Thus minimum polar section modulus
required:
0.577 𝑆𝑦 0.577 × 63000 𝑇𝑒 3606
Using MDET, design shear stress can be expressed as: 𝜏𝑑 = = = 18176 psi 𝑍𝑝 = = = 0.198 in3
N 2 𝑑 18176

3
𝐷= 16𝑍𝑝 /𝜋 = 1.00 in
MSST provides more conservative results.
 Example-Brittle Material
Determine the safety factor for the bracket rod made of class 50 Gray cast iron with 𝑆𝑢𝑡 = 52500 psi and 𝑆𝑢𝑐 = −164000 psi as shown below.
The arm is rigid member and it is used to just transfer the load. The rod length 𝑙 = 6 in, the arm length 𝑎 = 8 in. , the rod diameter 𝑑 = 1.5 in
and the applied load F=1000 lb. 4
π𝑑
𝐽 = 2𝐼 = = 0.497 in4
64 The material is brittle so let us use
4 4 the Modified-Mohr Theory (MMT).
π𝑑 π × 1.5
𝐼= = = 0.249 in4
64 64

At point A:
Modified Mohr
Diagram

Machine Design-An Integrated Approach by R. Norton. 5th Edition, 2013, Copyright, Pearson
 Example-Brittle Material

At point B:
𝑇𝐶 𝐹𝑎 𝑐 1000 × 8 × 0.75
𝜏𝑡𝑜𝑟𝑠𝑖𝑜𝑛 = = = = 12072 psi
𝐽 𝐽 0.497

Principal Stresses:

As it can be realized point A is more critical than point B.

Machine Design-An Integrated Approach by R. Norton. 5th Edition, 2013, Copyright, Pearson