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STRENGTHS OF MATERIALS
Unit code:
K/601/1409
QCF level:
Credit value: 15
OUTCOME 1 - TUTORIAL 2
THEORIES OF ELASTIC FAILURE
1.
You should judge your progress by completing the self assessment exercises.
It is assumed that students doing this tutorial are already familiar with complex
stress theory covered in tutorial 1.
CONTENTS
1. INTRODUCTION
2. THE GREATEST PRINCIPAL STRESS THEORY (RANKINE)
3. THE GREATEST PRINCIPAL STRAIN THEORY (St. VENANT)
4. THE MAXIMUM SHEAR STRESS THEORY (GUEST and COULOMB)
5. STRAIN ENERGY
D.J.Dunn
1.
INTRODUCTION
Modern CADD systems allow the engineer to calculate stress levels in a component using finite
stress analysis linked to the model. The reasons why a given material fails however, is not
something a computer can predict without the results of research being added to its data bank. In
some cases it fails because the maximum tensile stress has been reached and in others because the
maximum shear stress has been reached. The exact combination of loads that makes a component
fail depends very much on the properties of the material such as ductility, grain pattern and so on.
This section is about some of the theories used to predict whether a complex stress situation is safe
or not. There are many theories about this and we shall examine three. First we should consider
what we regard as failure. Failure could be regarded as when the material breaks or when the
material yields. If a simple tensile test is conducted on a ductile material, the stress strain curve may
look like this.
Figure 1
The maximum allowable stress in a material is max. This might be regarded as the stress at
fracture (ultimate tensile stress), the stress at the yield point or the stress at the limit of
proportionality (often the same as the yield point). The Modulus of elasticity is defined as E =
stress/strain = / and this is only true up to the limit of proportionality. Note that some materials
do not have a proportional relationship at all. The maximum allowable stress may be determined
with a simple tensile test.
There is only one direct stress in a tensile test ( = F/A) so it follows that max = 1 and it will
have a corresponding strain max = 1. Complex stress theory tells us that there will be a shear
stress and strain that has a maximum value on a plane at 45 o to the principal plane. It is of
interest to note that in a simple tensile test on a ductile material, at the point of failure, a cup and
cone is formed with the sides at 45o to the axis. Brittle materials often fail with no narrowing
(necking) but with a flat fail plane at 45 o to the axis. This suggests that these materials fail due to
the maximum shear stress being reached.
Figure 2
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Figure 3
2.
This simply states that in a complex stress situation, the material fails when the greatest principal
stress equals the maximum allowable value.
1= max
max could be the stress at yield or at fracture depending on the definition of failure.
If 1 is less than max then the material is safe.
Safety Factor = max /1
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3.
This states that in a complex stress situation, the material fails when the greatest principal strain
reaches the maximum allowable strain determined in a simple tensile test.
1 = max
max is the value determined in a simple tensile test. If the maximum allowable stress is taken as
the value at the limit of proportionality, we may further develop the theory using the modulus of
elasticity. max = max/E
From 3 dimensional relationships (covered in other tutorials) we have:
1
1 1 2 3
E
max
Safety factor max
and the material fails when
1 2 3
1
Safety factor
max
600
1.103
1 2 3 600 0.28400 - 200
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4.
This states that in a complex stress situation, the material fails when the greatest shear strain in the
material equals the value determined in a simple tensile test. Applying complex stress theory to a
tensile test gives this as max = max
In a simple tensile test, max could be what ever stress is regarded as the maximum allowable.
In a 3 dimensional complex stress situation the maximum shear strain is = (1 - 3 )
If this is less than max then the material is safe.
max
max
1 3
On the limit when the safety factor is 1 it follows that max = (1 - 3 )
Safety factor
Put into words, failure occurs when the maximum allowable stress is equal to the difference
between the greatest and the smallest principal stresses. Note negative stresses are smaller than
zero.
Safety factor
max
600
max
0.75
1 3 600 (200)
The component should have failed as the safety factor is less than 1.
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A certain steel fails in a simple tensile test when the stress is 30 MPa. The same steel is used in
a complex stress situation and the principal stresses are 11 MPa, 3 MPa and 0 MPa. Determine
the factor of safety based on the three theories. = 0.3
(Answers 2.73, 2.97 and 2.73)
2.
A certain steel fails in a simple tensile test when the stress is 30 MPa. The same steel is used in
a complex stress situation and the principal stresses are 11 MPa, 0 MPa and -3 MPa. Determine
the factor of safety based on the three theories. = 0.3
(Answers 2.73, 2.52 and 2.14)
3.
A certain steel failed in a simple tensile test when the stress is 460 MPa. The same steel is used
in a complex stress situation and the principal stresses are 200 MPa, 150 MPa and -100 MPa.
Determine the factor of safety based on the three theories. = 0.3
(Answers 2.3, 2.49 and 1.53)
4.
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5.
STRAIN ENERGY
Another theory for failure of materials is based on strain energy. This simply states that a
component will fail when the total strain energy reaches a critical level. This is only covered in
simple terms here because you need to develop formulae for the strain energy stored under various
conditions and this is a major topic. This is covered in outcome 3.
Consider a bar of length L and cross sectional area A. If a tensile force is applied it stretches and the
graph of force v extension is usually a straight line as shown. When the force reaches a value of F
and corresponding extension x, the work done (W) is the area under the graph. Hence W = Fx/2
(the same as the area under the graph).
Figure 4
Since the work done is the energy used up, this is now stored in the material as strain energy hence
U = Fx/2
The stress in the bar is = F/A hence F = A
The strain in the bar is = x/L hence x = L
For an elastic material up to the limit of proportionality, / = E (The modulus of elasticity) hence
= /E
Substituting we find
U = AL/2 = 2AL/2E
The volume of the bar is A L so
U = (2/2E ) x volume of the bar
If is the critical stress level obtained from a tensile test then U is the critical strain energy then
failure will occur in a stressed component of the same material when the strain energy reaches this
value.
In the same way it can be shown that the strain energy in a round bar under pure torsion is given by:
U = (2/4G) x volume of the bar. ( is the maximum shear stress on the surface)
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