Theories of Failure

Dr. Benedict Thomas

School of Mechanical Engineering
 Theories of Failure
The material properties are usually determined by simple
tension or compression tests.
The mechanical members are subjected to biaxial or
triaxial stresses.
To determine whether a component will fail or not, some
failure theories are proposed which are related to the
properties of materials obtained from uniaxial tension or
compression tests.
Initially we will consider failure of a mechanical member
subjected to biaxial stresses
The Theories of Failures which are applicable for
this situation are:

• Max principal or normal stress theory

(Rankine’s theory)
• Maximum shear stress theory (Coulomb,
Tresca and Guest’s theory)
• Distortion energy theory (Huber Von
Mises & Hencky’s theory)
• Max. strain energy theory (St. Venant’s
theory)
• Max. total strain theory (Haigh’s theory)
 Ductile materials usually fail by yielding
and hence the limiting strength is the
yield strength of material as determined
from simple tension test which is
assumed the same in compression also.
 For brittle materials limiting strength of
material is ultimate tensile strength in
tension or compression.
Max. Principal or Normal stress theory
(Rankine’s Theory):

• “The theory states that the failure of the

mechanical component subjected to bi-axial or
tri-axial stresses occurs when the maximum
principal or normal stress reaches the yield or
ultimate strength of the material”.
• In this case max. principal stress is calculated in
a biaxial stress case and is equated to limiting
strength of the material.
Maximum principal stress
 x   y   x   y 
2

1        2xy
 2   2 
Minimum principal stress
 x   y   x   y 
2

 2        2xy
 2   2 

•For ductile materials

 S yt 
1 should not exceed   in tension, FOS=Factor of safety
 FOS 
•For brittle materials
 S ut 
 
1 should not exceed  FOS  in tension
This theory is basically applicable for brittle materials
which are relatively stronger in shear and not applicable
to ductile materials which are relatively weak in shear.
 +σ2

Syt

-σ1 o
+σ1
Syt
Syc

Syc

-σ2

Boundary for maximum – normal – stress theory under bi – axial stresses

2. Maximum Shear Stress theory (Coulomb, Tresca and
Guest’s theory):
 “The theory states that the failure of the mechanical
component subjected to bi-axial or tri-axial stresses
occurs when the maximum shear stress at any point
in the component becomes equal to the maximum
shear stress in the standard specimen of the tension
test, when yielding starts”.
 x  y  2
 max      xy2
 2 
 In a biaxial stress case max shear stress developed
is given by
 S yt
 max 
FOS max = 2  FOS
This theory is mostly used for ductile materials.
 

max

max
σ
σ2= σ3 =0
o

σ1 -σ2 o σ3 =0
+σ1 σ

Mohr’s circle for uni – axial

tension

max

Mohr’s circle for bi– axial stress

condition
 S yt
According to the Maximum shear stress theory,  max 
2
Max. direct stress  Min. direct stress
And also  max 
2
Assuming that σ1> σ2> σ3 and σ3 =0
CASE – 2 (Second quadrant)
σ1 is -ve and σ2 is +ve ,Then +σ2 CASE – 1 (First quadrant )
  (1 )  2  1 21 σ1 and σ2 are +ve
max  2   1  3 1  0 1 S yt
2 2 2 max    
S yt Syt σ1=Syt 2 2 2 2
Then max  1 
2 i.e. 1  S yt

+σ1
-σ1 Syc o Syt
CASE – 3 (Third quadrant) CASE – 4 (Fourth quadrant)
σ1 is -ve and σ2 is more -ve σ1 is +ve and σ2 is -ve ,Then
Syc
,Then
  (  2 ) 0   2 σ1=Syc   ( 2 ) 1   2 2
 max  3  max  1  
2 2 2 2 2
 S yc -σ2 S yt
Then  max   Then max   
2 2 2
i.e   S yc
3. Max. Distortion energy theory (Huber, Von Mises &
Hencky’s theory):

 “The theory states that the failure of the mechanical

component subjected to bi-axial or tri-axial stresses
occurs when the strain energy of distortion per unit
volume at any point in the component, becomes equal
to the strain energy of distortion per unit volume in
the standard specimen of the tension test, when
yielding starts”.
 The maximum distortion energy is the difference
between the total strain energy and the strain energy
due to uniform stress.
3. Max. Distortion energy theory (Huber, Von Mises &
Hencky’s theory):
3. Max. Distortion energy theory (Huber, Von Mises &
Hencky’s theory):

• The criteria of failure for the distortion – energy

theory is expressed as

S yt 
1
2

 1   2 2   2   3 2   3   1 2 
• Considering the factor of safety
S yt
FOS

1
2

 1   2 2   2   3 2   3   1 2 
• For bi – axial stresses (σ3=0),
S yt
FOS

 1  2  1  2
2 2

3. Max. Distortion energy theory (Huber, Von Mises &
Hencky’s theory):

• A component subjected to pure shear stresses and the

corresponding Mohr’s circle diagram is 
Y



o σ
-σ2 σ1


X


Element subjected to pure shear stresses 
Mohr’s circle for pure shear stresses
3. Max. Distortion energy theory (Huber, Von Mises &
Hencky’s theory):

From the figure, σ1 = -σ2 =  and σ3=0

Substituting the values in the equation
S yt
FOS

 1  2  1  2
2 2

We get
S yt  3
Replacing  by Ssy, we get
S yt
S sy   0.577 S yt
3
In the biaxial stress case, principal stress 1, 2 are
calculated based on x ,y & xy which in turn are used
to determine whether the left hand side is more than
right hand side, which indicates failure of the
component.
 Case 2 (Second quadrant)
Case 1 (First quadrant)
σ1 is -ve and σ2 is +ve and equal
to σ, then
 
S yt σ1 and σ2 are +ve and equal
   2  1  2
2 2
1
+σ2 to σ, then
FOS
S yt
FOS
  1
2
 2
2
  
1 2
Syt
S yt

 1   2  1  2
2 2

S yt FOS
 3 2  3 S yt
FOS 
S yt FOS
  0.577
FOS
Syc
-σ1 o Syt +σ1
Case 4 (Fourth quadrant)
Case 3 (Third quadrant)
σ1 is +ve and σ2 is -ve and equal
σ1 is -ve and σ2 is +ve and to σ, then
equal to σ, then
Syc
S yt
  2
  2  1  2
2

 
1
S yt FOS
 1   2  1  2
   
2 2
S yt
  2
2 2
FOS -σ2 1 1 2
S yt FOS
 S yt
FOS  3 2  3
FOS
S yt
  0.577
FOS
Boundary for distortion – energy theory under bi – axial stresses
4. Max. Strain energy theory (Haigh’s Thoery):

 Failure is assumed to take place at a point in a

member where strain energy per unit volume in a
biaxial stress system reaches the limiting strain
energy that is strain energy at yield point per unit
volume as determined from a simple tension test.
 Strain energy per unit volume in a biaxial system is
1  2 2 1 2 
U1  1  2 
2

2E  m 
 The limiting strain energy per unit volume for
yielding as determined from simple tension test is
2
1  S yt 
U2   
2 E  FOS 
Equating the above two equations then we get
2
2 1  2  S yt 
1  2
2 2
   
m  FOS 
In a biaxial case 1, 2 are calculated based as x, y & xy
It will be checked whether the Left Hand Side of
Equation is less than Right Hand Side of Equation or
not. This theory is used for ductile materials.
5.Max. Principal Strain theory (Saint Venant’s Theory):

 It is assumed that the failure or yielding occurs at a

point in a member where the maximum principal
(normal) strain in a biaxial stress exceeds limiting value
of strain (strain at yield port) as obtained from simple
tension test.
 In a biaxial stress case

σ1 σ 2 Syt
E max   
E mE FOS E

 One can calculate 1 & 2 given x , y & xy and check

whether the material fails or not, this theory is not
used in general as reliable results could not be
detained in variety of materials.
 Example :1

Qu.1. A mild steel shaft of 50 mm diameter is subjected to a

bending moment of 2000 N-m and a torque T. If the
yield point of the steel in tension is 200 MPa, find the
maximum value of this torque without causing yielding
of the shaft according to 1. the maximum principal
stress; 2. the maximum shear stress; and 3. the
maximum distortion strain energy theory of yielding.
 Example :2
Qu. 2. The load on a bolt consists of an axial pull of
10kN together with a transverse shear force of
5kN. Find the diameter of bolt required
according to
1. Maximum principal stress theory
2. Maximum shear stress theory
3. Maximum principal strain theory
4. Maximum strain energy theory
5. Maximum distortion energy theory
Permissible tensile stress at elastic limit =100MPa
and Poisson’s ratio =0.3
 Solution 2
• Cross – sectional area of the bolt,
 2
A  d  0.7854 d 2
4
• Axial stress,
P 10 12.73
1    kN / mm 2

A 0.7854 d 2 d2

• And transverse shear stress,

Ps 5 6.365
   kN / mm 2

A 0.7854 d 2 d2
According to maximum principal stress theory
• Maximum principal stress,
   
2

1   x    x    2xy
 2   2 
 x   y   x   y 
2

1        2xy
 2   2 

 12.73   12.73  2  6.365  2 

1   2 
  2 
 2  
 2d   2d   d  
15365
1  N / mm 2

d2
• According to maximum principal stress
theory, Syt = σ1

15365
100  2
 d  12.4mm
d
According to maximum shear stress theory
• Maximum shear stress,
 x   y 
2

max     2xy
 2 
 x 
2

 max      2xy
 2 
 12.73  2  6.365  2  9 9000
  2    2    2 kN / mm  2 N / mm2
2

 d   d   d d
• According to maximum shear stress,
S yt
9000 100
max   2 
2 d 2
d  13.42mm
According to maximum principal strain theory
• The maximum principal stress,
 x   y   x   y 
2

1        2xy
 2   2 

   
2
15365
1   x    x    2xy 
 2   2  d2
• And minimum principal stress,

 x   y   x   y 
2

 2        2xy
 2   2 

 x   x 
2 2 2
12.73  12.73   6.365 
 2         xy  2  
2
2 
 2 
 2   2  d  2d   d 
 2635
2  N / mm 2

d2
• And according to maximum principal strain theory,

σ1 σ 2 Syt
 
E mE E
σ2 15365 2635  0.3
σ1   Syt  2
 2
 100
m d d
d  12.7mm
• According to maximum strain energy
theory
21  2
1   2   S yt
2 2 2

m
15365    2635  15365  2635
2 2


 d2   d2   2    0.3  100 2

   
2 2
d d
d  12.78mm
• According to maximum distortion theory
S yt  
1
2
  2  1  2
2

 15365  2   2635  2 15365  2635 
100    2      
  d   d  2
d 2
d 2 
 
d  13.4mm