BudynasNisbett: Shigleys II. Failure Prevention 5.

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51
52
5 Chapter Outline
Static Strength 208
Stress Concentration 209
Failures Resulting
from Static Loading

53 Failure Theories 211

54 Maximum-Shear-Stress Theory for Ductile Materials 211
55 Distortion-Energy Theory for Ductile Materials 213
56 Coulomb-Mohr Theory for Ductile Materials 219
57 Failure of Ductile Materials Summary 222
58 Maximum-Normal-Stress Theory for Brittle Materials 226
59 Modications of the Mohr Theory for Brittle Materials 227
510 Failure of Brittle Materials Summary 229
511 Selection of Failure Criteria 230
512 Introduction to Fracture Mechanics 231
513 Stochastic Analysis 240
514 Important Design Equations 246

205
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Figure 525 2.2 A A

Off-center crack in a plate in 

longitudinal tension; solid
curves are for the crack tip at
2.0
A; dashed curves are for the
2a
tip at B.
A B A

d
1.8

2b

 1.6


0.4
B
1.4
db = 1.0 0.2
B
0.4

1.2
0.2

1.0
0 0.2 0.4 0.6 0.8
ad ratio

Figure 526 7.0

Plate loaded in longitudinal 

tension with a crack at the
edge; for the solid curve there
6.0
are no constraints to bending; h
the dashed curve was a
obtained with bending
constraints added.
h b
5.0

 4.0

3.0
hb = 0.5

1.0
2.0

1.0
0 0.2 0.4 0.6 0.8
ab ratio 235
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236 Mechanical Engineering Design

Figure 527
Beams of rectangular cross 2.0
h
section having an edge crack. a
M M
F

1.8
h
a
F F
2 2
l l
1.6


Pure bending

1.4

l =4
h
1.2
l =2
h

1.0

0 0.2 0.4 0.6 0.8

ah ratio

Figure 528 3

Plate in tension containing a
circular hole with two cracks. 2a
r = 0.5
b
2
r

 2b r = 0.25
b

1 r
=0
b

0
0 0.2 0.4 0.6 0.8
ab ratio

loading rate, and the state of stress at the crack site (such as plane stress versus plane
strain). The critical stress intensity factor K I c is also called the fracture toughness of
the material. The fracture toughness for plane strain is normally lower than that for
plane stress. For this reason, the term K I c is typically dened as the mode I, plane strain
fracture toughness. Fracture
toughness K I c for engineering metals lies in the range
20 K I c 200 MPa m; for engineering polymers and ceramics, 1 K I c
5 MPa m. For a 4340 steel, where the yield strength dueto heat treatment ranges
from 800 to 1600 MPa, K I c decreases from 190 to 40 MPa m.
 BudynasNisbett: Shigleys II. Failure Prevention 5. Failures Resulting from The McGrawHill 241
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Failures Resulting from Static Loading 237

Figure 529 4.0


A cylinder loading in axial
tension having a radial crack
ri ro = 0
of depth a extending a a
3.0
completely around the
circumference of the cylinder. 0.1

0.4

2.0
0.8
ri ro

1.0
0 0.2 0.4 0.6 0.8
a(ro ri ) ratio

Figure 530 3.4

Cylinder subjected to internal

pressure p, having a radial a
crack in the longitudinal
3.0
direction of depth a. Use pi
Eq. (451) for the tangential ri
stress at r = r 0 . ro

2.6

 2.2

1.8
ri ro = 0.9
0.75

0.35
1.4

1.0
0 0.2 0.4 0.6 0.8
a(ro ri ) ratio

Table 51 gives some approximate typical room-temperature values of K I c for

several materials. As previously noted, the fracture toughness depends on many factors
and the table is meant only to convey some typical magnitudes of K I c . For an actual
application, it is recommended that the material specied for the application be certi-
ed using standard test procedures [see the American Society for Testing and Materials
(ASTM) standard E399].
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248 Mechanical Engineering Design

KIc
p. 238 n= (538)
KI
where K I c is found in Table 51 (p. 238)

Stochastic Analysis
Mean factor of safety dened as n = S / ( S and are mean strength and stress,
respectively)

Normal-Normal Case

1 1 (1 z 2 Cs2 )(1 z 2 C2 )
p. 241 n= (542)
1 z 2 Cs2
where z can be found in Table A10, C S = S / S , and C = / .

Lognormal-Lognormal Case
      
. Cn
p. 242 n = exp z ln(1 + Cn ) + ln 1 + Cn = exp Cn z +
2 2
2
(545)
where

C S2 + C2
Cn =
1 + C2
(See other denitions in normal-normal case.)

PROBLEMS
51 A ductile hot-rolled steel bar has a minimum yield strength in tension and compression of 50 kpsi.
Using the distortion-energy and maximum-shear-stress theories determine the factors of safety
for the following plane stress states:
(a) x = 12 kpsi, y = 6 kpsi
(b) x = 12 kpsi, x y = 8 kpsi
(c) x = 6 kpsi, y = 10 kpsi, x y = 5 kpsi
(d) x = 12 kpsi, y = 4 kpsi, x y = 1 kpsi

52 Repeat Prob. 51 for:

(a) A = 12 kpsi, B = 12 kpsi
(b) A = 12 kpsi, B = 6 kpsi
(c) A = 12 kpsi, B = 12 kpsi
(d) A = 6 kpsi, B = 12 kpsi
53 Repeat Prob. 51 for a bar of AISI 1020 cold-drawn steel and:
(a) x = 180 MPa, y = 100 MPa
(b) x = 180 MPa, x y = 100 MPa
(c) x = 160 MPa, x y = 100 MPa
(d) x y = 150 MPa
54 Repeat Prob. 51 for a bar of AISI 1018 hot-rolled steel and:
(a) A = 100 MPa, B = 80 MPa
(b) A = 100 MPa, B = 10 MPa
(c) A = 100 MPa, B = 80 MPa
(d) A = 80 MPa, B = 100 MPa
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55 Repeat Prob. 53 by rst plotting the failure loci in the A , B plane to scale; then, for each stress
state, plot the load line and by graphical measurement estimate the factors of safety.

56 Repeat Prob. 54 by rst plotting the failure loci in the A , B plane to scale; then, for each stress
state, plot the load line and by graphical measurement estimate the factors of safety.

57 An ASTM cast iron has minimum ultimate strengths of 30 kpsi in tension and 100 kpsi in com-
pression. Find the factors of safety using the MNS, BCM, and MM theories for each of the fol-
lowing stress states. Plot the failure diagrams in the A , B plane to scale and locate the
coordinates of each stress state.
(a) x = 20 kpsi, y = 6 kpsi
(b) x = 12 kpsi, x y = 8 kpsi
(c) x = 6 kpsi, y = 10 kpsi, x y = 5 kpsi
(d) x = 12 kpsi, x y = 8 kpsi

58 For Prob. 57, case (d), estimate the factors of safety from the three theories by graphical mea-
surements of the load line.

59 Among the decisions a designer must make is selection of the failure criteria that is applicable to
the material and its static loading. A 1020 hot-rolled steel has the following properties:
Sy = 42 kpsi, Sut = 66.2 kpsi, and true strain at fracture f = 0.90. Plot the failure locus and, for
the static stress states at the critical locations listed below, plot the load line and estimate the fac-
tor of safety analytically and graphically.
(a) x = 9 kpsi, y = 5 kpsi.
(b) x = 12 kpsi, x y = 3 kpsi ccw.
(c) x = 4 kpsi, y = 9 kpsi, x y = 5 kpsi cw.
(d) x = 11 kpsi, y = 4 kpsi, x y = 1 kpsi cw.

510 A 4142 steel Q&T at 80 F exhibits Syt = 235 kpsi, Syc = 275 kpsi, and f = 0.06. Choose and
plot the failure locus and, for the static stresses at the critical locations, which are 10 times those
in Prob. 59, plot the load lines and estimate the factors of safety analytically and graphically.

511 For grade 20 cast iron, Table A24 gives Sut = 22 kpsi, Suc = 83 kpsi. Choose and plot the fail-
ure locus and, for the static loadings inducing the stresses at the critical locations of Prob. 59,
plot the load lines and estimate the factors of safety analytically and graphically.

512 A cast aluminum 195-T6 has an ultimate strength in tension of Sut = 36 kpsi and ultimate
strength in compression of Suc = 35 kpsi, and it exhibits a true strain at fracture f = 0.045.
Choose and plot the failure locus and, for the static loading inducing the stresses at the critical
locations of Prob. 59, plot the load lines and estimate the factors of safety analytically and graph-
ically.

513 An ASTM cast iron, grade 30 (see Table A24), carries static loading resulting in the stress state
listed below at the critical locations. Choose the appropriate failure locus, plot it and the load
lines, and estimate the factors of safety analytically and graphically.
(a) A = 20 kpsi, B = 20 kpsi.
(b) x y = 15 kpsi.
(c) A = B = 80 kpsi.
(d) A = 15 kpsi, B = 25 kpsi.

514 This problem illustrates that the factor of safety for a machine element depends on the particular point
selected for analysis. Here you are to compute factors of safety, based upon the distortion-energy
theory, for stress elements at A and B of the member shown in the gure. This bar is made of AISI
1006 cold-drawn steel and is loaded by the forces F = 0.55 kN, P = 8.0 kN, and T = 30 N m.
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10
0m
m
A

B
Problem 514
F

20-mm D.

T P
x

515 The gure shows a crank loaded by a force F = 190 lbf which causes twisting and bending of
the 34 -in-diameter shaft xed to a support at the origin of the reference system. In actuality, the
support may be an inertia which we wish to rotate, but for the purposes of a strength analysis we
can consider this to be a statics problem. The material of the shaft AB is hot-rolled AISI 1018
steel (Table A20). Using the maximum-shear-stress theory, nd the factor of safety based on the
stress at point A.

1 in
F
A C
3 1
4
-in dia. -in dia.
1 2
Problem 515 4 in
1
14 in
B
z

4 in
5 in

516 Solve Prob. 515 using the distortion energy theory. If you have solved Prob. 515, compare the
results and discuss the difference.

517* Design the lever arm CD of Fig. 516 by specifying a suitable size and material.

518 A spherical pressure vessel is formed of 18-gauge (0.05-in) cold-drawn AISI 1018 sheet steel. If the
vessel has a diameter of 8 in, estimate the pressure necessary to initiate yielding. What is the esti-
mated bursting pressure?

*The asterisk indicates a problem that may not have a unique result or may be a particularly challenging
problem.
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519 This problem illustrates that the strength of a machine part can sometimes be measured in units
other than those of force or moment. For example, the maximum speed that a ywheel can reach
without yielding or fracturing is a measure of its strength. In this problem you have a rotating ring
made of hot-forged AISI 1020 steel; the ring has a 6-in inside diameter and a 10-in outside diameter
and is 1.5 in thick. What speed in revolutions per minute would cause the ring to yield? At what
radius would yielding begin? [Note: The maximum radial stress occurs at r = (ro ri )1/2 ; see Eq.
(355).]
520 A light pressure vessel is made of 2024-T3 aluminum alloy tubing with suitable end closures.
This cylinder has a 3 21 -in OD, a 0.065-in wall thickness, and = 0.334. The purchase order spec-
ies a minimum yield strength of 46 kpsi. What is the factor of safety if the pressure-release valve
is set at 500 psi?

521 A cold-drawn AISI 1015 steel tube is 300 mm OD by 200 mm ID and is to be subjected to an
external pressure caused by a shrink t. What maximum pressure would cause the material of the
tube to yield?
522 What speed would cause fracture of the ring of Prob. 519 if it were made of grade 30 cast iron?
523 The gure shows a shaft mounted in bearings at A and D and having pulleys at B and C. The
forces shown acting on the pulley surfaces represent the belt tensions. The shaft is to be made of
ASTM grade 25 cast iron using a design factor n d = 2.8. What diameter should be used for the
shaft?

x
6-in D.
300 lbf

y 50 lbf
27 lbf

360 lbf D
Problem 523
C 6 in
8-in D.

z 8 in
B

A 8 in

524 By modern standards, the shaft design of Prob. 523 is poor because it is so long. Suppose it is
redesigned by halving the length dimensions. Using the same material and design factor as in
Prob. 523, nd the new shaft diameter.

525 The gear forces shown act in planes parallel to the yz plane. The force on gear A is 300 lbf.
Consider the bearings at O and B to be simple supports. For a static analysis and a factor of safe-
ty of 3.5, use distortion energy to determine the minimum safe diameter of the shaft. Consider
the material to have a yield strength of 60 kpsi.

526 Repeat Prob. 525 using maximum-shear-stress.

527 The gure is a schematic drawing of a countershaft that supports two V-belt pulleys. For each
pulley, the belt tensions are parallel. For pulley A consider the loose belt tension is 15 percent of
the tension on the tight side. A cold-drawn UNS G10180 steel shaft of uniform diameter is to be
selected for this application. For a static analysis with a factor of safety of 3.0, determine the
minimum preferred size diameter. Use the distortion-energy theory.
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20 in

O 16 in
FC
10 in
20
Problem 525 z

Gear A B
24-in D. A

FA Gear C x
10-in D.
20

300
45
O 400
T2
T1

Problem 527 z 150

Dimensions in millimeters
250 Dia. A 300 Dia.

50 N

B
C x

270 N

528 Repeat Prob. 527 using maximum shear stress.

529 The clevis pin shown in the gure is 12 mm in diameter and has the dimensions a = 12 mm and
b = 18 mm. The pin is machined from AISI 1018 hot-rolled steel (Table A20) and is to be
loaded to no more than 4.4 kN. Determine whether or not the assumed loading of gure c yields
a factor of safety any different from that of gure d. Use the maximum-shear-stress theory.

530 Repeat Prob. 529, but this time use the distortion-energy theory.

531 A split-ring clamp-type shaft collar is shown in the gure. The collar is 2 in OD by 1 in ID by 12
in wide. The screw is designated as 14 -28 UNF. The relation between the screw tightening torque
T, the nominal screw diameter d, and the tension in the screw Fi is approximately T = 0.2 Fi d .
The shaft is sized to obtain a close running t. Find the axial holding force Fx of the collar as a
function of the coefcient of friction and the screw torque.
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(b)

b
d 2
Problem 529

a+b

(c)
a a
F
b

b
a+b
(a)
(d )

Problem 531

532 Suppose the collar of Prob. 531 is tightened by using a screw torque of 190 lbf in. The collar
material is AISI 1040 steel heat-treated to a minimum tensile yield strength of 63 kpsi.
(a) Estimate the tension in the screw.
(b) By relating the tangential stress to the hoop tension, nd the internal pressure of the shaft on
the ring.
(c) Find the tangential and radial stresses in the ring at the inner surface.
(d) Determine the maximum shear stress and the von Mises stress.
(e) What are the factors of safety based on the maximum-shear-stress hypothesis and the distortion-
energy theory?

533 In Prob. 531, the role of the screw was to induce the hoop tension that produces the clamping.
The screw should be placed so that no moment is induced in the ring. Just where should the screw
be located?

534 A tube has another tube shrunk over it. The specications are:

Inner Member Outer Member

ID 1.000 0.002 in 1.999 0.0004 in

OD 2.000 0.0004 in 3.000 0.004 in

Both tubes are made of a plain carbon steel.

(a) Find the nominal shrink-t pressure and the von Mises stresses at the t surface.
(b) If the inner tube is changed to solid shafting with the same outside dimensions, nd the
nominal shrink-t pressure and the von Mises stresses at the t surface.
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535 Steel tubes with a Youngs modulus of 207 GPa have the specications:

Inner Tube Outer Tube

ID 25 0.050 mm 49.98 0.010 mm

OD 50 0.010 mm 75 0.10 mm

These are shrink-tted together. Find the nominal shrink-t pressure and the von Mises stress in
each body at the t surface.

536 Repeat Prob. 535 for maximum shrink-t conditions.

537 A 2-in-diameter solid steel shaft has a gear with ASTM grade 20 cast-iron hub (E = 14.5 Mpsi)
shrink-tted to it. The specications for the shaft are
+ 0.0000
2.000 in
0.0004

The hole in the hub is sized at 1.999 0.0004 in with an OD of 4.00 321 in. Using the midrange
values and the modied Mohr theory, estimate the factor of safety guarding against fracture in the
gear hub due to the shrink t.

538 Two steel tubes are shrink-tted together where the nominal diameters are 1.50, 1.75, and 2.00
in. Careful measurement before tting revealed that the diametral interference between the tubes
to be 0.00246 in. After the t, the assembly is subjected to a torque of 8000 lbf in and a bend-
ing-moment of 6000 lbf in. Assuming no slipping between the cylinders, analyze the outer
cylinder at the inner and outer radius. Determine the factor of safety using distortion energy with
Sy = 60 kpsi.

539 Repeat Prob. 538 for the inner tube.

540 For Eqs. (536) show that the principal stresses are given by
 
KI
1 = cos 1 + sin
2r 2 2
 
KI
2 = cos 1 sin
2r 2 2

0 (plane stress)
3 =  2
K I cos (plane strain)
r 2
541 Use the results of Prob. 540 for plane strain near the tip with = 0 and = 13 . If the yield
strength of the plate is Sy , what is 1 when yield occurs?
(a) Use the distortion-energy theory.
(b) Use the maximum-shear-stress theory. Using Mohrs circles, explain your answer.

542 A plate 4 in wide, 8 in long, and 0.5 in thick is loaded in tension in the direction of the length.
The plate contains a crack asshown in Fig. 526 with the crack length of 0.625 in. The material
is steel with K I c = 70 kpsi in, and Sy = 160 kpsi. Determine the maximum possible load that
can be applied before the plate (a) yields, and (b) has uncontrollable crack growth.

543 A cylinder subjected to internal pressure pi has an outer diameter of 350 mm and a 25-mm wall

thickness. For the cylinder material, K I c = 80 MPa m, Sy = 1200 MPa, and Sut = 1350 MPa.
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If the cylinder contains a radial crack in the longitudinal direction of depth 12.5 mm determine
the pressure that will cause uncontrollable crack growth.

544 A carbon steel collar of length 1 in is to be machined to inside and outside diameters, respec-
tively, of
Di = 0.750 0.0004 in Do = 1.125 0.002 in

This collar is to be shrink-tted to a hollow steel shaft having inside and outside diameters,
respectively, of
di = 0.375 0.002 in do = 0.752 0.0004 in

These tolerances are assumed to have a normal distribution, to be centered in the spread interval,
and to have a total spread of 4 standard deviations. Determine the means and the standard devi-
ations of the tangential stress components for both cylinders at the interface.

545 Suppose the collar of Prob. 544 has a yield strength of S y = N(95.5, 6.59) kpsi. What is the
probability that the material will not yield?

546 A carbon steel tube has an outside diameter of 1 in and a wall thickness of 18 in. The tube is to
carry an internal hydraulic pressure given as p = N(6000, 500) psi. The material of the tube has
a yield strength of S y = N(50, 4.1) kpsi. Find the reliability using thin-wall theory.