Machine Design

Tutorials
Spring/Summer 2021
May 21st - Week 3
DGD3
Problem 1 Background: Distortion-Energy Failure Theory

Max Distortion Energy Failure Theory:

Yielding occurs when at any point in the body, the distortion energy per unit
volume in a state of combined stress becomes equal to that associated with
yielding in a simple tension test
 Problem 1 Background: Distortion Energy Failure Theory
Von Mises Stress (𝝈′ )

𝜎1 − 𝜎2 2 + 𝜎1 − 𝜎3 2 + 𝜎2 − 𝜎3 2
′
𝜎 =
3D 2

…derived from principles of strain energy

and represents distortion due to shear

equivalent

Given non-zero
𝜎′ = 𝜎12 − 𝜎1 𝜎2 + 𝜎22 principal stresses
σ1 and σ2 (no shear)
2D
(planar)
Given σx ,
𝜎′ = 𝜎𝑥2 − 𝜎𝑥 𝜎𝑦 + 𝜎𝑦2 + 2
3𝜏𝑥𝑦 σy , and τxy :
Note: 𝜎 ′ is denoted
𝜎𝑒 in the textbook
Problem 1 Background: Distortion Energy Failure Theory

Safety factor (n) using DE failure theory

Using the Von Mises stress and the material property, of yield strength, Sy, we can determine
safety factor of a material with a given loading condition

𝑆𝑦
𝑛= ′
𝜎
Problem 1 Background: Distortion-Energy Failure Theory
Graphical Representation
Failure locus: represents the envelope of all the safe stresses for a particular theory.

Max shear stress

theory envelope

Distortion energy failure

theory envelope

𝜎1 − 𝜎2 2 + 𝜎1 − 𝜎3 2 + 𝜎2 − 𝜎3 2
𝜎′ =
2

…General eq for ellipsoid partially rotated…

2 2 2
𝑎−𝑥 + 𝑦−𝑏 + 𝑧−𝑐 =𝐶
Problem 1 Background: Distortion-Energy Failure Theory
Graphical Representation
Load Line: represents loading cases for a particular stress element/location on a part
(you need 2 or more to construct the load line)

load line
1) Determined from given loading conditions
𝑃
2) Same forces would be applied, but
the component has an infinite cross 𝑁
sectional area 𝑶𝑷
𝑂 𝒏=
𝐹 𝐹 𝑶𝑵
𝜎= → 𝜎= →𝜎=0
𝐴 ∞
Problem 1
A 1020 hot-rolled steel has the following properties:
𝑆𝑦 = 30 𝑘𝑝𝑠𝑖, 𝑆𝑢 = 55 𝑘𝑝𝑠𝑖, 𝜀𝑓 = 0.90, 𝑆𝑦𝑡 = 𝑆𝑦𝑐 .

a) Plot the failure locus for the distortion-energy theory and a load line
starting from the origin.

b) For the static stress states at the critical locations listed below, determine
the factor of safety analytically and understand how to obtain it graphically.
i) 𝜎𝑥 = 9 𝑘𝑝𝑠𝑖, 𝜎𝑦 = −5 𝑘𝑝𝑠𝑖
ii) 𝜎𝑥 = 12 𝑘𝑝𝑠𝑖, 𝜏𝑥𝑦 = 3 𝑘𝑝𝑠𝑖 𝑐𝑐𝑤
iii) 𝜎𝑥 = −4 𝑘𝑝𝑠𝑖, 𝜎𝑦 = −9 𝑘𝑝𝑠𝑖, 𝜏𝑥𝑦 = 5 𝑘𝑝𝑠𝑖 𝑐𝑤
iv) 𝜎𝑥 = 11 𝑘𝑝𝑠𝑖, 𝜎𝑦 = 4 𝑘𝑝𝑠𝑖, 𝜏𝑥𝑦 = 1 𝑘𝑝𝑠𝑖 𝑐𝑤
 Problem 1
a) Plot the failure locus for the distortion-energy theory and a load
line starting from the origin. 𝜎𝐵
load line

𝑃
𝑆𝑦
Note: We know that the
distortion-energy (DE) failure locus for DE theory
theory applies because 𝜀𝑓 = 𝑁

0.90 is a high value for failure −𝑆𝑦

strain, which means that the 𝜎𝐴
𝑂 𝑆𝑦
material is ductile, and
because 𝑆𝑦𝑡 = 𝑆𝑦𝑐 .
𝑂𝑃
−𝑆𝑦
𝑛=
𝑂𝑁
b) For the static stress states at the critical locations listed below,
determine the factor of safety analytically and understand how to
obtain it graphically.

i) 𝜎𝑥 = 9 𝑘𝑝𝑠𝑖, 𝜎𝑦 = −5 𝑘𝑝𝑠𝑖

Principal stresses are: 𝜎1 = 9 𝑘𝑝𝑠𝑖, 𝜎2 = 0, 𝜎3 = −5 𝑘𝑝𝑠𝑖

Using : 𝜎′ = 92 − 9 5 + 52 = 12.3 𝑘𝑝𝑠𝑖

30
Using : 𝑛=
12.3
= 2.43 Ans.
Graphical approach:

i) 𝜎𝑥 = 9 𝑘𝑝𝑠𝑖, 𝜎𝑦 = −5 𝑘𝑝𝑠𝑖

9 22 30
𝜎1
𝜎1 = 9 𝑘𝑝𝑠𝑖
𝜎2 = 0 −5
𝜎3 = −5 𝑘𝑝𝑠𝑖

load line
𝑆𝑠𝑦 = 0.577𝑆𝑦
(17, −17)
𝑆𝑠𝑦 = 0.577 30 = 17.31 ≅ 17

22
𝑛= = 2.44 Ans.
−30 9
𝜎3
b) For the static stress states at the critical locations listed below,
determine the factor of safety analytically and understand how to
obtain it graphically.

ii) 𝜎𝑥 = 12 𝑘𝑝𝑠𝑖, 𝜏𝑥𝑦 = 3 𝑘𝑝𝑠𝑖 𝑐𝑐𝑤

Using : 𝜎′ = 122 − 3(32 ) = 13.1 𝑘𝑝𝑠𝑖

30
Using : 𝑛= = 2.29 Ans.
13.1
Graphical approach: 29
12.7 30
ii) 𝜎𝑥 = 12 𝑘𝑝𝑠𝑖, 𝜏𝑥𝑦 = 3 𝑘𝑝𝑠𝑖 𝑐𝑐𝑤 𝜎1
−0.7

𝝈𝒙 +𝝈𝒚 𝝈𝒙 −𝝈𝒚 𝟐 load line

𝝈𝟏,𝟐 = ± + 𝝉𝟐𝒙𝒚
𝟐 𝟐

2
12 𝑘𝑝𝑠𝑖 + 0 12 𝑘𝑝𝑠𝑖 − 0 2
𝜎1 = + + 3 𝑘𝑝𝑠𝑖 = 12.7 𝑘𝑝𝑠𝑖
2 2 (17, −17)

𝜎2 = 0 𝑘𝑝𝑠𝑖

12 𝑘𝑝𝑠𝑖 + 0 12 𝑘𝑝𝑠𝑖 − 0
2 −30
𝜎3 = − + 3 𝑘𝑝𝑠𝑖 2 = −0.7 𝑘𝑝𝑠𝑖 𝜎3
2 2
29
𝑛= = 2.28 Ans.
12.7
𝑆𝑠𝑦 = 0.577𝑆𝑦 ≅ 17
b) For the static stress states at the critical locations listed below,
determine the factor of safety analytically and understand how to
obtain it graphically.

iii) 𝜎𝑥 = −4 𝑘𝑝𝑠𝑖, 𝜎𝑦 = −9 𝑘𝑝𝑠𝑖, 𝜏𝑥𝑦 = 5 𝑘𝑝𝑠𝑖 𝑐𝑤

Using : 𝜎′ = (−4)2 − −4 −9 + −9 2 + 3(52 ) = 11.7 𝑘𝑝𝑠𝑖

30
Using : 𝑛= = 2.56 Ans.
11.7
 −29.5
Graphical approach:
−30 −12.1
iii) 𝜎𝑥 = −4 𝑘𝑝𝑠𝑖, 𝜎𝑦 = −9 𝑘𝑝𝑠𝑖, 𝜏𝑥𝑦 = 5 𝑘𝑝𝑠𝑖 𝑐𝑤 𝜎2 −0.9

𝝈𝒙 +𝝈𝒚 𝝈𝒙 −𝝈𝒚 𝟐
load line
𝝈𝟏,𝟐 = ± + 𝝉𝟐𝒙𝒚
𝟐 𝟐

𝜎1 = 0 𝑘𝑝𝑠𝑖
(−17, −17)
2
−4 − 9 −4 + 9
𝜎2 = + + 52 = −0.9 𝑘𝑝𝑠𝑖
2 2

2 −30
−4 − 9 −4 + 9 𝜎3
𝜎3 = + + 52 = −12.1 𝑘𝑝𝑠𝑖
2 2
−29.5
𝑛= = 2.43 Ans.
−12.1
𝑆𝑠𝑦 = 0.577𝑆𝑦 ≅ 17
b) For the static stress states at the critical locations listed below,
determine the factor of safety analytically and understand how to
obtain it graphically.

iv) 𝜎𝑥 = 11 𝑘𝑝𝑠𝑖, 𝜎𝑦 = 4 𝑘𝑝𝑠𝑖, 𝜏𝑥𝑦 = 1 𝑘𝑝𝑠𝑖 𝑐𝑤

Using : 𝜎′ = 112 − (11) 4 + 42 + 3(12 ) = 11.7 𝑘𝑝𝑠𝑖

30
Using : 𝑛= = 2.56 Ans.
11.7
Graphical approach:
𝜎2
iv) 𝜎𝑥 = 11 𝑘𝑝𝑠𝑖, 𝜎𝑦 = 4 𝑘𝑝𝑠𝑖, 𝜏𝑥𝑦 = 1 𝑘𝑝𝑠𝑖 𝑐𝑤 30

𝝈𝒙 +𝝈𝒚 𝝈𝒙 −𝝈𝒚 𝟐
𝝈𝟏,𝟐 = ± + 𝝉𝟐𝒙𝒚
𝟐 𝟐 (17,17)

2 load line
11 + 4 11 − 4
𝜎1 = + + 12 = 11.2 𝑘𝑝𝑠𝑖
2 2

2
3.8
11 + 4 11 − 4
𝜎2 = − + 12 = 3.8 𝑘𝑝𝑠𝑖 𝜎1
2 2 11.2 24.9 30
𝜎3 = 0 𝑘𝑝𝑠𝑖
24.9
𝑛= = 2.22 Ans.
11.2
𝑆𝑠𝑦 = 0.577𝑆𝑦 ≅ 17
Visit page 266 in your textbook for more on DE Theory
(Section 6.8) and page 360 for more on the graphical
interpretation of load lines and safety factors
Problem 2
The member drawn below has 3-mm radius fillets at every step. Determine the
stress concentration factors at the 3 critical locations below, considering:
(a) a rectangular cross-section and an axial load
(b) a circular cross-section and a torsional load
(c) a circular cross-section and a bending load
Stress Concentration Factors, Kt
Locations of stress concentration in a material include:
• Notches • Fillets
• Large surface imperfections • Grooves
• Holes

Kt =theoretical stress concentration factor

(based on theoretical elastic homogeneous, isotropic material)

𝜎𝑚𝑎𝑥 = 𝐾𝑡 𝜎𝑛𝑜𝑚 𝜏𝑚𝑎𝑥 = 𝐾𝑡 𝜏𝑛𝑜𝑚

(a) Rectangular cross section and axial load

From diagram:
𝐻 = 32 𝑚𝑚 ℎ = 30 𝑚𝑚 𝑟 = 3 𝑚𝑚 (𝑓𝑖𝑙𝑙𝑒𝑡)

𝐻 32 𝑟 3
= = 𝟏. 𝟎𝟕 = = 𝟎. 𝟏
ℎ 30 ℎ 30

Using figure 4.38:

𝐾𝑡 ≅ 1.6 ANS.
(a) Rectangular cross section and axial load; cont.

From diagram: From diagram:

H = 38 𝑚𝑚 ℎ = 32 𝑚𝑚 𝑟 = 3 𝑚𝑚 (𝑓𝑖𝑙𝑙𝑒𝑡) H = 38 𝑚𝑚 ℎ = 30 𝑚𝑚 𝑟 = 3 𝑚𝑚 (𝑓𝑖𝑙𝑙𝑒𝑡)

𝐻 38 𝑟 3 𝐻 38 𝑟 3
= = 𝟏. 𝟏𝟗 = = 𝟎. 𝟎𝟗 = = 𝟏. 𝟐𝟕 = = 𝟎. 𝟏
ℎ 32 ℎ 32 ℎ 30 ℎ 30

Using figure 4.38: Using figure 4.38:

𝐾𝑡 ≅ 1.8 ANS. 𝐾𝑡 ≅ 1.9 ANS.
(b) Circular cross-section with torsional load

From diagram:
𝐷 = 32 𝑚𝑚 𝑑 = 30 𝑚𝑚 𝑟 = 3 𝑚𝑚 (𝑓𝑖𝑙𝑙𝑒𝑡)

𝐷 32 𝑟 3
= = 𝟏. 𝟎𝟕 = = 𝟎. 𝟏
𝑑 30 𝑑 30

Using figure 4.38:

𝐾𝑡 ≅ 1.15 ANS.
(b) circular cross section and torsional load; cont.

From diagram: From diagram:

𝐷 = 38 𝑚𝑚 𝑑 = 32 𝑚𝑚 𝑟 = 3 𝑚𝑚 (𝑓𝑖𝑙𝑙𝑒𝑡) D = 38 𝑚𝑚 𝑑 = 30 𝑚𝑚 𝑟 = 3 𝑚𝑚 (𝑓𝑖𝑙𝑙𝑒𝑡)

𝐷 38 𝑟 3 𝐷 38 𝑟 3
= = 𝟏. 𝟏𝟗 = = 𝟎. 𝟎𝟗 = = 𝟏. 𝟐𝟕 = = 𝟎. 𝟏
𝑑 32 𝑑 32 𝑑 30 𝑑 30

Using figure 4.38: Using figure 4.38:

𝐾𝑡 ≅ 1.35 ANS. 𝐾𝑡 ≅ 1.38 ANS.
(c) Circular cross-section with bending load

From diagram:
𝐷 = 32 𝑚𝑚 𝑑 = 30 𝑚𝑚 𝑟 = 3 𝑚𝑚 (𝑓𝑖𝑙𝑙𝑒𝑡)

𝐷 32 𝑟 3
= = 𝟏. 𝟎𝟕 = = 𝟎. 𝟏
𝑑 30 𝑑 30

Using figure 4.38:

𝐾𝑡 ≅ 1.55 ANS.
(b) circular cross section and torsional load; cont.

From diagram: From diagram:

𝐷 = 38 𝑚𝑚 𝑑 = 32 𝑚𝑚 𝑟 = 3 𝑚𝑚 (𝑓𝑖𝑙𝑙𝑒𝑡) D = 38 𝑚𝑚 𝑑 = 30 𝑚𝑚 𝑟 = 3 𝑚𝑚 (𝑓𝑖𝑙𝑙𝑒𝑡)

𝐷 38 𝑟 3 𝐷 38 𝑟 3
= = 𝟏. 𝟏𝟗 = = 𝟎. 𝟎𝟗 = = 𝟏. 𝟐𝟕 = = 𝟎. 𝟏
𝑑 32 𝑑 32 𝑑 30 𝑑 30

Using figure 4.38: Using figure 4.38:

𝐾𝑡 ≅ 1.65 ANS. 𝐾𝑡 ≅ 1.62 ANS.
Problem 3
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 on the DE theory at points A and B. The
bar shown in the figure is made of AISI 1030 annealed steel.
F = 0.55 kN
P = 8.0 kN
T = 30 Nm
Recall: How to find safety factor using the DE theory of failure

To find safety factor:

𝑆𝑦
𝑛=
𝜎′

Von Mises Stress in 3D:

𝜎 − 𝜎 2+ 𝜎 −𝜎 2 + 𝜎2 − 𝜎3 2 1/2
1 2 1 3
𝜎′ =
2

Von Mises Stress in 2D

𝜎 ′ = 𝜎𝐴2 − 𝜎𝐴 𝜎𝐵 + 𝜎𝐵2 1/2
AISI 1030 annealed steel
…For a single normal and shear stress, 2D Von Mises Stress →(from Appendix C-4a in Juvinall
Marshek Txtbk)
reduces to:
𝑆𝑢 = 463.7 𝑀𝑃𝑎
𝜎 ′ = (𝜎 2 + 3𝜏 2 )1/2
𝑆𝑦 = 341.3 𝑀𝑃𝑎
 y
F=550N

A
P=8000 N
z
B 20 mm x

T=30Nm

100 mm

A T
(internal)

z
B
At point A:
Normal Stress Shear Stress

𝑷 𝑴𝒄 𝑻𝒓
𝝈𝒙 = + 𝝉𝒙𝒛 =
𝑨 𝑰 𝑱
y
Axial Bending
y A T
F (internal)
P A
z P
x
M z

State of Stress at A in
𝐴𝑥𝑖𝑎𝑙 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 xz plane
A A

A x
+
𝑆ℎ𝑒𝑎𝑟
+𝝉𝒙𝒛
z
At point A:
Normal Stress
𝑃 𝐹𝐿 𝑟 8000 𝑁 550 𝑁 0.1 𝑚 0.01 𝑚
𝜎𝑥 = 2 + 4 = + = 25.46 𝑀𝑃𝑎 + 70.03 𝑀𝑃𝑎
𝜋𝑟 𝜋𝑑 𝜋 0.01 𝑚 2 𝜋 0.02 𝑚 4
64 64
𝝈𝒙 = 𝟗𝟓. 𝟒𝟗 𝑴𝑷𝒂

Shear Stress
𝑇𝑟 30 𝑁𝑚 0.01 𝑚
𝜏𝑥𝑧 = =
𝜋𝑑 4 𝜋 0.02 𝑚 4
32 32

𝝉𝒙𝒛 = 𝟏𝟗. 𝟏 𝑴𝑷𝒂

**Single normal and shear stress, so can use reduced 2D version of Von Mise Stress Equation
Von Mises stress and safety factor (DE failure theory)
→ at point A

Von Mises Stress

𝜎𝐴′ = (𝜎𝑥2 + 3𝜏𝑥𝑧

2
)= 95.49 𝑀𝑃𝑎 2 + 3 19.1 𝑀𝑃𝑎 2 = 𝟏𝟎𝟏 𝑴𝑷𝒂

Safety Factor (DE Theory of Failure)

𝑆𝑦 341.3 𝑀𝑃𝑎
𝑛= ′=
𝜎𝐴 101 𝑀𝑃𝑎

𝑛 = 3.38 𝐴𝑁𝑆.
At point B:
Normal Stress Shear Stress

𝑷 𝑻𝒓
𝝈𝒙 = 𝝉𝒙𝒚 =
𝑨 𝑱
*no bending stress because B is on neutral axis y

y T
F
(internal)
P P
B x
M
z
State of Stress at B in
B
xy plane
𝐴𝑥𝑖𝑎𝑙 𝐵𝑒𝑛𝑑𝑖𝑛𝑔
y

B + B B
x
𝑆ℎ𝑒𝑎𝑟
−𝝉𝒙𝒛
At point B:
Normal Stress
𝑃 8000 𝑁
𝜎𝑥 = =
𝜋𝑟 2 𝜋 0.01 𝑚 2

𝝈𝒙 = 𝟐𝟓. 𝟒𝟔 𝑴𝑷𝒂

Shear Stress
𝑇𝑟 30 𝑁𝑚 0.01 𝑚
𝜏𝑥𝑦 =− 4 =−
𝜋𝑑 𝜋 0.02 𝑚 4
32 32

𝝉𝒙𝒚 = −𝟏𝟗. 𝟏 𝑴𝑷𝒂

**Single normal and shear stress, so can use reduced 2D version of Von Mise Stress Equation
Von Mises stress and safety factor (DE failure theory)
→ at point B

Von Mises Stress:

𝜎𝐵′ = (𝜎𝑥2 + 3𝜏𝑥𝑧

2
)= 25.46 𝑀𝑃𝑎 2 + 3 −19.1 𝑀𝑃𝑎 2 = 𝟒𝟏. 𝟖 𝑴𝑷𝒂

Safety Factor (DE Theory of Failure)

𝑆𝑦 341.3 𝑀𝑃𝑎
𝑛= ′ =
𝜎𝐵 41.8 𝑀𝑃𝑎

𝑛 = 8.2 𝐴𝑁𝑆.
See you next
week!