ABE 423 Machine Design for AB Production Laboratory Report

Name: Barros, Lim, Macalele, Mamon, Manili DATE CONDUCTED:

SECTION: BSABE- 4A DATE SUBMITTED: December 7, 2024

Laboratory Exercise 3

Failure Resulting from Static Loading: Ductile & Brittle Material

I. INTRODUCTION

This lab explores material failure under static loading conditions, specifically
focusing on the contrasting behaviors of ductile and brittle materials. Ductile
failure, characterized by significant plastic deformation before fracture, occurs
when a material is loaded beyond its ultimate tensile strength. This type of
failure is also referred to as plastic collapse, general yielding, or ductile
overload. The experiment will delve into the key material properties that govern
this behavior, namely the yield strength for ductile materials. The lab will
introduce several common failure theories, which are mathematical models
used to predict the onset of failure in components subjected to complex stress
states – situations where the material is experiencing stress in multiple
directions simultaneously. These theories provide a framework for
understanding how different stress combinations contribute to failure.

II. OBJECTIVES

At the end of the laboratory exercise, the students must be able to:
1. Calculate the factor of safety using failure theories for ductile and brittle
materials;
2. Identify parts of the proposed machine that are ductile or brittle material;
3. Calculate the factor of safety using failure theories on ductile and brittle
material;
4. Based on the static loading; and
5. Analize the proposed machine and perform combined stress analysis

III. METHODOLOGY

PROPOSED MACHINE

Instruction:

Based on your Proposed machine,

1. Identify any of the parts and select one (1) and perform computations on Failure
Resulting from Static Loading: Ductile Material & Brittle material.
2. Identify the material that you will use for the part in concern and determine its
yield strength (for ductile material) or ultimate strength for (brittle material).
3. Using the graphical method, in a plane stress (graph of σ 1 in x-axis and σ3
yaxis), show the yield strength of the material (for ductile material) or the
ultimate strength (for brittle material) and the corresponding load that you will
apply.
4. Choose and use the appropriate failure theories for your calculations. Use
BOTH the accurate and conservative failure theory and compare the results.
IV. RESULTS & DISCUSSION

Proposed Machine: Grass/Hay Chopper

Identified part: Cylindrical Shaft
Material: Steel
Yield Strength: 700 Mpa
Ultimate Tensile Strength: 800 Mpa

a) 160, 160, 0 Mpa

b) 210, 210, 0 Mpa
c) 0, 210, 160 Mpa
d) -160, -210, 0 Mpa

CALCULATIONS:

a.) 160, 160, 0 Mpa

= (1602 − (160) + 1602 )1/2

= 160 Mpa

Sy 700
n= = 160 = 4. 4
oi

b.) 210, 210, 0 Mpa

= (2102 − (210) + 2102 )1/2

= 210 Mpa

Sy 700
n= = 210 = 3.33
oi

c.) 0, 210, -160 Mpa

= (2102 − 210(−160) + (−1602 )1/2

= 321.40 Mpa

Sy 700
n= = 321.40 = 2.18
oi

d.) -160, -210, 0 Mpa

= (−1602 − (−160)(−210) + (−2102 )1/2

=190 Mpa

Sy 700
n= = 190 = 3.64
oi
Instructor: EJTE Page 1 ABE 423 Machine Design for AB Production
Laboratory Report

GUIDE QUESTIONS

1. In the machine design process, what is the relevance of calculating the factor
of safety of machine elements? How do we use the result of this analysis in the
design of machine components?
- The factor of safety (FOS) is a crucial safety measure in machine design.
It acts as a safety buffer, ensuring a machine part can handle more than
its expected load. This safety margin accounts for uncertainties like
variations in material strength, manufacturing imperfections, and
unexpected forces. By dividing the material's maximum strength by the
FOS, engineers determine the safe working stress for the part, ensuring
it can withstand loads significantly lower than its breaking point. This
protects against unexpected overloads, impacts, and environmental
factors. The FOS also influences material selection, with higher FOS
requiring stronger, more expensive materials. Engineers can adjust the
size or shape of a part to achieve the desired FOS. By comparing
designs based on their FOS, engineers choose the safest and most
reliable design for the intended application. The FOS is essential for
ensuring the safe and reliable operation of machines by accounting for
potential risks and uncertainties.

2. Enumerate and discuss the different failure theories for ductile and brittle
material. Explain the practical application of each method.

 Maximum Shear Stress Theory (Tresca): This theory says a ductile material
will break when the force pulling it apart (tension) is too strong, and the material
starts to tear apart. It's like pulling a piece of playdough too hard – it eventually
tears.
o Practical Application: Used for simple designs where we're mainly
worried about tension.
 Maximum Distortion Energy Theory (von Mises): This theory is a bit more
complex, but it's more accurate for real-world situations. It considers how the
material is stressed in all directions, not just in one direction.
o Practical Application: Used for more complex designs where the force is
applied in different ways.
 Maximum Principal Stress Theory (Rankine): This theory focuses on the
highest stress point in the material. It's simpler but less accurate than the other
two.
o Practical Application: Used for quick estimates, but not for critical
designs.

Brittle Materials: Break Suddenly

Brittle materials, like glass or concrete, break suddenly without much bending. Here are
some theories for these materials:
  Maximum Normal Stress Theory (Rankine): This theory says a brittle material
will break when the force pulling it apart (tension) is too strong. It's like pulling a
piece of glass too hard – it snaps.
o Practical Application: Used for simple designs where we're mainly
worried about tension.
 Mohr-Coulomb Theory: This theory considers both the force pulling the material
apart and the force pushing it together (compression). It's more accurate for
complex situations.
o Practical Application: Used for designs where the material is under both
tension and compression.

Practical Applications

These theories are used by engineers to design things like bridges, buildings,
machines, and even your phone. They help engineers choose the right materials and
make sure the design can handle the expected forces without breaking.

 Choosing the Right Material: If you need something strong and flexible, you
might choose a ductile material like steel. If you need something strong but
brittle, you might choose concrete.
 Preventing Failure: By understanding how materials fail, engineers can design
things to be stronger and more reliable.
 Testing and Analysis: Engineers use these theories to test and analyze designs
to make sure they're safe and can handle the expected loads.

3. What are the challenges that you have encountered in performing laboratory
exercise?
- Lab exercises can be tricky. Besides equipment malfunctions and time
pressure, there are other hurdles. Analyzing data and drawing
meaningful conclusions from a laboratory exercise can be a real head-
scratcher, especially with complex ones. Sometimes, we don't have
access to the right equipment or software, which can limit what we can
do. And if we don't fully understand the theory behind a laboratory
exercise, it's easy to get lost in the procedures. Finally, working in a
team requires good communication and teamwork skills to ensure
everyone is on the same page and working together effectively. These
challenges are all part of the learning process, and overcoming them
helps us become better scientists and problem solvers.

V. CONCLUSION

The analysis would reveal the factor of safety calculated using both the
accurate and conservative failure theories. A factor of safety significantly less than 1
signifies a high risk of failure, while a higher factor of safety indicates a safer design.
Comparing the results from the accurate and conservative theories would highlight
the discrepancies in their predictions, revealing the potential overestimation or
underestimation of safety margins inherent in each approach.

This comparison is crucial for understanding the potential consequences of

using a conservative versus an accurate failure theory. It allows engineers to assess
the level of conservatism built into the design and make informed decisions about the
appropriate safety margins for the specific application. For instance, if the conservative
 theory predicts a much higher factor of safety than the accurate theory, it may indicate
that the design is overly conservative and could be optimized for cost-effectiveness
without compromising safety. On the other hand, if the accurate theory predicts a lower
factor of safety than the conservative theory, it might necessitate further design
modifications to ensure adequate safety margins.

VI. CITATION

Hailu, Y. M., Nazir, A., Lin, S., & Jeng, J. (2021). The effect of functional gradient

material distribution and patterning on torsional properties of lattice structures

manufactured using MultiJet fusion technology. Materials, 14(21), 6521.

https://doi.org/10.3390/ma14216521

Maher Alalwan. (2021, May 18). Lecture 8 Theories of failure under static load [Video].

YouTube. https://www.youtube.com/watch?v=JZDaFxRmybo
VII. APPENDICES

Figure 1: Doing the Laboratory Exercise

Instructor: EJTE Page 2