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Theories of Failure
A good understanding of theories of failure are imperative in the design of civil structures or types of mechanical
equipment. This lecture will give you a conceptual introduction on the theories of failure. So sit back and Enjoy

Theories of Failure | Strength of Materials

A detailed webpage version of the above lecture along with the industrial application of Failure Theories are given
below.

The Weight Lifter Analogy

Consider a weight lifter problem.

(https://3.bp.blogspot.com/-5PJJ5fdCajM/VGRHZv19IHI/AAAAAAAADUg/Iq7asxuyd4k/s1600/Weight_lifter_Analogy.jpg)

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Fig.1 A weight lifter analogy

In the first case he is able to lift maximum up to 50 k.g in a relatively simple fashion. Now consider a second case,
here he is lifting the same amount of weight in a different manner.Is it true to say here also his maximum lifting ability
is 50 k.g?. Answer to this question could be Yes or No. If you assume that, his lifting ability is same in the second
case also , then this can be considered as a failure theory for a weight lifter.

The Backbone of Failure Theories

In materials also we can apply the same concept of weight lifter failure theory.Here material will undergo a simple
force test(simple tension test), so one can determine what's the maximum load capability the material has. Now, we
will assume that in a complex loading condition also, the material has the same capability. This assumption forms the
backbone of Failure theories.Concepts of Simple tension test and Principal stresses are the main 2 prerequisites to
understand the Failure theories effectively.

Simple Tension Test

In Simple tension test material is pulled from both the ends, the elongation of material(strain) with respect to the load
is noted. From such an observation one can easily determine maximum strength of the material. For ductile material
upper yield point is considered to be maximum strength of material, while for brittle material it is taken as ultimate
strength of the material. From the maximum strength value of the material, values of various other parameters can
easily be calculated.Simple tension graph and upper yield point value for a ductile material case is shown in the figure
below.

(https://1.bp.blogspot.com/-

xiBgglMX_Xs/UOU5zg3fAaI/AAAAAAAAASE/46uE_Wpf0FE/s1600/simple-tension-test.gif)
Fig.2 Simple tension test

Principal Stress
Principal stress (https://www.learnengineering.org/2013/01/principal-stress-plane-mohr-circle.html) is the maximum
normal stress occurring at a given point. In order to find out this value easy way is to do a Mohr circle analysis
(https://www.learnengineering.org/2013/01/principal-stress-plane-mohr-circle.html). Once you know Principal stress
values you can go ahead with failure theories.Figure below shows principal stress values induced at point in a 3
dimensional complex loading case.

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(https://4.bp.blogspot.com/-

RuvFfR_x9DE/UL7wOckhXAI/AAAAAAAAACU/9jRk0jmN-5U/s1600/trans_struc_princi.jpg)
Fig.3 Principal stresses and planes

The Failure Theories

The interesting thing in the Failure theories is that, just by looking at the name of the theory you will be able to
formulate condition of failure in an actual case. Just make sure that your concept of STT and Principal stresses are
clear. The theories along with its usability is given below.

1. Maximum principal stress theory - Good for brittle materials*

According to this theory when the maximum principal stress induced in a material under complex load condition
exceeds the maximum normal strength in a simple tension test the material fails. So the failure condition can be
expressed as

(https://1.bp.blogspot.com/-
nxL0qADhxag/UOVU1SwcAoI/AAAAAAAAAWM/S6sPm4fh9hE/s1600/max-normal-stress.gif)
2. Maximum shear stress theory - Good for ductile materials
According to this theory when the maximum shear strength in actual case exceeds maximum allowable shear
stress in simple tension test the material case. Maximum shear stress in actual case in represented as

(https://3.bp.blogspot.com/-
ctyC5qDXQEk/UOVJbpE1zKI/AAAAAAAAAS8/fOtGhGkpf34/s1600/max-shear-actual.gif)
Maximum shear stress in simple tension case occurs at angle 45 with load, so maximum shear strength in a
simple tension case can be represented as

(https://2.bp.blogspot.com/-

IlfbOG6E60M/UOVKyDZmWQI/AAAAAAAAATU/L_0a4F7VzKY/s1600/max-shear-simp.gif)
Comparing these 2 quantities one can write the failure condition as

(https://1.bp.blogspot.com/-1d5CQGbf9bg/UOVLhMXhshI/AAAAAAAAATg/-

tKEPujiWoA/s1600/max-shear-failure-condition.gif)

3. Maximum normal strain theory - Not recommended

This theory states that, when the maximum normal strain in actual case is more than maximum normal strain
occurred in simple tension test case the material fails. The maximum normal strain in actual case is given by

(https://4.bp.blogspot.com/-

NpRUY6TvMik/UOVNq9q1q2I/AAAAAAAAAT8/81d8dBO5jss/s1600/strain-max-actual.gif)
Maximum strain in simple tension test case is given by

(https://3.bp.blogspot.com/-2jMtVntyPoA/UOVN5j7dLYI/AAAAAAAAAUI/Wl4WgNcrTzc/s1600/strain-max-
simple-tension.gif)

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So condition of failure according to this theory is

(https://1.bp.blogspot.com/-
dpn4ST4aylY/UOVOGTAcKsI/AAAAAAAAAUU/_p8tL7APolE/s1600/max-strain-failure-condition.gif)
Where E is Youngs modulus of the material

4. Total strain energy theory - Good for ductile material

According to this theory when the total strain energy in actual case exceeds the total strain energy in simple
tension test at the time of failure, the material fails. The total strain energy in actual case is given by
(https://1.bp.blogspot.com/-

g0XxQfNQecw/UPN_cdJWVsI/AAAAAAAABA0/PWQgL7xyPsg/s1600/TSE-act.gif)
The total strain energy in simple tension test at time of failure is given by

(https://2.bp.blogspot.com/-

dAqIi2xE26Q/UOVRKdglrnI/AAAAAAAAAU8/jingJBevDeQ/s1600/total-strain-energy-simple.gif)
So failure condition can be simplified as

(https://2.bp.blogspot.com/-

nWYgeh55cZE/UOVRS33HwHI/AAAAAAAAAVI/qfL_YOoPcag/s1600/TSE-failure.gif)

5. Shear strain energy theory - Highly recommended

According to this theory when the shear strain energy in the actual case exceeds shear strain energy in simple
tension test at the time of failure the material fails. Shear strain energy in the actual case is given by

(https://2.bp.blogspot.com/-1BXMmwKx0Es/UOVTpQ-
FubI/AAAAAAAAAVo/7N886OoQDjc/s1600/SSE-act.gif)
Shear strain energy in simple tension test at the time of failure is given by

(https://3.bp.blogspot.com/-

QBNWknfU38s/UOVTqsmtXmI/AAAAAAAAAVw/_cUsdGvqeLw/s1600/SSE-simp.gif)
So the failure condition can be deduced as

(https://3.bp.blogspot.com/-

Si9HVAg6dew/UOVTq184OcI/AAAAAAAAAV8/n-2caGFHPnI/s1600/SSE-condition.gif)
Where G is shear modulus of the material

Out of the 5 theories discussed, the Shear strain energy theory or Von-mises theory is the most valuable one.

*Since brittle materials does not have yield point, you can use ultimate tensile stress as failure criterion.

Industrial Applications of Failure Theories

Nowadays FEA based solvers are well integrated to use failure theories. User can specify kind of failure criterion in
his solution method. Shear strain energy theory is the most commonly used method. These softwares can produce
Von-mises stress (https://www.learnengineering.org/2012/12/von-mises-stress.html) along material,which is based on
Shear strain energy theory. So user can check whether maximum Von-mises stress induced in the body crosses
maximum allowable stress value. It is a common practice to introduce Factor of Safety(F.S) while designing, in order
to take care of worst loading scenario. So the engineer can say his design is safe if following condition satisfies.

(https://3.bp.blogspot.com/-

rSXBSWeVw1A/UObPcWgtpkI/AAAAAAAAAXM/_XEkccIjZj8/s1600/designer_eqn.gif)

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