004 Factor of Safety

Machine Design - I
Semester VI (CBCGS)
Factor of Safety
Dr. Sanjay Rukhande

Machine Design - I
Modes of failures
•Failure by elastic deflection
•Failure by general yielding
•Failure by fracture
Machine Design - I
Factor of Safety
While designing a component, it is necessary to ensure sufficient reserve strength in
case of an accident. This is ensured by taking suitable Factor of Safety (F.O.S.)
Why?
There are number of factors which are difficult to evaluate accurately in the design
analysis, but the stresses used in the design of a component must be safe so as not to
cause failure.
Machine Design - I
Factor of Safety
Certain uncertainties which are not possible to evaluate at the design stage are :
1. Uncertainty in the magnitude of the external load applied on the component.
2. Variation in the mechanical properties of material like yield or ultimate strength.
3. Variation in the dimensions of the component due to improper workmanship.
4. Assumptions made during design to simplify the calculations which may not be
valid exactly in actual working condition.

Machine Design - I
Factor of Safety
Factor of Safety is defined as the ‘ratio of critical stress or stress at failure to the
Definition
design or permissible stress.
Failure Stress Failure Load

F.O.S .  F.O.S . 
Allowable Stress Working Load
Allowable Stress is a stress value which is used in design

to determine the dimensions of component. It is considered
as stress, which the designer expects will not exceeded
under normal operating conditions.
Machine Design - I
Factor of Safety
S yt
For ductile materials the allowable stress is given by :  
F .O.S .
S ut
For brittle materials the allowable stress is given by :  
F .O.S .
Machine Design - I
Factors for selection of magnitude of Factor of Safety
1. Effect of Failure : factor of safety is taken high, where failure of machine part may result in
serious accidents.
2. Type of Load : Low for static load and high for impact loading conditions
3. Degree of Accuracy in Force Analysis : When the forces acting on the machine component
are determined precisely, low factor of safety is taken else high F.O.S. is taken.
4. Material of Component : Low for ductile material and high for brittle materials.
5. Reliability of Component : Factor of safety increases with increasing reliability.
6. Cost of Component : F.O.S. is low for cheap materials.
7. Testing of Machine Element : When machine component can be tested under actual
conditions, low F.O.S. is taken.
Machine Design - I
Theories of Failure
Theories of failure are those theories which help us to

determine the safe dimensions of a machine component when it
is subjected to combined stresses due to various loads acting
on it during its functionality.
Various Theories of Failure
1. Maximum Principal Stress theory (RANKINE’S THEORY)
2. Maximum Shear Stress theory (GUEST AND TRESCA’S THEORY)
3. Maximum Principal Strain theory (St. VENANT’S THEORY)
4. Total Strain Energy theory (HAIGH’S THEORY)
5. Maximum Distortion Energy theory (VONMISES AND HENCKY’S THEORY)

Machine Design - I
Maximum Principal Stress theory (RANKINE’S THEORY)

This theory states that the failure of the mechanical component
subjected to bi-axial or tri-axial stresses occurs when the maximum principal
stress reaches the yield or ultimate strength of the material.
𝝈𝟏 > 𝝈𝟐 > 𝝈𝟑 Safe Region

𝜎1 = 𝑆𝑦𝑡 or 𝜎1 = 𝑆𝑢𝑡
For tensile stress, For compressive stress,
𝑆𝑦 𝑆 𝑢𝑡 𝑆𝑦 𝑆 𝑢𝑐
𝜎1 = 𝑡 or 𝜎1 = 𝜎1 = or 𝜎1 =
𝑓𝑠 𝑓𝑠 𝑓𝑠
𝑓𝑠
Good for brittle materials. Not recommended for ductile
materials.
Machine Design - I
Maximum Shear Stress theory (GUEST AND TRESCA’S THEORY)

The theory states that the failure of a 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.
𝜎1
𝑟𝑚 𝑎 =
2
𝑆𝑦𝑡
𝑟 𝑚𝑎𝑥 =
2
𝑆𝑦𝑠 = 0.5 ∗ 𝑆𝑦𝑡
𝜎 −𝜎 𝜎 −𝜎 𝜎 −𝜎
𝑟12 = 1 2; 𝑟23 = 2 3; 𝑟31 = 1 3
2 2 2
𝑆𝑦𝑡 Widely used by designers for predicting the failure
max 𝜎1 − 𝜎2 , 𝜎2 − 𝜎3 , 𝜎1 − 𝜎3 = of components, which are made of ductile materials.
2
Machine Design - I
Maximum Distortion Energy theory (VONMISES AND 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
tension-test, when yielding starts.
𝑆𝑦𝑡 1
= 𝜎1 − 𝜎2 2 + 𝜎2 − 𝜎3 2 + 𝜎1 − 𝜎3 2
𝑓𝑠 2
For bi-axial stresses,

𝑆𝑦𝑡
= 𝜎12 − 𝜎1 𝜎2 + 𝜎22
𝑓𝑠
Shear stress,
The distortion energy theory is in better agreement for
𝑆𝑦 𝑡 = 3 ∗ 𝑟 predicting the failure of a ductile component than any
𝑆𝑦𝑠 = 0.577 ∗ 𝑥𝑆𝑦𝑡 other theory of failure.
Machine Design - I
Selection of Theories of Failure

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Machine Design - I

Dr. Sanjay Rukhande

1. Uncertainty in the magnitude of the external load applied on the component.

2. Variation in the mechanical properties of material like yield or ultimate strength.

3. Variation in the dimensions of the component due to improper workmanship.

valid exactly in actual working condition.

Failure Stress Failure Load

Allowable Stress is a stress value which is used in design

5. Reliability of Component : Factor of safety increases with increasing reliability.

6. Cost of Component : F.O.S. is low for cheap materials.

Theories of failure are those theories which help us to

Various Theories of Failure

1. Maximum Principal Stress theory (RANKINE’S THEORY)

2. Maximum Shear Stress theory (GUEST AND TRESCA’S THEORY)

3. Maximum Principal Strain theory (St. VENANT’S THEORY)

4. Total Strain Energy theory (HAIGH’S THEORY)

5. Maximum Distortion Energy theory (VONMISES AND HENCKY’S THEORY)

Maximum Principal Stress theory (RANKINE’S THEORY)

𝝈𝟏 > 𝝈𝟐 > 𝝈𝟑 Safe Region

Maximum Shear Stress theory (GUEST AND TRESCA’S THEORY)

Maximum Distortion Energy theory (VONMISES AND HENCKY’S THEORY)

For bi-axial stresses,

Selection of Theories of Failure

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