Failure Analysis in Design VI Semester 2023
Chapter 1
INTRODUCTION
1.1 Study of Failure Criteria and its importance
Any change in the size, shape, or material properties of a machine or machine part that renders
it incapable of performing its intended function must be regarded as a mechanical failure. It should
be carefully noted that the key concept here is that improper functioning of a machine or machine
part constitutes failure. Thus, a shear pin that does not separate into two or more pieces upon the
application of a preselected overload must be regarded as having failed as surely as a drive shaft has
failed if it does separate into two pieces under normal expected operating loads.
Failure of a machine or machine part to function properly might be brought about by any one or
a combination of many different responses to loads and environments while in service. For
example, too much or too little elastic deformation might produce failure. A load-carrying member
that fractures or a shear pin that does not shear under overload conditions each would constitute
failure. Progression of a crack due to fluctuating loads or an aggressive environment might lead to
failure after a period of time if resulting excessive deflection or fracture of the part interferes with
proper function. A list of potential mechanical Failure modes that have been observed in various
machine parts and machines is presented in the next section, followed by a brief description of each
one.
1.2 Role of failure prevention analysis in mechanical design
A primary responsibility of any mechanical designer is to ensure that the proposed design will
function as intended, safely and reliably, for the prescribed design lifetime and, at the same time,
compete successfully in the marketplace. Success in designing competitive products while averting
premature mechanical failures can be consistently achieved only by recognizing and evaluating all
potential modes of failure that might govern the design of a machine and each individual part within
the machine.
If a designer is to be prepared to recognize potential failure modes, he or she must at least be
acquainted with the array of failure modes actually observed in the field and with the conditions
leading to those failures. For a designer to be effective in averting failure, he or she must have a
good working knowledge of analytical and/or empirical techniques for predicting potential failures
at the design stage, before the machine is built. These predictions must then be transformed into
selection of a material, determination of a shape, and establishment of the dimensions for each part
to ensure safe, reliable operation throughout the design lifetime. It is clear that failure analysis,
prediction, and prevention perspectives form the basis for successful design of any machine element
or machine.
1.3 Modes of Mechanical failure
Failure modes are the physical processes that take place or combine their effects to produce
failure, as just discussed. The following list includes the failure modes most commonly observed in
machines and machine parts.
Nagaraj Ekabote School of Mechanical Engineering KLETU, Hubballi.
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Failure Analysis in Design VI Semester 2023
As these terms are used in this text, and as commonly used in engineering practice, the
failure modes just listed may be defined and described briefly as follows. It should be emphasized
that these potential failure modes only produce failure when they generate a set of circumstances
that interferes with the proper functioning of a machine or device.
Nagaraj Ekabote School of Mechanical Engineering KLETU, Hubballi.
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Failure Analysis in Design VI Semester 2023
Nagaraj Ekabote School of Mechanical Engineering KLETU, Hubballi.
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Failure Analysis in Design VI Semester 2023
Nagaraj Ekabote School of Mechanical Engineering KLETU, Hubballi.
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Failure Analysis in Design VI Semester 2023
Nagaraj Ekabote School of Mechanical Engineering KLETU, Hubballi.
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Failure Analysis in Design VI Semester 2023
Nagaraj Ekabote School of Mechanical Engineering KLETU, Hubballi.
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Failure Analysis in Design VI Semester 2023
Nagaraj Ekabote School of Mechanical Engineering KLETU, Hubballi.
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Failure Analysis in Design VI Semester 2023
Nagaraj Ekabote School of Mechanical Engineering KLETU, Hubballi.
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