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Related Concept Videos

Fatigue01:21

Fatigue

218
Fatigue occurs when materials rupture under repeated or fluctuating loads, even at stress levels far below their static breaking strength. It typically results in brittle failure, even for ductile materials. It is a critical consideration in designing machines and structural components subjected to repetitive or varying loads. The nature of these loadings can range from fluctuating loads like unbalanced pump impellers causing vibrations to repeatedly bending a thin steel rod wire back and forth...
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Yield Criteria for Ductile Materials under Plane Stress01:25

Yield Criteria for Ductile Materials under Plane Stress

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In designing structural elements and machine parts using ductile materials, it is crucial to ensure that these components withstand applied stresses without yielding. Yielding is initially determined through a tensile test, which evaluates the material's response to uniaxial stress. However, tensile stress is insufficient when components face biaxial or plane stress conditions This condition requires advanced criteria to predict failure.
The Maximum Shearing Stress Criterion, also known as...
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Stress-Strain Diagram - Ductile Materials01:24

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The stress-strain relationship in ductile materials such as structural steel or aluminium is intricate and progresses through several stages. When a specimen is loaded, it initially exhibits a linear length increase, depicted by a steep straight line on the stress-strain diagram. It indicates the material is elastically deforming and will return to its original shape once unloaded. However, when a critical stress value is reached, plastic deformation begins. This stage sees substantial...
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Tensile Strength Considerations of Concrete01:16

Tensile Strength Considerations of Concrete

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Considering the tensile strength of concrete involves recognizing that the theoretical strength of cement paste can be up to a thousand times higher than what is observed in practical applications. This significant discrepancy is largely attributed to the presence of microscopic cracks within the concrete. These cracks tend to amplify stress at their tips when a load is applied, a phenomenon explained by Griffith's theory of brittle fracture.
The dimensions and shape of a concrete specimen...
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Stress-Strain Diagram - Brittle Materials01:24

Stress-Strain Diagram - Brittle Materials

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Brittle materials, including glass, cast iron, and stone, exhibit unique characteristics. They fracture without considerable change in their elongation rate, indicating that their breaking and ultimate strength are equivalent. Such materials also show lower strain levels at the point of rupture. The failure in brittle materials predominantly results from normal stresses, as evidenced by the rupture created along a surface perpendicular to the applied load. These materials do not display...
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Plastic Deformation in Circular Shafts01:20

Plastic Deformation in Circular Shafts

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When materials are subjected to forces that surpass their yield strength, they undergo a process known as plastic deformation. This results in a permanent alteration or strain in their structure. This concept can be specifically applied to circular shafts, where the deformation leads to a change in its shape. The precise evaluation of this plastic deformation requires understanding the stress distribution within the circular shaft, which is achieved by calculating the maximum shearing stress in...
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Related Experiment Video

Updated: Aug 5, 2025

Cutting Procedures, Tensile Testing, and Ageing of Flexible Unidirectional Composite Laminates
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Predicting Failure of Additively Manufactured Specimens with Holes.

Gina Eileen Chiara Schmeier1,2, Clara Tröger1,2, Young W Kwon1

  • 1Department of Mechanical & Aerospace Engineering, Naval Postgraduate School, Monterey, CA 93943, USA.

Materials (Basel, Switzerland)
|March 29, 2023
PubMed
Summary

A new failure theory accurately predicts fracture loads for 3D-printed parts with holes. This stress and stress gradient-based model shows excellent agreement with experimental data for polylactic acid and polycarbonate specimens.

Keywords:
additive manufacturingcombined loadingfailure criterionfailure loadperforated specimen

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Additive Manufacturing

Background:

  • Additive Manufacturing (AM) enables complex geometries but requires accurate failure prediction.
  • Understanding material behavior under stress, especially with geometric defects like holes, is crucial for AM applications.

Purpose of the Study:

  • To develop and validate a novel failure theory for predicting fracture loads in AM specimens.
  • To assess the theory's performance on different materials (PLA, PC) and loading conditions (uniaxial, combined).

Main Methods:

  • Experimental testing of flat (PLA) and tubular (PC) AM specimens under various loads.
  • Application of a new failure theory incorporating stress and stress gradient conditions.
  • Development of a semi-empirical equation for critical failure surface energy.

Main Results:

  • The new failure theory accurately predicted failure loads, showing close agreement with experimental results.
  • The theory's effectiveness was demonstrated across different specimen types, materials, and loading scenarios.
  • A semi-empirical equation was established to predict critical failure surface energy, enhancing predictive accuracy.

Conclusions:

  • The developed failure theory provides a reliable method for predicting the fracture behavior of 3D-printed components.
  • The integration of stress and stress gradient conditions is key to accurate failure load prediction in AM parts.
  • The study offers valuable insights for designing and manufacturing reliable AM structures.