Machine Element Design & Process - I

MEEG 315

Module IV : Working Stresses

Lecture 3 : Stress Concentration

 DISCLAIMER
The presentation contains extraction of contents from books, technical
paper, studies and other public domain.

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 Working Stresses
You should be familiar with
• Load, Stress & Strain
• Tension, Compression & Shear
• Tensile, Compressive & Shear Stress
• Torsion, Bending Moment
• Elasticity & Plasticity
• Stress – Strain Curve
– Tensile Testing in UTM
• Failure Modes and Theories
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 Working Stresses
You should be familiar with

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New Terms
• Stress Distribution
– Photoelasticity
– Radiometric Thermoelasticity
• Discontinuity
• Stress Concentration
• Notch Sensitivity
• Factor of Safety

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Stress Distribution
• Lines of Forces

Stress Test on Paper

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Discontinuity
• The state of having intervals or
gaps; lack of continuity.

• Any such discontinuity in a

member affects the stress
distribution in the neighborhood
and the discontinuity acts as a
stress raiser.
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Stress Distribution around Discontinuity

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Geometric Stress Concentration Factor
• Geometric stress concentration factors can be used
– to estimate the stress amplification in the vicinity of a geometric
discontinuity

Flawless material /
d no discontinuity :1

Great discontinuity : >1

t
w

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 Working Stresses
Determination of Stress Concentration Value
• Experimental Methods
– Optical Methods, grid method, brittle coating, brittle-
model, strain gauge
• Analytical Methods
– Theory of elasticity
• Computational Methods
– Finite-element techniques (powerful and inexpensive)

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Experimental Method: Photoelasticity
• A visual method for viewing the full field stress
distribution in a photoelastic material.
• When a photoelastic material is strained and
viewed with a polariscope, distinctive colored
fringe patterns are seen.
(http://www.measurementsgroup.com/)

• is an experimental method to determine the

stress distribution in a material.
• mostly used in cases where mathematical
methods become quite cumbersome.
(https://en.wikipedia.org/wiki/Photoelasticity)

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 Working Stresses
Experimental Method: Radiometric Thermoelasticity
• When materials are stressed the change in atomic spacing creates temperature
differences in the material.
• Cameras which sense differences in temperature can be used to display the stress
field in special materials.

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 Working Stresses
Analytical Method: Curves (using Theory of Elasticity)
(in Tension)

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Analytical Method: Curves (using Theory of Elasticity)
(in Bending)

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Analytical Method: Curves (using Theory of Elasticity)
(in Torsion)

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Computational Methods

Simulation based on Finite element method

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Fatigue Stress Concentration Factor
- Some materials are not as sensitive to notches as implied by the
theoretical stress concentration factor.
- For these materials reduced value of Kt is used : Kf
Max stress = Kf x Nominal stress
- Notch sensitivity, q = (Kf-1)/(Kt-1) [0 ≤ q ≤ 1]
- If q = 0, Kf = 1; i.e. material is not sensitive to notches
- If q = 1, Kf = 1; i.e. material is completely sensitive to notches
Normal Procedure
- First find Kt form geometry
- Specify material
- Lookup for notch sensitivity for the notch
radius from chart Cast Iron: less sensitive to notches
Their microstructure contains many notches, so insensitive to additional
- Then calculate Kf machined ones
q = 0.2
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Notch Sensitivity
• Is a measure of how sensitive a material is to notches or geometric discontinuities

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Notch Sensitivity

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Practice
• Find the most critically stressed • Factor of Safety
location on the stepped shaft. Note
that you will need to use the stress
concentration factors contained in the
lecture notes.

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