STRESS CONCENTRATION

Introduction
Stress distribution in loaded members are assumed uniform
throughout the cross section due to uniformity in cross section.
Real machines will have varying cross section like stepped shafts to
accommodate bearings, pulleys and gears.
A shaft may have grooves to accommodate O-rings or keys
Any change in cross sectional geometry will cause localised stress
concentrations.
Definition of stress concentration
Stress concentration is defined as the localisation of high stress due to
flaws, defects or abrupt change of cross section in a component.
STRESS CONCENTRATION FACTOR
STRESS RAISERS
o The geometric changes ,notches, holes or flaws in a
component are called stress raisers.
o It should be minimized or avoided as far as possible.

Measurement of stress concentration

o Using Theory of elasticity

o Experimental Measurement using strain gauges

o Photo elastic techniques

o Finite Element methods

o Stress concentration factors are plotted for various

configurations against non dimensional number, why?
o It depends on shape rather than size
STRESS CONCENTRATION AROUND AN ELLIPTICAL
HOLE
STRESS CONCENTRATION CONTD.
STRESS CONCENTRATION CONTD.

No material can withstand infinite stress

A material that contains a sharp crack should theoretically fail
upon the application of an infinitesimally small load.
Materials deform plastically and causes an initial crack to blunt
giving a finite radius of curvature.
In the absence of plastic deformation ,the minimum radius a
crack tip can have is of the order of atomic radius.
STRESS CONCENTRATION UNDER
STATIC LOADING
DUCTILE MATERIALS
Ductile materials yield locally at the stress raiser while the lower stressed
material away from the geometric discontinuity remains below the yield
point.
When the material yields locally, its stress-strain curve at that location
becomes non linear and prevents further increase in stress at that point.
As the load is increased ,more material is yielded bringing more of the cross
section to that stress.
Only when the entire cross section has been brought to the yield point, the
part moves to final fracture.
Hence it is common to ignore the effect of geometric stress concentration in
ductile materials under static loading.
At low temperatures, ductile materials behave like brittle material and hence
stress concentration factor to be considered.
STRESS CONCENTRATION UNDER
STATIC LOADING
BRITTLE MATERIALS
Brittle materials will not yield locally ,since they do not
have a plastic range.
Once the stress at the stress raiser exceeds the fracture
strength, the crack begins to form.
This reduces the material available to resist the load and
also increases the stress concentration in the narrow
crack and the component fails quickly.
Hence stress concentration factor to be considered for
brittle materials under static loading.
STRESS CONCENTRATION UNDER
DYNAMIC LOADING
VARIABLE STRESSES
VARIABLE STRESSES ( STRESS VS TIME )
a) Completely Reversed stress

b) Repeated stress
c) Fluctuating stress
FATIGUE
FATIGUE STRENGTH
FACTORS TO BE CONSIDERED TO AVOID FATIGUE
FAILURE
Variation in size should be as gradual as possible
Notches, holes and other stress raisers should be reduced
or avoided as possible
Fillets and notches should be provided wherever
necessary
Protecting parts from corrosion
Provide smooth surface finish
High fatigue strength materials should be used
Impart residual compressive strength on the surface of
the part to improve the fatigue strength.
FATIGUE STRENGTH MODIFICATION FACTORS
RELIABILITY FACTOR
% Reliability

50 % 1

90 % 0.897

95 % 0.868

99 % 0.814

99.9 % 0.753
FATIGUE FAILURE MODELS
1. Stress Life Model ( SN-Curve or Wohler’s curve based on rotating beam
experiment )
o This is the oldest theory( Classical theory)
o Stress based model
o Fatigue strength and Endurance limit are the basis for the design
o For low cycle fatigue ,it is less accurate.
2. Strain Life Model
o It gives a reasonably accurate picture of the crack initiation stage
o Combination of fatigue and temperature can be considered in this
o Mostly applied to LCF and finite life problems.
3. Linear Elastic Fracture Mechanics (LEFM)
o It defines crack propagation stage
o Most useful in predicting remaining life of cracked parts in service.
NOTCH SENSITIVITY FACTOR
The sensitivity of a material to stress concentration is
called notch sensitivity.
Materials have different sensitivity to stress
concentration
More ductile the material less sensitive
Brittle materials are more notch sensitive
As notch radius approaches zero, the notch sensitivity
also approaches zero.
FATIGUE STRESS CONCENTRATION FACTOR
NOTCH SENSITIVITY FACTOR
NEUBER FORMULA (APPROX) FOR NOTCH
FACTOR
THANK YOU

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