‫‪Stress concentration‬‬

‫‪Team members‬‬
‫‪Name‬‬ ‫‪ID‬‬
‫ابراهيم خالد ابراهيم علي‬ ‫‪17010009‬‬
‫عائشة رمضان احمد سويفي‬ ‫‪18010886‬‬
‫ندى عادل بدرى زكى‬ ‫‪18011973‬‬
‫دعاء حسن سالم‬ ‫‪18010619‬‬
‫سمية عبدالعال خضيري‬ ‫‪17010896‬‬
‫رضوه السيد فاروق‬ ‫السيد‬ ‫‪18013006‬‬
‫أسامه أيمن كمال طليس‬ ‫‪18010297‬‬
‫علي احمد علي محمد‬ ‫‪18011067‬‬
‫علي الحسيني علي السيد‬ ‫‪18011069‬‬
‫حسام جمال محمود خليل‬ ‫‪18010553‬‬
‫حسام احمد عبدالشافي بريقع‬ ‫‪18010550‬‬
‫أدهم السماحي مصطفي عبدالنبي‬ ‫‪18010283‬‬
‫حسام محمد احمد محمد‬ ‫‪17010643‬‬
‫محمد مصطفي عبد السالم محمد‬ ‫‪18011617‬‬
‫علي احمد علي رياض علي‬ ‫‪18011066‬‬

‫‪ Contents‬‬
‫‪1‬‬
 Introduction

 Definition

 Causes

 Effects

 factor + chart

 problems

 prevention

 Conclusion

 Reference
 Introduction

2
 A stress concentration
(also called a stress raiser or a stress riser) is a location in
an object where the stress is significantly greater than the
surrounding region.
Stress concentrations occur when there are irregularities
in the geometry or material of a structural component that
cause an interruption to the flow of stress.
This arises from such details as holes, grooves, notches
and fillets.
Stress concentrations may also occur from accidental
damage such as nicks and scratches.

The sharp corner at the brick has acted as a stress concentrator within the concrete causing it to cr

 Definition

3
Stress concentration is the accumulation of stress in a
body due to sudden change in its geometry.

When there is a sudden change in the geometry of the

body due to cracks, sharp corners, holes and decrease
in the cross-section area, then there is an increase in
the localized stress near these cracks, sharp corners,
holes, and decreased cross section area.

The body tends to fail from these places where the

stress concentration is more. So, to prevent a body
from getting failed, the concentration of stress should
be avoided or reduced.

It is also called as stress raisers or stress risers.

 Causes of stress concentration.

4
1. Variation in Properties of Materials:
 In the design of machine components, it is assumed
that the material is homogeneous throughout the
component.
 In practice, there is a variation in material properties
from one end to another due to the following factors:
(a) Internal cracks and flaws like blow holes;
(b) Cavities in welds;
(c) Air holes in steel components; and
(d) Nonmetallic or foreign inclusions.
 These variations act as discontinuities in the
component and cause stress concentration.

2. Load Application:
 Machine components are subjected to forces.
 These forces act either at a point or over a small
area of the component.
 Since the area is small, the pressure at these points
is excessive. This results in stress concentration.

5
The examples of these load applications are as follows:
(a) Contact between the meshing teeth of the driving and
the driven gear
(b) Contact between the cam and the follower
(c) Contact between the balls and the races of ball bearing
(d) Contact between the rail and the wheel
(e) Contact between the crane hook and the chain

 In all these cases, the concentrated load is applied

over a very small area which results in stress
concentration.

3. Abrupt Changes in Section:

 To mount gears, sprockets, pulleys, and ball
bearings on a transmission shaft, steps are cut on
the shaft and shoulders are provided from assembly
considerations.
 Although these features are essential, they create
change of the cross-section of the shaft.
 This results in stress concentration at these cross-
sections.

6
4. Discontinuities in the Component:

 Certain features of machine components such as oil

holes or oil grooves, keyways and splines, and
screw threads result in discontinuities in the cross-
section of the component.
 There is stress concentration in
thesediscontinuities.

5. Machining Scratches:
  Machining scratches, stamp marks or inspection
marks are surface irregularities, which cause stress
concentration.

 Effects of stress concentration

7
 In case of static loading, stress concentration in
ductile materials is not so serious as in brittle
materials, because in ductile materials local
deformation or yielding takes place which reduces
the concentration. In brittle materials, cracks may
appear at these local concentrations of stress which
will increase the stress over the rest of the section.
It is, therefore, necessary that in designing parts of
brittle materials such as castings, care should be
taken. To avoid failure due to stress concentration,
fillets at the changes of section must be provided.

 In case of cyclic loading, stress concentration in

ductile materials is always serious because the
ductility of the material is not effective in relieving
the concentration of stress caused by cracks, flaws,
surface roughness, or any sharp discontinuity in the
geometrical form of the member. If the stress at any
point in a member is above the endurance limit of
the material, a crack may develop under the action
of repeated load and the crack will lead to failure of
the member.

 Stress concentration factor (K (

8
A stress concentration factor (K) is a dimensionless factor that
is used to quantify how concentrated the stress is in a
mechanical part, it is defined as the ratio of the highest stress in
σmax
the part compared to an average stress ( K= σavg ).

Characteristics of stress concentration factor:

 Obtained experimentally, analytically, etc.
 Published in charts
 Geometric property
 Very important in brittle materials
 In ductile materials :
Important in fatigue calculation.
Important if safety is critical.
Localized yielding hardens material (strain hardening).
Redistributes stress concentration.

 Charts of stress concentration factor

9
10
 problems

11
Problem 1
Determine the maximum force P that can be applied so as
not to exceed an allowable tensile stress of 150 MPa.

w 60 r 15
= =2 = =0.5
h 30 h 30

K=1.4

σ max=σ allow =K σ avg

12
 P
150=1.4[ 30× 20 ¿
P=64.3× 103 N =64.3 kN

d 24
= =0.4
b 60 K=2.2
σ max=σ allow =K σ avg

P
150=2.2[ ]
( 60−24 ) 20

P=49.1× 103 N =49.1 kN Pmax =49.1 kN

Problem 2

The stepped shaft shown in the figure is supported by

bearings A and B. Determine the maximum stress in the

13
shaft due to the applied torque. The fillet at the junction of
each shaft has a radius of r=6mm.

D 40 r 6
= =2 = =0.15
d 20 d 2 ×20

K=1.3
16 ×30
τ max=K τ avg=1.3
[ ]
π ( 2 ×0.02 ) 3
=3.1 ×106 Pa=3.1 MPa

Problem 3
The bar is subjected to a uniform bending moment of 20
N.m . Determine The maximum stress resulting from
stress concentration.

14
w 25 r 5
= =1.67 = =0.33
h 15 h 15

K=1.32
Mc 6M
σ max=K σ avg=K [ ]
I
=K [ 2 ]
th

6 × 20
σ max=1.32
[ ]
0.004 × ( 0.015 )
2
=176× 106 Pa=176 MPa

15
  Methods of Stress Concentration
Reduction

By providing undercut or notches at the sharp corners.

The main idea to reducing stress concentrations is to ensure the

smooth transition of internal stress flow from one area to another
of the object. The first step to reducing stress concentrations in
parts of the machine is intentionally designing the part's shape
such that it does not contain sudden changes in its geometry.
However, this solution is rarely possible in the real world
because functional requirements often necessitate complex
shapes. In instances where high stress is unavoidable, it is
preferable to place them in regions where nominal stress is
considered to be minimal.

16
Sharp edges should be avoided by giving undercutting or notch
because the stress flow lines are more even in the slant notched
and grooved design. but in the case of sharp corners, the stress
flow lines are more irregular causes the more stress
concentration in the member.
Providing additional notches and holes in tension
member
 Use of several notches
In the case where holes or notches are unavoidable, multiple
small notches can be provided to facilitate smoother stress
flow. where a single groove causes the irregularity, this
technique involves surrounding a "design notch" with several
smaller ones. Additional material is removed to create mini
notches while the original notch retaining.

 Removal of unwanted material

This is called as the principle of minimization of the material.

17
  Drilling additional holes
Drilling additional holes reduce the stress concentration

By providing small holes near a big hole

If there are an internal hole in an object. Then there more
stress near that hole. To avoid this, create some smaller holes
near that hole. This make the stress more uniformly than it was
before.

By decreasing the nominal diameter of a threaded

object and make it equal to the core diameter.

Imagine we have something coherent and we increase the

pressure in the coiled portion. Chances of this part may fail. But
we can avoid this matter by a very simple trick, which is to
reduce the larger diameter of the shaft and make them equal to
the inner diameter (the core), and this in turn will distribute the

18
pressure, which will reduce the incidence of any overload and
make it more consistent along the body.

By Modifying welded joints

It is known that anything that has been repaired will not return to
what it was in the past, so there is a type of stress concentration
that occurs when welding parts with each other, and this type
occurs specifically in areas where there is no welding filler. So it
can act as a crack and a crack that induce pressure to be
concentrated through the hole in the corners. Can improve stress
flow. For example, fillet welded joints are usually subjected to
stress concentrations. The compression performance of the joint
can be improved by drilling the corners.

19
  Conclusion
We defined stress concentration as is the accumulation of
stress in a body and defined stress raisers then we talked about
causes of stress concentration as various reasons of different
material properties as internal cracks and air holes and we
talked about load applications as the contact between can and
follower and between rail and wheel .
Changes in cross section and discontinuities in the components
and machining scratches are reasons of stress concentration
also.
Then we headed to talk about effects of stress concentration in
static loading and in cyclic loadings.
After that, we defined stress concentration factor as it is used
to quantify how concentrated the stress is in a mechanical part
and we explained its properties briefly, and we showed charts
for some stress concentration factor applications as on plates
and bars .
After that we showed some problems that we can face and we
solved it in detail. Finally we introduced the importance of
prevention of stress concentration as to ensure the smooth
transition of internal stress flow from one area to another of
the object and introduced methods of prevention as providing
notches and sharp corners and more notches and corners in
20
tensile members and also we can drive more holes near big
holes an by modifying welded joints.

 References

Shigley, Joseph Edward (1977). Mechanical Engineering

Design (Third ed.). McGraw-Hill
Peterson, Rudolf Earl (1953). Stress Concentration
Design Factors. John Wiley & Sons
Pelkey, Walter D. (1999). Peterson's Stress Concentration
Factors (2nd ed.). Wiley
Mechanics of materials by Russel hibbeler, 4.7 stress
concentration, p158

Thanks
21
Dr./ Mohamed Abdel Qader

22