Design Against Fatigue Loads

Stress Concentration
Irregularity in Stress Distribution due to
Abrupt Change in Shape and Material
Discontinuity
 Stress Concentration Factor

• Theory of Elasticity (Mathematical Method)

• Photo Elasticity (Experimental Method)

• FEA Package Software

 Causes for Stress Concentration

• Variation of Properties of Materials

1) Internal Cracks and Flaws

2) Cavities in Welds

3) Non Metallic or Foreign Inclusions

 Causes for Stress Concentration
• Load Application

1) Gear teeth Contact

2) Cam and Follower Contact

3) Balls and Races contact in

Bearings

4) Rail and Wheel Contact

 Causes for Stress Concentration

• Irregular Geometry &

Material Discontinuity

1) Steps a on shafts to
mount gears, pulleys etc..

2) Shoulders for Assembly

3) Oil holes, Key ways, Screw

threads etc..
Stress Concentration Factor
Stress Concentration Factor
Stress Concentration Factor
Stress Concentration Factor
Stress Concentration due to Notch
Stress Concentration Reduction
Methods

• Fillet radius

• Drilled Holes

• Notches

• Undercuts
Stress Concentration Reduction
Stress Concentration Reduction
Stress Concentration Reduction
Stress Concentration Reduction
Stress Concentration Reduction
 To Avoid Stress Concentration ….
• Variation in the Size of component as gradual
as possible
• Avoid stress raisers like notches, holes etc..
• Provide proper de-concentrators such as
fillets, notches etc..
Mean and Variable Stress
Endurance Limit Approximate
Estimation
• Surface Finish Factor (Ksur)

• Size Factor (Ksz)

• Reliability Factor (Kr)

• Impact Factor (Ki)

• Temperature Factor (Kt)

 Endurance Limit Approximate
Estimation
• For Reversed Bending

• For Reversed Axial Load

• For reversed torsional or shear load

Gerber, Goodman and Soderberg
Methods of Combined Stresses
Gerber Method of Combined Stresses
Goodman Method of Combined Stresses
Soderberg Method of Combined Stresses