• Numerical and comparative study of the stress

concentration factor in geometries of machine

elements using Ansys
Prepared By: Shubham Jayswal (202030000112)
Bhumit Chauhan (202030000102)
Amit Muchhadiya (202030000101)
Content
• Introduction and literature survey
• Methodology
• Result and discussion
• Theoretical calculation
• Comparison
• Conclusion
Abstract
• In the project work we are going to study the stress
concentration factor by the finite element method in a round
bar grooved axially under tension, a stepped flat plate
subjected to bending and a stepped round bar subjected to
torsion. The stress concentration factor will be obtain using
the simulation laboratory through the commercial software
ANSYS and then we compared with the experimental curves
in design databook, we checked similarities in the work and
discuss the whole analysis.
Introduction
• Stress concentration factor:
Stress concentrations factor are discontinuities in the geometry of a machine
element when is subjected to a load, it can reach much higher values than the
average stress values. The SCF play an important role in the area of design,
manufacturing and industrial production; and are taken into account in the sizing of
the pieces because those are generally the cause of their failure.
•

• Reference stress is the total stress within an element under the same loading
conditions, but without any stress concentrators (i.e., the total stress on the part
when it is free from discontinuities).
• SCF are established relationships between the maximum value of the stress
that is developed in a piece and the average stress that it experiments from
the concentrator, usually expressed in graphic form. The graphics can be
obtain from the photo elastic experimental method was used or by the
fragile layer or cover method.

• These experimental techniques have been gradually replaced by more

flexible and efficient computational techniques. Today's computing
capabilities are powerful and effective, usually based on the finite element
method (FEM). The FEM is a path that in recent years has been presented
as a useful engineering tool, providing relationships between the geometric
parameters involved with such precision that their results can be compared
with those determined experimentally.
Literature Survey:
• Through the FEM, Ghuku, et al. studied the behavior of a crossbow suspension
and analyzed the concentration of stress occurring near the suspension holes.
Muminovic, et al. developed a computational algorithm to simulate the stress and
validated their data against commercial software. Based on the study by
Muminovic, Betancurt, et al. carried out a numerical study on machine elements
and elaborated their SCF curves through ANSYS WorkbenchR.
• Dimitri, et al. used two numerical approaches to predict the SCF in specimens
with notches and holes with a reduced computational cost, finding data coincident
with both methods, and demonstrating that the FEM is an ideal tool to solve the
problem of geometries with discontinuities.
• Based on the study, we carried out a numerical study on machine elements and
elaborated their SCF through ANSYS. We compared their results with the help of
theoretical calculation and design databook.
Methodology:
• With the help of ANSYS, simulation in a round bar grooved (axially under
tension), a stepped flat plate (subjected to bending) and a stepped round bar
(subjected to torsion) can be done.
• The applied loads were at tension of 2500 N; for bending moment of 2500 Nm
and for torsion of 2500 Nm.
• Geometry:
In ANSYS, geometries were modeled so that it allowed us to parameterize the
regions with discontinuity that were modified during the study of each Stress
Concentration factor.
We made 2D model NX 9.0 software and further analysis was done in Ansys
Workbench using fluent solver.
• Meshing:
In ANSYS, the meshing was developed in Ansys Workbench, refining
the places where the discontinuities were presented. The sizing tool was
used to densify the areas where stress is concentrated.

• Solver and configuration:

In the ANSYS, domains are configured, borders are established and
loads are applied. Accepting Newton's action-reaction principle, one
face of the geometry was fixed and the load to be analyzed was applied
on the other side. After finding the numerical SCF, we compared to the
experimental SCF reported in design databook.
 Result & Discussion
• The concentration of stresses due to the discontinuities of the
geometry and due to the load.
• It is difficult to conceive a complete machine with elements that
do not show changes in its sections and that when experiencing a
load they need to calculate the effort from a simplified average
effort.
• Figure 1 shows the distribution of the efforts studied with the
different programs : the maximum indicated in red is
concentrated in the area where the geometry changes,
• The variation of the zone of maximum effort depends on the type
of the load applied on it.
Isometric Design
Stepped flat plate Grooved Bar

Note: All dimension are consider in mm.

 Step round Bar

Note: All dimension are consider in mm.

Comparison of meshing Geometry

Meshing obtain in paper (Inventor software)

Meshing obtain by us (Ansys)

 Analysis Result and discussion

In Research Actual In
Paper Study
●
Software: Ansys
●
Software: Inventor
Workbench
●
Design Parameter ●
Design Parameter
(Size of geometry,
Vary ( Size of
Load
geometry, Load)

Note: We change design parameter according to that simulation result vary

Load Parameters
Round bar groove subjected to
●
Under tension Load

Stepped flat plate subjected to

●
Bending Load

Stepped round bar subjected to

●
Torsion Load
 Round bar groove simulation result Round bar groove simulation result
In paper In actual

- Tension load apply on both the section.

- The maximum effort indicated in red is concentrated in
the area where the geometry changes.
- Due to changes of geometry the stress concentration is very high in grooved section.

Note: One side of round bar is fixed in both the analysis and tension load applied on opposite side to it.
Stepped flat plate simulation result Stepped flat plate simulation result
In paper In Actual

- Bending Moment apply on both the section.

- The maximum effort indicated in red is concentrated in
the area where the geometry changes.
- Due to changes of geometry the stress concentration is very high in curvature
section.

Note: One side of flat plate is fixed in both the analysis and bending moment load applied on opposite side to it.
 Stepped Round Bar simulation result Stepped Round Bar simulation result
In paper In Actual

- C.W Torsion Load apply on both the section.

- The maximum effort indicated in red is concentrated in
the area where the geometry changes.
- Due to changes of geometry the stress concentration is very high in at intermediate
section.

Note: One side of step round bar is fixed in both the analysis and c.w torsion load applied on opposite side to it.
Calculation (Round grooved bar in Tension)
• The maximum stress is calculated as σmax = Kt σnom, where Kt is the stress
concentration factor as determined from the plot below, and σnom is
calculated as:
σnom= F/A , Where A= πd2/4
• Kt by Charts of Theoretical Stress-Concentration Factors , where D/d=1.5
And r/d=0.25.
• Kt = 1.67
• σmax = Kt σnom
• σmax = 4.87x 106 N/m2
Calculation (Stepped Flat plate in bending)
• The maximum stress is calculated as σmax = Kt σnom, where Kt is the stress
concentration factor as determined from the plot below, and σnom is
calculated as:
σnom= 6M/td2
• Kt by Charts of Theoretical Stress-Concentration Factors , where D/d=1.3
And r/d=0.15
• Kt = 1.58
• σmax = Kt σnom
• σmax = 7.22x 109 N/m2
Calculation (Stepped Round bar in Torsion)
•  The maximum stress is calculated as  τ max  = Kt  τ nom, where Kt is the stress
concentration factor as determined from the plot below, and σnom is calculated
as:
τ nom= 16T/
• Kt by Charts of Theoretical Stress-Concentration Factors , where D/d=1.2
And r/d=0.11
• Kt = 1.38
• τ max = Kt σnom
• τ max = 4.21 x 108 N/m2
 Theoretical σmax By Theoretical Kt By
σmax Simulation Kt Simulation
(N/m2)
(N/m2)

Round grooved 4.87 x 106 4.82 x 106 1.67 1.65

bar in Tension

Stepped Flat 7.22 x 109 7.48 x 109 1.58 1.64

Plate in bending

Stepped Round 4.21 x 108 4.1 x 108 1.38 1.41

bar in Torsion
Conclusions
• The stress concentration factor for machine elements modeled through
the analysis of finite elements gave numerical data approximate to
those extracted experimentally in design databook, so it is inferred that
the FEM is an effective tool for the study of this topic of mechanical
engineering.
• In the same way, in the study of the SCF, it was evidenced that when
comparing the results of both solvers, similar numerical data was
obtained, this will have a positive effect on the industry since a
suitable mechanical design criterion can be taken in time, already
under computational and budgetary cost.
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