Stress Concentration

The term stress concentration is applied to

any situation where the stresses may not be
distributed as indicated by the elementary
theory of materials.
The actual stress will be higher than that
calculated by the usual equations.
 Stress Concentration
In developing a machine it is impossible to
avoid changes in cross-section, holes, notches,
shoulders etc.
Any such discontinuity in a member affects
the stress distribution in the neighbourhood and
the discontinuity acts as a stress raiser.
Stress Concentration
 Stress Concentration
Stress distribution away from the hole is
uniform but at AA there is a sharp rise in stress
in the vicinity of the hole. Stress concentration
factor kt is defined as kt = σ3 / σav , where σav
average stress at section AA and section BB .
This is the theoretical or geometric stress
concentration factor and the factor is not
affected by the material properties.
 Stress Concentration
It is possible to predict the stress
concentration factors for certain geometric
shapes using theory of elasticity approach.
 Stress Concentration
According to such an analysis
𝟐𝒂
σ3 = σa ( 1+ )
𝒃
If a=b the hole reduces to a circular one and
therefore σ3 = 3 σa which gives kt =3.
If, however ‘b’ is large compared to ‘a’ then
the stress at the edge of transverse crack is very
large and consequently kt is also very large.
If ‘b’ is small compared to ‘a’ then the stress
at the edge of a longitudinal crack does not rise and
kt =1.
 Stress Concentration
Stress concentration factors may also be obtained
using any one of the following experimental techniques:
1. Strain gage method
2. Photo elasticity method
3. Brittle coating technique
4. Grid method
For more accurate estimation numerical methods
like Finite element analysis may be employed.
Theoretical stress concentration factors for
different configurations are available in handbooks. Some
typical plots of theoretical stress concentration factors
and r/d ratio for a stepped shaft are shown in figure
Stress Concentration
 Methods of reducing stress concentration
A number of methods are available to reduce
stress concentration in machine parts. Some of them are
as follows:
1. Provide a fillet radius so that the cross-section may
change gradually.
2. Sometimes an elliptical fillet is also used.
3. If a notch is unavoidable it is better to provide a
number of small notches rather than a long one. This
reduces the stress concentration to a large extent.
4. If a projection is unavoidable from design
considerations it is preferable to provide a narrow
notch than a wide notch.
5. Stress relieving groove are sometimes provided.
 Stress Concentration
The localised stresses are due to
 changes in shape, such as shoulders, holes,
notches and keyways.
 variations in the properties of materials
from point to point in a member, and
 pressures at points at which loads are
applied.
 Stress Concentration
These localised stresses are frequently of
large magnitude and may give rise to crack at
the region of localised stresses.
Hence it is important that the designer
reduces the stress concentration as minimum as
possible.(use of gradual transition curves and
generous fillets)
In general, the more gradual the transition
from one shape to another, the lower the
increase in stress.
Factors affecting Endurance Limit
σen= Ka KbKcKdKe σ’en
σen is the endurance limit of the mechanical part
σ’en is the endurance limit of the specimen
Ka is the surface finish factor
Kb is the size factor
Kc is the reliability factor
Kd is temperature factor
Ke is the modifying factor to account for stress
concentration
 Surface finish factor Ka
The surface conditions of machine parts
vary with the type of machining or shaping
operations that performed upon them.
Machine parts with poor surface finish will
reduce the fatigue limit compared to parts with
smooth surface finish.
 Size factor Kb
the endurance limit of the component is
found to be decreasing with the increasing size
of the specimen when it is subjected to bending
& torsion loading, because an increase in the
size of a specimen have more internal defects.
However, for axial loading, tensile tests that no
size correction is required.
Kb = 1 for d≤ 8mm
= 1.189d-0.097 for 8mm ≤ d ≤ 250mm
 Reliability Factor Kc
The design of a machine element subjected to fatigue
load should be such that it will last for any desired life.
Since the fatigue failure is statistical in nature and also
that the fatigue curve (σ-N)is not a straight line but a
scattered band, the life of a component at a particular
reliability may constitute a more effective method of
measuring design performance.

Reliability Reliability Factor

0.5 1
0.9 0.897
0.95 0.868
0.99 0.814
0.999 0.753
 Temperature Factor Kd
When the operating temp. is below room
temp., brittle fracture is a strong possibility and
should be investigated first.
When the operating temp. are higher than
room temp., yielding should be investigated first
because the yield strength drops off so rapidly
with temperature.
Any stress will induce creep in a material
operating at higher temperatures
 Temperature Factor Kd
Fatigue tests are most commonly done at
room temperature. The fracture toughness
decreases at low temperatures and increases
moderately at high temperatures(350° C). But,
the endurance-limit knee in the S-N diagram
disappears at high temperatures, making the
fatigue strength continue to decline with
number of cycles, N.
 Temperature Factor Kd
At temp. above 50% of the material’s
absolute melting temperature, creep becomes a
significant factor and the stress-life approach is
no longer valid. The strain-life approach can
account for the combination of creep and
fatigue under high temperature conditions.
For T ≤ 450°C : Kd = 1
For 450°C < T ≤ 550°C : Kd = 1-0.0058(T-450)
For 840°C < T ≤ 1020°C : Kd = 1-0.0032(T-840)
Only for steel
 Stress Concentration factor Ke
If a part is subjected to fatigue loading has
stress-raising notches, it causes more damage
than that caused by the ordinary stress raisers.

In fatigue design, a factor called fatigue

stress concentration factor is used, instead of
the form stress concentration factor, which is
defined as the ratio of endurance limit of the
notch-free specimen to endurance limit of the
notched specimen.
 Stress Concentration factor Ke

𝑒𝑛𝑑𝑢𝑟𝑎𝑛𝑐𝑒 𝑙𝑖𝑚𝑖𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑛𝑜𝑡𝑐ℎ−𝑓𝑟𝑒𝑒 𝑠𝑝𝑒𝑐𝑖𝑚𝑒𝑛

Kf =
endurance 𝑙𝑖𝑚𝑖𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑛𝑜𝑡𝑐ℎ𝑒𝑑 𝑠𝑝𝑒𝑐𝑖𝑚𝑒𝑛
the fatigue stress concentration factor is related
to the form stress concentration factor by a term
called the notch sensitivity factor q, it is the ratio
of increase in actual stress over the nominal to
the increase in theoretical stress value over the
nominal stress.
q = (Kf σo- σo )/(Kt σo - σo) = Kf -1/ Kt -1
 Stress Concentration factor Ke
Kf = 1 + q (Kt -1)
The value of fatigue stress concentration Factor
Kf is always greater than one. Therefore for
modifying the endurance limit to account for
stress concentration it is related to Ke as
Ke = 1/ Kf
Thankyou