Stress Concentration Examples

Theoretical Stress concentration factor (Kt)
1) Determine the maximum stress produced in a rectangular plate 50mm wide,

8 mm thick with a central hole of 10mm diameter. It is loaded in an axial
tension of 1 KN. Assume stress concentration factor Kt =2.5
Given data
W= 50 mm
h= 8 mm
a= 10 mm
p= 1 KN
Kt =2.5
Kt= maximum stress/nominal stress--------1
Nominal stress = load/area = P/(W-a) *h
= 1000 /(50-10)*8= 1000/320= 3.125 N/mm^2

Substitute nominal stress in equation 1
Nominal stress σ o= 3.125

Maximum stress = Kt* σ o= 2.5*3.125= 7.8125 N/mm^2
1) A stepped shaft has maximum dia = 45mm, minimum dia =
30mm, fillet radius = 6mm, if the shaft is subjected to an axial
load of 10KN. Find the maximum stress induced. Assume Kt =
1.45
σ max= maximum stress in N/mm^2

Kt= σ max /σ o
σ o=10000/¿0.785 d^2 = 10000/ 0.785*900
σ o=¿14.125 Mpa
σ max=¿ 14.125*1.45
= 20.48 Mpa
Note : while calculating nominal stress for a stepped shaft

consider minor diameter (d) in area equation
1. A hollow shaft of 0.5m outside diameter and 0.3m inside
diameter is used to drive a propeller of a marine vessel. The
shaft is mounted on bearings6m apart and it transmits 5600kW
at 150 rpm. The maximum axial propeller shaft is 500kN and
the shaft weighs 70kN. Determine (i).The maximum shear stress
developed in the shaft (ii).The angular twist between the
bearings.
Problems on fatigue theories of failure
1. A machine component is subjected to fluctuating stress that varies from 40

to 100 N/mm2. The corrected endurance limit stress for the machine
component is 270 N/mm2. The ultimate tensile strength and yield strength of
the material are 600 and 450 N/mm2 respectively. Find the factor of safety
using
(i) Gerber theory
(ii) Soderberg line
(iii) Goodman line
Also, find the factor of safety against static failure.
2. An automobile leaf spring is subjected to cyclic stress such that the average
stress is 150Mpa, variable stress is 350Mpa; the material properties are;
ultimate strength = 400Mpa; yield strength = 350Mpa; endurance limit =
270Mpa; estimate the factor of safety using Goodman method and
Soderberg method?
3. A steel rod is subjected to a reversed axial load of 180 kN. Find the diameter
of the rod for a factor of safty of 2. Neglect column action. The material has
an ultimate tensile strength of 1070 Mpa and yield strength of 910 Mpa. The
endurance limit is reversed bending may be assumed to be one half of the
ultimate tensile strength. The correction factors are as follows. Load factor =
0.7; Surface finish factor = 0.8 ;Size factor = 0.85; Stress concentration
factor = 1.
4. A thin wall cylindrical pressure vessel of mean diameter of 60 cm is
subjected to internal pressure varying from 0 to 40 MPa. Find the required
thickness of the pressure vessel based on yield point of 400 MPa, endurance
limit of 22 Mpa, and a factor of safety of 3. Use Soderberg criterion of
failure.
5. A machine component is subjected to a flexural stress which fluctuates
between +300 MN/m2 and –150 MN/m2. Determine the value of minimum
ultimate strength according to: i). Modified Goodman relation; and ii).
Soderberg relation. Take yield strength = 0.55 Ultimate strength; Endurance
strength = 0.5 Ultimate strength; and factor of safety = 2.
6. Find the diameter of a shaft to transmit twisting moment varying from
800N-m to 1200N-m. The ultimate tensile strength for the material is
600MPa and yield stress is 450MPa. Assume the stress concentration
factor=1.2, surface finish factor=0.8 and size factor=0.85.
7. A circular bar of 500mm length is supported freely at its two ends. It is acted
upon by a central concentrated cyclic load having a minimum value of 20kN
and a maximum value of 50kN. Determine the diameter of bar by taking a
factor of safety of 1.5, size effect of 0.85, surface finish of 0.9. The material
properties of bar are given by ultimate strength of 650 MPa, yield strength of
500 MPa and endurance strength of 350 Mpa
8. A steel connecting rod is subjected to a completely reversed axial load of
1,600MPa. Suggest the suitable diameter of the rod using a factor of safety
2. Theultimate tensile strength of the material is 1,100 MPa and yield
strength 930 MPa. Neglect column action and the effect of stress
concentration.
9. A 50 mm diameter shaft is made from carbon steel having ultimate tensile
strength of 630MPa. It is subjected to a torque which fluctuates between
2000 N-m to – 800 Nm. Using Soderberg methods, calculate the factor of
safety. Assume suitable values for any other data needed.
10.A shaft made of steel having ultimate tensile strength of 700 MPa and yield
point 420 MPa is subjected to a torque of 2000 N- m clockwise to 600 N- m
anti-clockwise. Calculate the diameter of the shaft if the factor of safety is 2
and it is based on the yield point and the endurance strength in shear
11.Determine the size of a piston rod subjected to a total load of having cyclic
fluctuations from 150 kN in compression to 25 kN in tension. The endurance
limit is 360 MPa and yield strength is 400 MPa. Take impact factor = 1.25,
factor of safety = 1.5, surface finish factor = 0.88 and stress concentration
factor = 2.25.
12.A simply supported beam has a concentrated load at the center, which
fluctuates from a value of P to 4 P. The span of the beam is 0.5 m and its
cross-section is circular with a diameter of 0.06 m. Taking for the beam
material an ultimate stress of 700 MPa, a yield stress of 500 MPa, endurance
limit of 330 MPa for reversed bending, and a factor of safety of 1.3,
calculate the maximum value of P. Take a size factor of 0.85 and a surface
finish factor of 0.9.
13.A simply supported beam has a point load at the centre which fluctuates
from a value F to 4F. Length of beam is 500 mm and cross section is circular
with a diameter of 60 mm. Ultimate, yield stresses are 700 MPa and 500
MPa respectively. Endurance limit in reverse bending is 330 MPa. Factor of
safety desired is 1.3.Assume size factor 0.83, Surface finish factor 0.9,
reliability factor 1.0.Find the maximum value of F.

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Theoretical Stress concentration factor (Kt)

1) Determine the maximum stress produced in a rectangular plate 50mm wide,

Kt= maximum stress/nominal stress--------1

Nominal stress = load/area = P/(W-a) *h

= 1000 /(50-10)*8= 1000/320= 3.125 N/mm^2

Nominal stress σ o= 3.125

σ max= maximum stress in N/mm^2

Note : while calculating nominal stress for a stepped shaft

Problems on fatigue theories of failure

1. A machine component is subjected to fluctuating stress that varies from 40

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