FME 451

Materials Science & Engineering IV

Fourth Year
Semester I

Stress Concentration

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Stress Concentration
How fatigue cracks are initiated in a component

➢ The existence of irregularities or discontinuities, such as holes and grooves,

in a part increases the theoretical stresses at these areas

➢ In fatigue analysis, the fatigue stress-concentration factor, 𝐾𝑓 , multiplies the

amplitude stresses (the material is subjected to) at these regions.

➢ This leads to high cyclic elastic and plastic strains

➢ Fatigue stress-concentration factor is also known as fatigue notch factor

➢ A notch refers to a geometric discontinuity or feature in a material that can

significantly affect its stress distribution and fatigue life

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Stress Concentration
Stress concentration factor

➢ Fatigue stress-concentration factor is given by

➢ When considering the nominal stress (static loading conditions), 𝜎0 , stress

concentration factor is denoted as, 𝐾𝑡 (𝐾𝑡𝑠 )

➢ 𝐾𝑡 multiplies the nominal stress to obtain the maximum resulting stress very
local to the irregularity or defect

➢ Nominal stress is the initial load applied to a material per unit area without
accounting for any geometric or material property changes that might occur due
to the applied load.
➢ To compute 𝐾𝑓 , 𝐾𝑡 must be taken into account

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Stress Concentration
Nominal stress and Theoretical 𝐾𝑡 (𝐾𝑡𝑠 ) detemination
Bar in tension or simple compression with a transverse hole.

𝜎0 = 𝐹 ∕ 𝐴, where 𝐴 = (𝑤 − 𝑑)𝑡 and t is the thickness

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Stress Concentration
Nominal stress and Theoretical 𝐾𝑡 (𝐾𝑡𝑠 ) detemination
Rectangular bar with a transverse hole in bending

𝑤 − 𝑑 ℎ3
𝐼 = , 𝑎𝑛𝑑 𝜎0 = 𝑀𝑐 ∕ 𝐼, 𝑤ℎ𝑒𝑟𝑒
12 5
Stress Concentration
Nominal stress and Theoretical 𝐾𝑡 (𝐾𝑡𝑠 ) detemination
Notched rectangular bar in tension or simple compression.

𝜎0 = 𝐹 ∕ 𝐴,
where 𝐴 = 𝑑𝑡 and t is the thickness. 6
Stress Concentration
Nominal stress and Theoretical 𝐾𝑡 (𝐾𝑡𝑠 ) detemination
Notched rectangular bar in bending

𝑐 = 𝑑Τ2 , 𝐼 = 𝑡𝑑 3 Τ12 , 𝑎𝑛𝑑 𝑡 𝑖𝑠 𝑡ℎ𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠. 𝜎0 = 𝑀𝑐 ∕ 𝐼, 𝑤ℎ𝑒𝑟𝑒

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Stress Concentration
Nominal stress and Theoretical 𝐾𝑡 (𝐾𝑡𝑠 ) detemination
Rectangular filleted bar in bending

𝜎0 = 𝑀𝑐 Τ𝐼 ,
𝑤ℎ𝑒𝑟𝑒 𝑐 = 𝑑Τ2 , 𝐼 = 𝑡𝑑 3 Τ12 , 𝑡 𝑖𝑠 𝑡ℎ𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠. 8
Stress Concentration
Nominal stress and Theoretical 𝐾𝑡 (𝐾𝑡𝑠 ) detemination
Round shaft with shoulder fillet in tension

𝑤ℎ𝑒𝑟𝑒 𝐴 = 𝜋𝑑 2 Τ4 𝜎0 = 𝐹 ∕ 𝐴,
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Stress Concentration
Nominal stress and Theoretical 𝐾𝑡 (𝐾𝑡𝑠 ) detemination
Round shaft with shoulder fillet in torsion

𝜏0 = 𝑇𝑐 Τ𝐽 ,
𝑤ℎ𝑒𝑟𝑒 𝑐 = 𝑑 ∕ 2 𝑎𝑛𝑑 𝐽 = 𝜋𝑑 4 ∕ 32
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Stress Concentration
Nominal stress and Theoretical 𝐾𝑡 (𝐾𝑡𝑠 ) detemination
Round shaft with shoulder fillet in bending

𝜎0 = 𝑀𝑐 Τ𝐼 ,
𝑤ℎ𝑒𝑟𝑒 𝑐 = 𝑑 ∕ 2 𝑎𝑛𝑑 𝐼 = 𝜋𝑑 4 ∕ 64
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Stress Concentration
Notch sensitivity

➢ Materials that are soft, ductile, and low strength with a large grain structure are
less sensitive to notches than materials that are hard, brittle, and high strength
with a small grain structure.

➢ To quantify the sensitivity of materials to notches, a notch sensitivity q is used

where q is usually between zero and unity

➢ Therefore, 𝐾𝑓 can be expressed as

➢ How is q determined?

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Stress Concentration
Finding the value of q
a) Graphical

Notch-sensitivity charts for steels and UNS A92024-T wrought aluminum alloys subjected to reversed
bending or reversed axial loads. For larger notch radii, use the values of q corresponding to the r = 4-mm 13
Stress Concentration
Finding the value of q
a) Graphical

Notch-sensitivity curves for materials in reversed torsion. For larger notch radii, use the values of qs
corresponding to r = 4 mm. 14
Stress Concentration
Finding the value of q
b) Using a model (Neuber and Kuhn)

Where
𝑎 = Neuber constant
r is the notch radius
➢ The Neuber constant is experimentally determined for each material

➢ For steels,
Bending or axial

Torsion:

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Stress Concentration
Example
A steel shaft in bending has an ultimate strength of 690 MPa and a shoulder with a
fillet radius of 3 mm connecting a 32-mm diameter with a 38-mm diameter. Estimate
𝐾𝑓 using:
(a) Graphical means.
(b) Neuber and Kuhn model

Solution
From the graph in slide 11, and using
𝐷 ∕ 𝑑 = 38 ∕ 32 = 1.1875, 𝑟 ∕ 𝑑 = 3 ∕ 32 = 0.093 7
We read the graph to find 𝐾𝑡 = 1.65
a) From graph in slide 13, for 𝑆𝑢𝑡 = 690 𝑀𝑃𝑎 𝑎𝑛𝑑 𝑟 = 3 𝑚𝑚, 𝑞 = 0.84

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Stress Concentration
Example
A steel shaft in bending has an ultimate strength of 690 MPa and a shoulder with a
fillet radius of 3 mm connecting a 32-mm diameter with a 38-mm diameter. Estimate
𝐾𝑓 using:
(a) Graphical means.
(b) Neuber and Kuhn model

Solution
b) for 𝑆𝑢𝑡 = 690 𝑀𝑃𝑎

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Stress Concentration
Example: Estimation of life of a shaft containing stress concentrators

The figure below shows a rotating shaft simply supported in ball bearings at A and D
and loaded by a nonrotating force F of 6.8 kN. The shaft is machined from AISI 1050
cold-drawn steel. All fillets have a 3-mm radius. Estimate the life of the part.
Take

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Stress Concentration
Example: Estimation of life of a shaft containing stress concentrators
The figure below shows a rotating shaft simply supported in ball bearings at A and D
and loaded by a nonrotating force F of 6.8 kN. The shaft is machined from AISI 1050
cold-drawn steel. All fillets have a 3-mm radius. Estimate the life of the part.
Take
Solution
By drawing the bending-moment diagram, we have

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Stress Concentration
Example: Estimation of life of a shaft containing stress concentrators
The figure below shows a rotating shaft simply supported in ball bearings at A and D
and loaded by a nonrotating force F of 6.8 kN. The shaft is machined from AISI 1050
cold-drawn steel. All fillets have a 3-mm radius. Estimate the life of the part.
Take
Solution

Failure will probably occur at B rather than at C or at the point of maximum moment

Point B has a smaller cross section, a higher bending moment, and a higher stress-
concentration factor than C, and the location of maximum moment has a larger size
and no stress-concentration factor

First, estimate the strength at point B (𝑆𝑒 ) and compare this strength with the stress at
B (𝜎𝑎𝑟 )

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Stress Concentration
Example: Estimation of life of a shaft containing stress concentrators
The figure below shows a rotating shaft simply supported in ball bearings at A and D
and loaded by a nonrotating force F of 6.8 kN. The shaft is machined from AISI 1050
cold-drawn steel. All fillets have a 3-mm radius. Estimate the life of the part.
Take
Solution

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Stress Concentration
Example: Estimation of life of a shaft containing stress concentrators
The figure below shows a rotating shaft simply supported in ball bearings at A and D
and loaded by a nonrotating force F of 6.8 kN. The shaft is machined from AISI 1050
cold-drawn steel. All fillets have a 3-mm radius. Estimate the life of the part.
Take
Solution

From the graph in slide 11, and using

𝐷 ∕ 𝑑 = 38 ∕ 32 = 1.1875, 𝑟 ∕ 𝑑 = 3 ∕ 32 = 0.09375
We read the graph to find 𝐾𝑡 = 1.65
for 𝑆𝑢𝑡 = 690 𝑀𝑃𝑎

= 1.55 22
Stress Concentration
Example: Estimation of life of a shaft containing stress concentrators
The figure below shows a rotating shaft simply supported in ball bearings at A and D
and loaded by a nonrotating force F of 6.8 kN. The shaft is machined from AISI 1050
cold-drawn steel. All fillets have a 3-mm radius. Estimate the life of the part.
Take
Solution
Find bending stress at B
For simply supported beam
𝑊𝑎𝑏 6.8 𝑘𝑁 × 325𝑚𝑚 × 225𝑚𝑚
𝑀𝑚𝑎𝑥 = = =
𝐿 550𝑚𝑚
Use similarity of triangles to find 𝑀𝐵
𝑀𝐵 = 695 𝑁𝑚

32
𝑐 = 𝑑 ൗ2 = = 16 𝑚𝑚 = 1.6 × 10−2 𝑚
2
𝐼 = 𝜋𝑑 4 Τ64 = (𝜋 × 324 )Τ64 = 51471.854 𝑚𝑚4 = 5.147 × 10−8 𝑚

𝜎0 = 𝑀𝑐 Τ𝐼 = (695 𝑁𝑚 × 1.6 × 10−3 𝑚)Τ(5.147 × 10−8 𝑚)

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Stress Concentration
Example: Estimation of life of a shaft containing stress concentrators
The figure below shows a rotating shaft simply supported in ball bearings at A and D
and loaded by a nonrotating force F of 6.8 kN. The shaft is machined from AISI 1050
cold-drawn steel. All fillets have a 3-mm radius. Estimate the life of the part.
Take
Solution

𝜎0 = 𝑀𝑐 Τ𝐼 = (695 𝑁𝑚 × 1.6 × 10−3 𝑚)Τ(5.147 × 10−8 𝑚)

𝜎0 = 216.048 𝑀𝑃𝑎
The reversing bending stress is, assuming infinite life
𝜎𝑎𝑟 = 𝐾𝑓 𝜎0
𝜎𝑎𝑟 = 1.55 × 216.048 𝑀𝑃𝑎 = 334.8744 𝑀𝑃𝑎

This stress is greater than Se and less than Sy. This means we have both finite life
and no yielding on the first cycle

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Stress Concentration
Example: Estimation of life of a shaft containing stress concentrators
The figure below shows a rotating shaft simply supported in ball bearings at A and D
and loaded by a nonrotating force F of 6.8 kN. The shaft is machined from AISI 1050
cold-drawn steel. All fillets have a 3-mm radius. Estimate the life of the part.
Take
Solution
For finite life

We know that

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Stress Concentration

Questions

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Stress Concentration
Next topic

Fatigue Failure Criteria

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Stress Concentration
Exercise
A 25.400 mm-diameter solid round bar has a groove 2.540-mm deep with a 2.540-mm
radius machined into it. The bar is made of AISI 1020 CD steel and is subjected to a
purely reversing torque of 203.400 N·m.
(a) Estimate the number of cycles to failure.
(b) If the bar is also placed in an environment with a temperature of 400°C,
estimate the number of cycles to failure.

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