ETBX Stress Concentration Factors Module

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Stress Concentration Factors

An EngineersToolbox Calculation Module

Background Information
This module calculates stress concentration factors for various shaft and plate geometries assuming homogenous, isotropic, and elastic material. Almost all machine components and structural members contain some form of geometrical (a notch or any abrupt change in cross section) or microstructural discontinuities. The maximum local stress, max, normally occurs at these discontinuities. This maximum local stress is many times greater than the nominal stress, nom, of the member. Thus, the discontinuities cause areas of stress concentration within the component, and are often called "stress raisers". In ideally elastic members, the ratio of the maximum stress to the nominal stress is designated, the theoretical stress concentration factor, Kt. The nominal stress is calculated for a particular loading and net cross section assuming a stress distribution across the section that would be obtained for a uniform geometry. Note that the nominal stresses are calculated using the net cross section, which is reduced by the notch geometry (use the small dimension, d, as opposed to the large dimension, D). The theoretical stress concentration factor is solely dependent on the geometry and the mode of loading. The maximum stress present in a component can be determined by multiplying the nominal stress by the appropriate theoretical stress concentration factor: max = Kt * nom The first mathematical treatments of stress concentrations were published in 1937. Closed form solutions are available for the very simple geometries. However, for more complex cases, experimental methods for measuring highly localized stresses (photoelastic tests, precision strain gage tests, membrane analogy for torsion, etc.) and computerized finite element solutions have been used. The results of the studies are available in the form of published graphs. This module uses polynomial and power regression curve fitting to approximate close form solutions of the graphs. These approximations are within 1% of the Kt value read directly from the graphs in the references. Note that the stress concentration graphs are theoretical factors based on a theoretical homogenous, isotropic, and elastic material. Real materials have microscopic irregularities causing a certain nonuniformity of microscopic stress distribution, even in notch -free parts. Thus, the addition of a stress raiser (notch, hole, etc.) may not cause as much additional damage as indicated by the theoretical factor. The ductility or brittleness of the material has a pronounced effect on its response to stress concentrations under static loads. Stress concentration will cause failure of brittle materials if the concentrated stress is larger than the ultimate strength of the material. In ductile materials, concentrated stresses larger than the yield strength will generally cause local plastic deformation and redistribution of stresses (rendering them more uniform). Thus, it is common to ignore the effects of geometric stress concentration in ductile materials under static loading. The stress for the net cross section is calculated as if the stress concentration were not there (the stresses are larger than for an unnotched part of the same overall dimensions because the smaller net cross-sectional area is used). Areas of stress concentration are possible sites for fatigue if the component is cyclically loaded (even for ductile materials).

Input
The Stress Concentration Factors module input form is shown in Figure 1.

ETBX Stress Concentration Factors Module

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Figure 1: The module input form.

The stress concentration factor analysis problem is defined by first selecting the proper type of solution from the Solution Type menu list (Note that as a selection is made the graphic window will update with the geometry for that particular case). All the required inputs fields for the analysis of the chosen loading will be shown in the Input Parameters section. Note that if you are only interested in the calculation of the Stress Concentration Factor (and not the nominal or maximum stress levels), enter 0 (zero) in the loading text field (P, M, T, etc.) The user must be consistent with the units to get correct answers. For example, the geometrical dimensions must all be in the same units (inches, m, mm) as well as the applied loads (ksi, Mpa, psi). The module will verify that proper loading and dimensions were entered. If the second biaxial stress is larger than the first, if any of the dimensions are less than or equal to zero, or if the small dimension is larger than the large dimension an error message will be displayed in a separate window.

Results
Results are displayed in the Results section. More details on the calculation and results can be obtained by pressing the button labeled SHOW DATA, see Figure 2. The results displayed are: All the inputs for the problem (loading and geometry) The power relationship constants (if power regression was used for that solution type) The theoretical stress concentration factor

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Figure 2. Module tabulated results.

Equations
Variables: Kt = Theoretical Stress Concentration Factor Kinf = Theoretical Stress Concentration Factor for an Infinite Plate Kta = Theoretical Stress Concentration Factor at Point A Ktb = Theoretical Stress Concentration Factor at Point B S1 = Biaxial Stress Normal to the Major Axis S2 = Biaxial Stress Parallel to the Major Axis r = Fillet or Notch Radius D = Large Dimension d = Small Dimension W = Width of the Plate t = Thickness of the Plate a = Ellipse Height b = Ellipse Width A = Power Relationship Constant (Multiplier) B = Power Relationship Constant (Exponent) A, B values obtained from curve fit and interpolation of experimental data

ETBX Stress Concentration Factors Module

e = Mathematical Constant = 2.71828

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POWER RELATIONSHIP (IF RELATIONSHIP NOT LISTED BELOW USE THE POWER RELATIONSHIP, WITH A AND B CONSTANTS DETERMINED FROM EMPIRICAL DATA LISTED IN ROARK DEPENDING ON THE GEOMETRY WITH LINEAR INTERPOLATION USED BETWEEN TABULATED VALUES): SHAFT WITH CIRCULAR TRANSVERSE HOLE IN BENDING:

SHAFT WITH CIRCULAR TRANSVERSE HOLE IN TORSION (ON THE SHAFT SURFACE AT THE HOLE):

FLAT PLATE WITH CIRCULAR HOLE IN AXIAL TENSION:

FLAT PLATE WITH CIRCULAR HOLE IN OUT-OF-PLANE BENDING:

FLAT PLATE WITH ELLIPTICAL HOLE IN AXIAL TENSION:

INFINITE FLAT PLATE IN BIAXIAL TENSION:

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FLAT PLATE WITH ELLIPTICAL HOLE IN BIAXIAL TENSION:

References
Bannantine, J., Comer, J., Handrock, J. (1990) Fundamentals of Metal Fatigue Analysis, Prentice Hall ( New Jersey). Juvinall, R. C., Marshek, K. M. (1991) Fundamentals of Machine Component Design - 2nd Edition, John Wiley and Sons (New York). Neuber, H. (1937) "Theory of Notch Stresses," J. W. Edwards (Ann Arbor, MI). Neuber, H. (1946) Theory of Notch Stresses: Principle for Exact Stress Calculations, J.W. Edwards (Ann Arbor, MI). Norton, Robert L. (1996) Machine Design, An Integrated Approach, Prentice-Hall (New Jersey). Osgood, C. C. (1982) Fatigue Design - 2nd Edition, Pergamon Press (Oxford). Peterson, R. E. (1953) Stress Concentration Design Factors, John Wiley and Sons (New York) . Peterson, R. E. (1974) Stress Concentration Factors, John Wiley and Sons (New York).

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