Machine Design - Lecture 2

Stress Concentration Factors, Notch Sensitivity and

Variable Stresses

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt, Kts):

Material subjected to loads may not experience uniform loading through out its
section but stresses may be concentrated in some of its areas; usually at holes,
notches, discontinuity, change in cross section, sharp corners and edges, and
on damaged surfaces which are left undressed.
Stress concentrations on materials can be detected by polariscope on
photoelastic material and radiography.

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt, Kts):

Discoloration , and magnified stress lines in

photoelasticity experiments indicate increase in
stress values at locations of holes, notches,
sharp corners, where failure can initiate.

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt, Kts):

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt, Kts):

Location of magnified
nominal stress

Nominal
(nom)
stress value
(Lecture 1)

Thus, max. stress value = Smax or Ơmax = Snom x Kt , or, Ơnom x Kt

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt):

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt):

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt):

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt):

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt):

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt):

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

1. Stress Concentration Factors (Kt, Kts):

Remember:

(Normal stresses are simple stresses)

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

2. Fatigue Stress Concentration Factor (Kf, Kfs)

Example;

Where : q is called notch sensitivity factor

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

2. Fatigue Stress Concentration Factor (Kf, Kfs)

Where : q is called notch sensitivity factor, values taken from fatigue

experiments on notch materials and un-notched similar material, and then
tabulated.

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

2. Fatigue Stress Concentration Factor (Kf, Kfs)

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

2. Fatigue Stress Concentration Factor (Kf, Kfs)

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

3. Fatigue, Variable Stress:

What is fatigue?
1. Fatigue = repeated or reversed variable loading.

Repeated tensile
Tension, variable stress, no
positive zero stress values.
stress
Repeated tensile
variable stress, with
zero stress values, i.e.,
stress is unloaded to
zero values at regular
intervals.

Repeated reversed
(tensile –compressive)
variable stress, also
Compression, with zero stress values
negative stress 17
 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses
3. Fatigue, Variable Stress:
What is fatigue?
Fatigue strength or endurance strength ( Sn, Sns) = resistance of material to
fatigue , or the max. Stress level that a material can withstand for a particular
number of ‘N’ cycles. (Cycles is the no of times the stress is reversed is
repeated or reversed.)
Fatigue or endurance strength is measured by a machine which applies
simultaneous bending on a rotating beam; which causes reversal/repetition of
stresses.

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses
3. Fatigue, Variable Stress:

points plotted present failure points

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses
3. Fatigue, Variable Stress:

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses
3. Fatigue, Variable Stress:
In calculations, we should consider :
(+) = for clockwise torque , (-) = for counterclockwise torque
(+) = for tensile stress or force, (-) = for compressive stress or force

Remember
Sa or these
equations!

Sm or

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses
3. Fatigue, Variable Stress:
Calculations involving Variable Stresses
Two criteria are considered:
- SODERBERG Criterion for DUCTILE materials ; and
- GOODMAN Criterion for BRITTLE materials

Note: Formula if parts

are loaded with
n normal stresses.

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses
3. Fatigue, Variable Stress:
Calculations involving Variable Stresses

Note: Formula if
parts are loaded
with normal
n stresses.

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses
3. Fatigue, Variable Stress:

Calculations involving Variable Stresses

If parts are loaded in SHEAR, use the following formulas:

- SODERBERG Criterion for

DUCTILE materials in shear

- GOODMAN Criterion for

BRITTLE materials in shear
Note: Sus = 0.75Su to 0.80Su for
steels

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

3. Fatigue, Variable Stress:

Calculations involving Variable Stresses, Values of Sn, and Sns; Kf and Kfs

In the absence of values from Tables or Tests , values of endurance limit/strength may be
estimated, which are decreased by several factors.
Important: The values of endurance limit as decreased by several factors are clarified in
discussion in pages 109 thru 111 and 115 of DOME by Faires.

1. For Wrought Steels (ductile materials ), BHN < 400:

a. Axial loading without bending: Sn = size factor SF x 0.8 x AF5 factor x (0.5 x Su or 250 BHN)
b. Bending: Sn = size factor SF x AF5 factor x (0.5 x Su or 250 BHN)
c. Shear/torsion: Sns = 0.6 x size factor SF x 0.8 x AF5 factor x (0.5 x Su or 250BHN)
2. For Cast Iron (brittle materials ):

a. Axial loading without bending: Sn = size factor SF x 0.8 x AF5 factor x (0.4 or 0.35Su)
b. Bending: Sn = size factor SF x AF5 factor x (0.4 or 0.35Su)
c. Shear/torsion: Sns = 0.8 x size factor SF x 0.8 x AF5 factor x (0.4 or 0.35Su)

Note: 1. Size factor SF = 0.85 for sizes between ½ inch to 2 inches.

2. For bending loads, remove 0.8 factor in Axial loading formulas, for brittle
and ductile materials. 25
Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

3. Fatigue, Variable Stress:

Calculations involving Variable Stresses, Values of Sn, and Sns; Kf and Kfs

The values of Kf and Kfs can be taken from useful tables in DOME by Faires,
handbooks and other textbooks, or calculated from q value- the notch
sensitivity factor. Some useful tables are previous presented , i.e., Tables
on values of Kt, similar to the ones in DOME by Faires.

USEFUL TABLES:
AT12, AT13, AF6, AF8, AF9, AF10, AF11, AF12, AF13 & AF14
(See APPENDIX in this presentation)

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

3. Fatigue, Variable Stress:

SAMPLE USEFUL TABLES:

Sn at specific
number of cycles

See APPENDIX in this

presentation for
other useful Tables!

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

VARIABLE STRESS:
Sample Problems:

1. A round shaft made of cold finished AISI1020 steel, is subjected to a variable

torque whose maximum value is 6283 in-lb. For N= 1.5 on the Soderberg
criterion, determine the diameter if (a) the torque is reversed, (b) the torque
varies from zero to maximum, (c) the torque varies from 3141 in-lb to a
maximum.
2. A machine part of uniform thickness t = b/2.5 is shaped as shown and
machined all over from AISIC1020 as rolled. The design is for indefinite life for a
load repeated from 1750 lb to 3500 lb. Let d=b. (a) For a design factor of 1.8
(Soderberg), what should be the dimensions of the part? (b) What is the
maximum tensile stress in the part as designed ?

SEE APPENDIX FOR SOLUTIONS AND ANSWERS! 28

Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

VARIABLE STRESS:
Homework:

Notes: Use Rc conversion Figure (Lec. 1) or Table

to determine Su. For item 4, select size from
choices as appropriate from calculated answer, if
page 269 in DOME by Faires is not available.
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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

VARIABLE STRESS:
Homework:

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

APPENDIX
USEFUL DATA– Tables taken from Design of
Machine Elements by Faires 4th ed.

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

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Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses

Solution to Sample Problems 1 and 2.

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 Machine Design Lecture 2: Stress Concentration Factors, Notch Sensitivity and Variable Stresses
SUMMARY:

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