Performance Evaluation of Stress Concentration Factor for Shoulder Fillet on Round Bar under Bending Loading

Abstract

In industries, many unexpected failures of machine components occurs due to lack of proper design, sudden changes that happen during working conditions and pre-existing geometrical irregularities. The geometric discontinuities cannot be avoided as they fulfill functional requirements. The shaft or round bar with shoulder fillet is one of the machine components working under different loading conditions. In the present work, shoulder filleted shaft/round bar working under bending loading conditions is taken for study and the stress concentration factor was evaluated. Finite element analysis (FEA) is performed for a total of seven different geometries with different D/d ratios and analyzed them using ANSYS 19.0 workbench software. Based on the equivalent (Von Mises) stresses obtained from the FEA, stress concentration factor (SCF) for the shoulder filleted shaft is calculated and compared with the theoretical results obtained from derived modified Pilkey’s equations, Roark’s equations, and S. M. Tipton equations. The outcome of results shows that for lower D/d ratios both results were identical in nature but for higher D/d ratios, the results found deviated. The SCFs are decreased with increasing D/d ratios. The results of SCFs are presented in the form of graphs for comparison purpose as well as one can refer it for his/her applications.