Capital University of Science and

Technology

Open Ended Project

Gr
ou
p
1
M.
O.
M
La
b
Pr
oje
ct
Re
po
rt

by

M.Hassan Khan Lodhi

Usman Umar
Faizan Basharat

Department of Mechanical Engineering

CUST, Islamabad
13 Jan, 2017

Contents
Introduction:.............................................................................................................................3
Project Purpose:.......................................................................................................................3
Literature review:.....................................................................................................................3
Calculations:.............................................................................................................................5
Graph:.......................................................................................................................................9
Learning Outcomes:.................................................................................................................9
Conclusion:...............................................................................................................................9

Introduction:
b
c

A specimen of given

ratio and determined fillet radius against a value of stress

concentration factor is made for experimental analysis. Load is applied on the specimen and
the fillet section is observed. Applied load is increased until the crack is generated in the
fillet. After the appearance of crack, the angle of crack is observed. The load at which the
crack appears is Pfail. Using this load, the nominal stress is calculated using the formula

nom =

P fail
c t

where,
c = smaller diameter
t = thickness
Using this value of nominal stress and Ultimate tensile stress (max) of the material, stress
concentration factor (K) can be calculated using the relation
K=

max
nom

Experiment is performed using stepped bar configuration of different materials and the values
of K is determined for the material into which the crack has occurred.

Project Purpose:
The main purpose of the project is to determine the fillet radius of stepped bar
required to withstand the applied load. The fillet radius is determined using stress
concentration factor and

b
c

ratio and then the stepped bar configuration is to be

experimentally analyzed to become familiar with the method for calculating appropriate fillet
radius.

Literature review:
The stresses near the points of application of concentrated loads can be much larger
than the average value of stress member. When a structural member contains a discontinuity,
such as a hole or a sudden change in cross section, high localized stress can occur near the
discontinuity. Stress concentration in stepped bar with fillets is shown in the figure below:

Figure

The D/d (b/c in this report) ratio is used along with stress concentration factor to find fillet
radius from r/c ratio.1

In the graph shown above, D/d (b/c) ratio lines are used and the value for fillet radius of
stepped bar is determined against a value of stress concentration factor (K).

Calculations:
The b/c ratio is set to 1.1 and stress concentration factor (K) has a range from 1.5 1.75.
The ultimate tensile strength of Styrofoam is 0.15 MPa.2
1 F. Beer, Mechanics of materials, 5th ed. New York: McGraw-Hill Higher Education, 2009,
pp. 107,108
5

b/c = 1.1
let c = 4.4cm
so b = c(1.1)
b = 4.4(1.1)
b = 4.84cm
we assume the fillet radius to be 6mm
r/c = 0.1
r=0.45cm
nom =

P fail
c t

nom =

12
(0.044 0.003)

nom =0.0896 MPa

K = 0.15MPa/0.0896 MPa
K = 1.67
Similarly by changing the values for stress and thickness etc. we can calculate all the values
for other specimens.

2 www.epsindustry.org/packaging/physical-properties
6

Specimens:
We used different materials for our experiment. These are wood, acrylic sheet and Styrofoam.

Figure 1 (Wood)

Figure 2

Figure 3

Figure 4

Figure 5

Specimen #
Width b (mm)
Width c (mm)
Thickness t
(mm)
Fillet radius r
(mm)
b/c ratio
r/c ratio
Load at
appearance of first
visible crack Pfail
(N)
Nominal stress in
portion c (MPa)
max
(MPa)

Wood

Styrofoa
m
48.4
44
3

Styrofoam

22
20
3.5

Styrofoa
m
48.4
44
3

42
37.4
3

Acrylic
Sheet
55
50
2

2.2

4.5

4.5

3.4

1.1
0.1

1.1
0.1

1.1
0.1

1.1
0.1

1.1
0.1

60

15

12

14

43

0.0896

40

0.15

Location of crack
Angle of crack
Stress
concentration
factor K

Fillet
35
1.675

Graph:

10

Stress concentration factor graph

Learning Outcomes:
The method to determine the appropriate fillet radius against a value of stress concentration
factor required to withstand the applied load is the learning outcome of the experiment.
Moreover, the method to retrieve the value of fillet radius from the stress concentration graph
is also learned. We have also become familiar with the ultimate tensile stress values of the
materials used.

Conclusion:
The nominal stress in the case in which crack has occurred is 0.0896 MPa which whereas
maximum stress is 0.15 MPa. Maximum stress has occurred in the fillet section. The value of
fillet radius was taken against the value of stress concentration factor (K) equal to 1.6 and the
experimental value obtained is 1.675 which is approximately equal to the value used.
Percentage error is
1.6751.6
100=4.68
1.6
So, the error is only 4.68%.

11