Finding Stress Concentration Factor K for Chamfered Joints

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Discussion Overview

The discussion revolves around determining the stress concentration factor, K, for chamfered joints in a rod with two different diameters. Participants explore methods for calculating K, particularly in the absence of established references for chamfered configurations, and consider alternative approaches such as modeling and assumptions.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant seeks guidance on finding the stress concentration factor K for a chamfered joint, noting their familiarity with fillet joints but not chamfers.
  • Another participant suggests using CAD software like SolidWorks to perform stress analysis, indicating it should be straightforward.
  • A third participant points out the lack of references in standard texts for chamfered joints and recalls a similar inquiry from a previous thread, recommending treating the chamfer as a very small radius due to practical machining limitations.
  • A later reply reiterates the suggestion of using CAD modeling but emphasizes the challenges of obtaining accurate stress results from sharp corners, proposing that a conservative approach might involve assuming a filleted case instead.

Areas of Agreement / Disagreement

Participants express differing views on the best approach to determine K for chamfered joints, with no consensus reached on a definitive method or solution.

Contextual Notes

Participants note the absence of established references for chamfered joints and the complexities involved in modeling sharp corners accurately, which may limit the reliability of stress analysis results.

Who May Find This Useful

Engineers and designers interested in stress analysis of mechanical joints, particularly those working with chamfered configurations or seeking alternative modeling approaches.

patrickv
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Hello, I have a rod of two different diameters and I'm trying to find the stress concentration at the chamfer between the two diameters. I understand how to find the stress concentration factor, K, if the joint was a fillet (using r/d and D/d to find K in the appropriate table). However I can't find any way of getting K for a chamfered joint. Please help point me in some direction. Thanks so much. I've attached a quick diagram showing the filleted and chamfered versions of the shaft. The chamfered one is the actual piece I'm trying to find K for.
 

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I would make a model in SolidWorks or some other CAD program, and do stress analysis. Should be pretty easy.
 
There is no reference in either Peterson's or Roark's for this. I do remember Q_Goest having the same post a year or so ago. You may want to do a search for that thread. I can not remember what conclusion he came to. I would start by treating it as a very small radius, which in reality is the truth. You will not machine a perfectly sharp corner.
 
Brian_C said:
I would make a model in SolidWorks or some other CAD program, and do stress analysis. Should be pretty easy.

Chamfers are by definition sharp corners. Getting real stress results from a sharp corner numerically is quite a challenge, dare I say impossible. It's hard enough getting real stress numbers in a fillet where you can actually get grid to follow the surface.

You may have to assume a filleted case and take some sort of worst conservative case.
 
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