 Stress concentration

A stress concentration is a localized increase of stress caused by geometry or another disturbance of the load path. Holes, notches and abrupt section changes can make the largest local normal stress much greater than a stress calculated from the total force divided by a reference cross-sectional area. A stress concentration factor $K_t={\sigma }_{\max }/{\sigma }_{\mathrm{ref}}$ is meaningful only after both the stress component and its reference have been specified.

The Kirsch equations give an instructive exact result for a circular hole of radius $a$ in an infinite, isotropic linear elastic elastic plate under remote tensile stress ${\sigma }_{\infty }$ in one direction, using a plane stress model. Measure the polar angle $\theta$ from the loading direction. At the hole boundary,At $\theta =\pi /2,3\pi /2$, the tangential normal stress reaches $3{\sigma }_{\infty }$, giving $K_t=3$ relative to remote stress. At $\theta =0,\pi$, it is $-{\sigma }_{\infty }$. A traction-free hole therefore does not require every component of its stress tensor to vanish: it requires zero traction on the radial boundary.^[ref]

For a finite plate, distinguish gross and net reference areas. A plate of width $W$, thickness $t$ and central hole diameter $d$ transmits force $P$ through gross area $A_g=tW$ and minimum net area $A_n=t(W-d)$. Defining ${\sigma }_g=P/A_g$ and ${\sigma }_n=P/A_n$ gives the exact conversionThis is a change of normalization, not a solution for the finite plate's stress field. For an original numerical example, take $W=40\mathrm{mm}$, $t=2\mathrm{mm}$, $d=10\mathrm{mm}$ and $P=800\mathrm{N}$. The reference stresses are $10$ and $13.333\mathrm{MPa}$. If the local maximum is stipulated as $32\mathrm{MPa}$, the same physical maximum gives $K_{tg}=3.2$ and $K_{tn}=2.4$. Neither number changes the local stress by choosing a different denominator.

The distinction appears in real historical measurements. In 1939, C. Dumont loaded a perforated aluminum-alloy plate in out-of-plane bending and measured strain and deflection at two loads. The reported peak tangential stress was 1.59 times the computed net-section stress, but 1.85 times the computed stress for an unperforated plate under the same bending forces. These are bending results for that geometry, rather than the infinite-plate tensile factor three.^[ref]

Modern demonstrations can combine a metal plate instrumented with strain gauges and a transparent polymer viewed in a polariscope. The latter uses stress-induced birefringence; its fringes respond to differences of principal stresses. The MIT laboratory compares local and remote strain measurements with qualitative photoelasticity observations around holes and a slot.^[ref]

The elastic stress concentration factor is dimensionless. It differs from the stress intensity factor used to describe a sharp crack's singular field. Local yielding or a crack changes the mechanical problem; multiplying a remote stress by the elastic $K_t$ does not, by itself, establish a failure load.

Stress concentration refers to the occurrence of localized increases in stress within a material, often resulting from geometric discontinuities, such as holes, notches, fillets, or changes in cross-section. When a load is applied to a component, rather than distributing the stress uniformly throughout the material, certain areas may experience significantly higher stress. This can lead to failure at these concentrated locations rather than through the bulk of the material.