Why Do We Use Fillets in High Stress Concentration Areas?
In mechanical design, fillets play a crucial role in reducing stress concentration — especially at sharp internal corners where sudden geometry changes occur. High stress concentration areas are common failure points under load, making this design detail essential.
In my FEA comparison study, I analyzed three cases:
No Fillet – Extremely high stress near the sharp corner due to abrupt geometry transition. This is the most unsafe and prone to crack initiation.
Small Fillet – Noticeable improvement in stress distribution, but still moderate localized stress.
Large Fillet – Best performance with significantly smoother stress flow and minimal concentration. This results in increased durability and reliability.
DP DESIGN
Why Do We Use Fillets in High Stress Concentration Areas?
In mechanical design, fillets play a crucial role in reducing stress concentration — especially at sharp internal corners where sudden geometry changes occur. High stress concentration areas are common failure points under load, making this design detail essential.
In my FEA comparison study, I analyzed three cases:
No Fillet – Extremely high stress near the sharp corner due to abrupt geometry transition. This is the most unsafe and prone to crack initiation.
Small Fillet – Noticeable improvement in stress distribution, but still moderate localized stress.
Large Fillet – Best performance with significantly smoother stress flow and minimal concentration. This results in increased durability and reliability.
Why Large Fillets Are Safer:
They distribute stress over a wider area.
Minimize the peak stress values.
Reduce the risk of fatigue failure and cracks.
Improve component life under cyclic loading.
Conclusion:
When designing mechanical parts, especially those under dynamic or repeated loading, larger fillets at high-stress regions are a simple yet highly effective way to enhance strength and safety.
.
.
.
#FEA #StressAnalysis #MechanicalDesign #FiniteElementAnalysis #MechanicalEngineering #FilletDesign #DesignOptimization #EngineeringDesign #CAE #SolidMechanics #StressConcentration #FatigueAnalysis #ProductDesign #EngineeringTips #DesignForDurability #Simulation #StructuralAnalysis #CAD #EngineeringSimulation
8 months ago | [YT] | 12