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RESEARCH PAPERS

Stress Analysis of Near Optimal Surface Notches in 3D Plates

[+] Author and Article Information
R. Wescott, B. Semple

 Aerostructures Technologies, Level 14, 222 Kingsway, South Melbourne, Victoria 3205, Australia

M. Heller

 Air Vehicles Division, DSTO, 506 Lorimer Street, Fishermans Bend, Victoria 3207, Australiamanfred.heller@dsto.defence.gov.au

J. Mech. Des 127(6), 1173-1183 (Oct 12, 2004) (11 pages) doi:10.1115/1.1998908 History: Received October 01, 2003; Revised October 12, 2004

This paper presents a method of using two-dimensional (2D) optimal notch shapes to create near optimal surface notches with various depth and aspect ratios in uniaxially loaded three-dimensional (3D) plates. Axisymmetric and elongated surface notches are created by rotating 2D optimal notch shapes about two types of fixed axes, a major reason being to enable the surface notches to be manufactured by elementary methods. Stresses in the surface notches are determined using intensive 3D finite element analyses. Axisymmetric notches show small reductions in local peak stress relative to spherical notches with the same bounding dimensions. Local peak stresses in elongated notches are reduced by up to 26% relative to comparable spherical notches. The given method and results are transferable for the initial design, re-shaping, and damage repair of components manufactured from any commonly used metal. In damage removal applications a significant advantage of both notch types over spherical notches is that they allow more material to be extracted for the same notch length and maximum depth.

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Copyright © 2005 by American Society of Mechanical Engineers
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Figures

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Figure 1

Geometry, notation and loading for a 2D plate with symmetric notches

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Figure 2

Geometry and loading for a 3D plate with symmetric notches. (Area of FE modeling is hatched; lower notch is not shown.)

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Figure 3

Geometry of one-eighth of 3D plate and notation used for all notches. (Net area of section is hatched.)

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Figure 4

Close-up view of one-eighth of 3D plate showing methods for creating notch surfaces (a) spherical, (b) axisymmetric using 2D optimal notch shape, and (c) elongated using 2D optimal notch shape

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Figure 5

Close-up view of typical FE meshes (a) spherical or axisymmetric notch, and (b) elongated notch

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Figure 6

2D non-dimensionalized spherical and optimal notch shapes used to create spherical and nominal notches in a 3D plate. (Note that vertical scale is 10 times horizontal scale.)

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Figure 7

Normalized maximum principal stress along the profile in the xy-plane for spherical and axisymmetric notches with Lx∕d=5 and (a) Wy∕d=2, (b) Wy∕d=5, and (c) Wy∕d=10

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Figure 8

Normalized maximum principal stress for surface notches with Lx∕d=5 and Wy∕d=5 (a) spherical and (b) nominal axisymmetric

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Figure 12

2D non-dimensionalized spherical and optimal notch shapes used to create notches in a 3D plate. (Note that vertical scale is 10 times the horizontal scale.)

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Figure 9

2D non-dimensionalized optimal notch shapes used to create near optimal notches a 3D plate. (Note that vertical scale is three times the horizontal scale.)

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Figure 10

Normalized maximum principal stress along the profile in the xy-plane for elongated notches with Lx∕d=5 and (a) Wy∕d=2, (b) Wy∕d=5, and (c) Wy∕d=10

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Figure 11

Normalized maximum principal stress for elongated notches with Lx∕d=5, Wy∕d=2 and J∕d=1.5 (a) nominal and (b) near optimal

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Figure 13

Normalized maximum principal stress for nominal axisymmetric notch case, Lx∕d=2 and Wy∕d=2

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Figure 14

Comparison of optimal and spherical profiles with sample profile of corrosion damage in Hercules component. (Note that vertical scale is 40 times the horizontal scale.)

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