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- MakaleAçık Erişim2026Scopus SJRQ4Comparative analysis of stress distributions and safety factor in tensile test specimens with different notch and hole geometries by finite element method
Korkmaz, Sümeyye Erdem; Gavgali, Esma
This study analyzes the effects of different notch and hole geometries (V-Notched, U-Notched, circular hole) on stress concentration in Ti-6Al-4V (Grade 5) Titanium alloy tensile specimens to provide optimized design recommendations for aerospace and biomedical applications. Finite element method (ANSYS Workbench) was employed to analyze three geometries under 15000 N static tensile loading. Von Mises stress distributions and stress concentration factors (Kt) were calculated and validated against Peterson and Neuber theoretical formulas with average error ±1.5%. Results revealed that V-Notched exhibited highest stress concentration (Kt = 5.78, σmax = 1156 MPa), while circular hole showed lowest (Kt = 2.25, σmax = 454.12 MPa). U-Notched demonstrated intermediate performance (Kt = 2.84, σmax = 995.45 MPa). Increasing notch root radius from 0.5 mm to 2.0 mm achieved 51% reduction in stress concentration factor. Maximum shear stress values were 232.74 MPa, 506.38 MPa, and 640 MPa for circular, U-Notched, and V-Notched respectively, while maximum normal stress values reached 467.06 MPa, 1015.1 MPa, and 1809 MPa. Safety factor analysis showed that circular hole configuration meets aerospace standards (FS = 2.05 > 1.5), while U-Notched (FS = 0.93) and V-Notched (FS = 0.80) fall below minimum safety criteria. U-Notched exhibited highest total displacement (1.210 mm), indicating compliance effects. For aerospace and biomedical applications, circular holes should be preferred over sharp notches (154% stress reduction), and minimum corner radius ≥2.0 mm is recommended. The critical finding that geometric optimization provides 2.6× safety improvement without material changes demonstrates the powerful role of design in structural reliability for weight-critical applications.
