How can stress in a part be reduced?

Using a fillet in a part design effectively reduces stress concentrations that can occur at sharp corners or edges. Stress concentration is a phenomenon where stress is magnified in a localized area, often leading to potential failure points within the material.

When a fillet is incorporated into the design, it provides a smooth transition between surfaces instead of a sharp angle, distributing the applied load more evenly across the material. This gradual transition allows for a more uniform stress distribution, which minimizes the likelihood of cracking or failure.

While sharper edges may initially seem beneficial for cutting efficiency, they can actually increase stress concentrations. Increasing the width or minimizing thickness might adjust the overall load the part can handle, but the primary factor in controlling localized stress is the presence of rounded forms, such as a fillet, which directly counteracts stress peaks. Thus, using a fillet is the most effective method for reducing stress within a part.