Stress Concentration Factors in Excavation Repairs of Surface Defects in Forgings and Castings

This paper provides an analytical formula for the theoretical stress concentration factor in a common type of excavation repair for large forgings and castings. Mechanical components obtained with these processes are often subjected to superficial defects. As the rejection of such pieces is out of question, given the relevant size and costs associated with them, usual industrial practice consists in the removal of the defect and a portion of the surrounding material through milling processes. The authors have selected a reference geometry of the excavation to be left on the mechanical pieces, which can be easily controllable in practice by three operating parameters. Then, the domain of existence of such a repair was investigated on a sequence of discrete points, by means of FEA, obtaining for each, the values of the stress concentration factor Kt. Finally, through polynomial regression, the Kt functions have been accurately approximated by a sixth degree polynomial formulation, which, given a triplet of dimensional geometric parameters, is able to compute the stress concentration factor Kt, with an error that never exceeds 8%.