Fatigue failure remains a critical concern in structural engineering and material science, prompting extensive research to understand and predict the behaviour of materials under cyclic loading conditions. The present study aims to investigate the fatigue life of carbon steel specimens containing opposite semicircular edge notches through a comprehensive experimental and numerical analysis. In this study, stress concentration factors (SCF, Kt) of rectangular plate with opposite semicircular notches are considered under uniform tensile stress to analyse the notch deformation because of stretching of plate. Furthermore, the research focuses on quantifying stress concentration factors (SCFs) for these notches based on S-N curves of carbon steel. The study employs a combination of experimental and numerical techniques to understand the influence of these notches on the fatigue performance of carbon steel structures. A plate with opposite semicircular edge single notches under the axial load creates stress concentration near the notch and it is much larger than the average stress on the plate. Both analytical and finite element methods are used to calculate the maximum stress around the notch. SOLIDWORKS Premium Student Edition 2023 has been employed for modelling and SOLIDWORKS Simulation Premium Student Edition 2023 has been used for stress analysis and fatigue notch factor of rectangular plate of size 31 mm x 25.4 mm x 6.35 mm. The uniform tensile load with a magnitude of 20195 N is applied on one sides of rectangular plate normal to the sides of notches with ratio h/r = 1, for the semicircular notch. The result obtained on both analytical and finite element methods are compared and the percentage of error has been evaluated. Subsequently, these specimens undergo fatigue testing under varying loading conditions to capture their fatigue behaviour. The acquired fatigue data is then plotted against stress amplitude to construct S-N curves, forming the foundation for assessing the fatigue life of the notched specimens. To complement the experimental findings and to gain a deeper understanding of the stress concentration phenomenon, numerical simulations are conducted using advanced finite element analysis (FEA) techniques. The finite element models are carefully calibrated against the experimental results to ensure their accuracy and reliability. The FEA simulations enable the determination of stress concentration factors at critical locations within the notched specimens, further validating the experimental observations. The investigation reveals crucial insights into the effect of opposite semicircular edge notches on the fatigue life of carbon steel structures. The obtained S-N curves allow engineers and designers to predict the fatigue life of components with similar notches, aiding in the development of reliable and durable structures in practical applications. Moreover, the stress concentration factors determined from the numerical simulations provide valuable data to assess the potential failure modes and to optimise designs, effectively mitigating fatigue-related failures. The combination of experimental and numerical approaches ensures a comprehensive and rigorous analysis of the fatigue behaviour in notched specimens, offering a reliable basis for making informed engineering decisions. The comparison between the analytical method and the Finite Element Method (FEM) demonstrated good agreement, with an error percentage of 4.272%. The analysis revealed that the specimen would experience failure after approximately 2882 cycles, with a maximum stress of 395.914 MPa. This research study enhances the understanding of fatigue life in carbon steel structures containing opposite semicircular edge notches and contributes valuable data to the field of fatigue mechanics. The outcomes serve as a valuable resource for professionals engaged in structural engineering, material science, and design optimisation, ultimately leading to safer and more durable industrial components in critical applications. The findings of this research contribute to the understanding of fatigue behaviour in carbon steel components with stress concentration effects caused by semicircular notches. Moreover, the validated numerical simulations and data curves facilitate the prediction of fatigue life and aid in determining the critical conditions leading to fatigue failure. In conclusion, this research highlights the significance of combining experimental testing with numerical simulations to comprehensively analyse the fatigue life of carbon steel specimens with opposite semicircular edge notches. The obtained stress concentration factors provide crucial information for structural integrity assessment and offer potential for further optimising design criteria to mitigate fatigue-related failures. The findings of this study could play a vital role in enhancing the reliability and safety of carbon steel structures subjected to cyclic loading conditions. The comprehensive experimental and numerical analyses establish a foundation for future studies exploring other materials and geometries with notches, fostering advancements in fatigue life prediction and structural integrity assessment.
