What is a common application for fillets in engineering design?

Fillets are commonly used in engineering design to strengthen the joint areas of parts. When two components are joined, sharp corners can create stress concentration points, which are known to be weak spots that may lead to failure under load. By applying a fillet—a rounded transition between two surfaces—engineers help to distribute stress more evenly across the joint. This curvature enhances the structural integrity by reducing the likelihood of cracks forming at the edges and promotes better load transfer between the parts.

Additionally, fillets can aid in reducing the chances of fatigue failure by minimizing stress concentration. The rounded nature of a fillet allows for smoother flow in both material and stress, making it a critical design feature in applications requiring durability and reliability, especially in mechanical components, structural connections, and various product parts.