The effects of surface topography on the method of caustics

An investigation was performed to establish the effects of surface topography on the determination of stress intensity factors of opaque components using the method of caustics. Theoretical predictions of caustics produced by curved surfaces were generated and validated by experiment. The errors introduced for stress intensity factors determined at various radii of curvature were assessed. It was found that relatively small surface curvatures caused significant errors in the stress intensity factor. These errors were affected by the initial radius, load and material properties.