The Split Hopkinson Shear Bar (SHSB) test is used to study how materials behave when they experience high-speed shear loading. This research uses a double-notch specimen, but machining limitations cause variations in the fillet radius, which may influence the accuracy of the shear response. For this reason, a numerical study was carried out to examine how different fillet radius affect the test results. Finite element simulations were performed in Abaqus/CAE using Aluminium 2024-T351 specimens with four fillet radius variations: 0.1 mm, 0.15 mm, 0.2 mm, and 0.4 mm. Each specimen was evaluated using three main criteria: force equilibrium, stability of strain-rate change, and the ratio of shear stress to normal stress, which indicates how pure the shear condition is. The results show that all specimens satisfy the force-equilibrium requirement with differences below 1%. The strain-rate gradients range from -72 to -87 s?ยน, meaning the deformation remains relatively stable. Among all variations, the DN-0.4 specimen shows the highest and most consistent ratio of shear to normal stress, indicating the best shear purity. Based on these findings, the DN-0.4 specimen is considered the most optimal design. It provides the best balance between shear purity, stable strain-rate behaviour, and acceptable force equilibrium, making it suitable for producing reliable dynamic shear-testing data.
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