Sections and stress
The corner a soap film cannot finish
Cut a keyway into a round shaft and its torsional stiffness falls by only 11 per cent. The stress does not fall; it moves. It leaves the surface beside the keyway's mouth almost unloaded and crowds into the keyway's bottom corners, where a soap film stretched over the section would have to stand vertical. Computed on finer and finer grids, a sharp corner's stress never settles — it grows by the cube root of two every time the grid is halved — and a fillet of a few tenths of a millimetre is what turns an infinite answer into three times the plain shaft's.