In continuum mechanics, a material is said to be under plane stress if the stress vector is zero across a particular plane. When that situation occurs over an entire element of a structure, as is often the case for thin plates, the stress analysis is considerably simplified, as the stress state can be represented by a tensor of dimension 2 (representable as a 2×2 matrix rather than 3×3). A related notion, plane strain, is often applicable to very thick members.
Plane stress typically occurs in thin flat plates that are acted upon only by load forces that are parallel to them. In certain situations, a gently curved thin plate may also be assumed to have plane stress for the purpose of stress analysis. This is the case, for example, of a thin-walled cylinder filled with a fluid under pressure. In such cases, stress components perpendicular to the plate are negligible compared to those parallel to it.
In other situations, however, the bending stress of a thin plate cannot be neglected. One can still simplify the analysis by using a two-dimensional domain, but the plane stress tensor at each point must be complemented with bending terms.
Mathematically, the stress at some point in the material is a plane stress if one of the three principal stresses (the eigenvalues of the Cauchy stress tensor) is zero. That is, there is Cartesian coordinate system in which the stress tensor has the form
For example, consider a rectangular block of material measuring 10, 40 and 5 cm along the , , and , that is being stretched in the direction and compressed in the direction, by pairs of opposite forces with magnitudes 10 N and 20 N, respectively, uniformly distributed over the corresponding faces. The stress tensor inside the block will be
More generally, if one chooses the first two coordinate axes arbitrarily but perpendicular to the direction of zero stress, the stress tensor will have the form
and can therefore be represented by a 2 × 2 matrix,
Hooke's law#Plane stress
In certain cases, the plane stress model can be used in the analysis of gently curved surfaces.