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Reducing stress concentration is mainly done by fillets. However, new concepts toward better material properties lead designers and engineers to use these materials in their design, still changing in geometrical shape of desired models can help us in reducing stress concentration factors. New devices, including fast computers, reliable numerical methods (FEM), and numerical optimization approach can bring special devices for better designing besides considering design limitations in special industries. In this paper we focus on geometrical change (rounded groove) in the sudden changed section of the rounded shaft to reduce stress concentration in the most dangerous section. By optimizing this proposed change in the geometry of shaft we reduce the stress, so using of fillets can be neglected in the future designs to prevent metallurgical and design limitations.