It is common in FE modeling to remove small features such as small rounds or fillets to reduce the model size, save computer time, and avoid meshing difficulties. Removing a small feature at a sharp corner induces a strong singularity and stress concentration. FE solutions vary dramatically with the element size close to the stress concentration zone. This often creates confusion in the selection of element size. The influence of element size at the stress concentration with the small radii removed on the FE solution was studied in this paper. An Intermediate Element Size (IES) concept was proposed. The IES for a range of small radii was calculated to obtain a rational solution at the stress concentration. Examples are provided to illustrate the application of the IES concept.