Dynamic ductile fracture in aluminum round bars: experiments and simulations

The application of rate-dependent cohesive elements is validated in simulation of ductile fracture in aluminum round bars under dynamic loading conditions. Smooth and notched round bars made of AA6060-T6 are tested and simulated under quasi-static and dynamic loadings. The smooth round bar is modeled using finite elements that obey Gurson–Tvergaard–Needleman (GTN) formulation as the constitutive equation. Comparing with experimental results, corresponding GTN parameters and rate-dependent plasticity of the alloy are obtained. A single strain rate-dependent GTN element with the obtained parameters is examined under different values of stress triaxiality and loading rates. The resulting stress-elongation curves represent the traction separation law (TSL) for cohesive elements and the variations of the maximum traction and the energy absorbed are investigated. The notched round bars are modeled by axisymmetric continuum and cohesive elements. The undamaged bulk material is elastic-visco plastic and the cohesive elements obey the TSL defined from the single element calculations. The experiments are simulated by these models in which the cohesive elements are rate sensitive and automatically obtain the values of the total strain rate from their adjacent continuum elements to update the values of the cohesive strength during the analysis. The results of the analysis, including maximum load, time of failure and diameter reduction are validated with the experimental results. The effects of element size, rate-dependent plasticity of the material and stress triaxiality are also discussed.     

Numerical investigation on stable crack growth in plane stress

Large deformation finite element analysis has been carried out to investigate the stress-strain fields ahead of a growing crack for compact tension (a/W=0.5) and three-point bend (a/W=0.1 and 0.5) specimens under plane stress condition. The crack growth is controlled by the experimental J-integral resistance curves measured by Sun et al. The results indicate that the distributions of opening stress, equivalent stress and equivalent strain ahead of a growing crack are not sensitive to specimen geometry. For both stationary and growing cracks, similar distributions of opening stress and triaxiality can be found along the ligament. During stable crack growth, the crack- tip opening displacement (CTOD) resistance curve and the cohesive fracture energy in the fracture process zone are independent of specimen geometry and may be suitable criteria for characterizing stable crack growth in plane stress. This revised version was published online in August 2006 with corrections to the Cover Date.     

Three-dimensional modeling of ductile crack growth: Cohesive zone parameters and crack tip triaxiality

For 10 mm thick smooth-sided compact tension specimens made of a pressure vessel steel 20MnMoNi55, the interrelations between the cohesive zone parameters (the cohesive strength, T_max, and the separation energy, Γ) and the crack tip triaxiality are investigated. The slant shear-lip fracture near the side-surfaces is modeled as a normal fracture along the symmetry plane of the specimen. The cohesive zone parameters are determined by fitting the simulated crack extensions to the experimental data of a multi-specimen test. It is found that for constant cohesive zone parameters, the simulated crack extension curves show a strong tunneling effect. For a good fit between simulated and experimental crack growth, both the cohesive strength and the separation energy near the side-surface should be considerably lower than near the midsection. When the same cohesive zone parameters are applied to the 3D model and a plane strain model, the stress triaxiality in the midsection of the 3D model is much lower, the von-Mises equivalent stress is distinctly higher, and the crack growth rate is significantly lower than in the plane strain model. Therefore, the specimen must be considered as a thin specimen. The stress triaxiality varies dramatically during the initial stages of crack growth, but varies only smoothly during the subsequent stable crack growth. In the midsection region, the decrease of the cohesive strength results in a decrease of the stress triaxiality, while the decrease of the separation energy results in an increase of the triaxiality.     

Crack growth predictions using a strip‐yield model for variable‐amplitude and spectrum loading

Fatigue‐crack‐growth tests were conducted on compact, C(T), specimens made of D16Cz aluminum alloy. Constant‐amplitude tests were conducted over a range of stress ratios (R = P_min/P_max = 0.1 to 0.75). Comparisons were made between test data from middle‐crack tension, M(T), specimens from the literature and C(T) specimens. A crack‐closure analysis was used to collapse the rate data from both specimen types into a fairly narrow band over many orders of magnitude in rates using proper constraint factors. Constraint factors were established from single‐spike overload and constant‐amplitude tests. The life‐prediction code, FASTRAN, which is based on the strip‐yield‐model concept, was used to calculate the crack‐length‐against‐cycles under constant‐amplitude (CA) loading and the single‐spike overload (OL) tests; and to predict crack growth under variable‐amplitude (VA) loading on M(T) specimens and simulated aircraft loading spectrum tests on both specimen types. The calculated crack‐growth lives under CA and the OL tests were generally within ±20 % of the test results, the predicted crack‐growth lives for the VA and Mini‐Falstaff tests on the M(T) specimens were short by 30 to 45 %, while the Mini‐Falstaff+ results on the C(T) specimens were within 10 %. Issues on the crack‐starter notch effects under spectrum loading are discussed, and recommendations are suggested on avoiding these notch effects.     

Ductile tearing in thin aluminum panels: experiments and analyses using large-displacement, 3-D surface cohesive elements

This paper describes a large-displacement formulation for a 3-D, interface-cohesive finite element model and its application to predict ductile tearing in thin aluminum panels. A nonlinear traction-separation relationship defines the constitutive response of the initially zero thickness interface elements. Applications of the model simulate crack extension in C(T) and M(T) panels made of a 2.3 mm thick, Al 2024-T3 alloy tested as part of the NASA-Langley Aging Aircraft program. Tests of the M(T) specimens without guide plates exhibit significant out-of-plane (buckling) displacements during crack growth which necessitates the large-displacement, cohesive formulation. The measured load vs. outside surface crack extension behavior of high constraint (T-stress>0) C(T) specimen drives the calibration process of the cohesive fracture model. Analyses of low constraint M(T) specimens, having widths of 300 and 600 mm and various a/W ratios, demonstrate the capabilities of the calibrated model to predict measured loads and measured outside surface crack extensions. The models capture accurately the strong 3-D effects leading to out-of-plane buckling and various degrees of crack front tunneling in the C(T) and M(T) specimens. Previous analyses of these specimens using a crack tip opening angle (CTOA) criterion for growth show good agreement with measured peak loads. However, without the ability of the interface-cohesive model to predict tunneling behavior, the CTOA approach overestimates crack extensions early in the loading when tunneling behavior dominates the response.     

Cohesive fracture modeling of elastic-plastic crack growth in functionally graded materials

This work investigates elastic-plastic crack growth in ceramic/metal functionally graded materials (FGMs). The study employs a phenomenological, cohesive zone model proposed by the authors and simulates crack growth by the gradual degradation of cohesive surfaces ahead of the crack front. The cohesive zone model uses six material-dependent parameters (the cohesive energy densities and the peak cohesive tractions of the ceramic and metal phases, respectively, and two cohesive gradation parameters) to describe the constitutive response of the material in the cohesive zone. A volume fraction based, elastic-plastic model (extension of the original Tamura-Tomota-Ozawa model) describes the elastic-plastic response of the bulk background material. The numerical analyses are performed using WARP3D, a fracture mechanics research finite element code, which incorporates solid elements with graded elastic and plastic properties and interface-cohesive elements coupled with the functionally graded cohesive zone model. Numerical values of volume fractions for the constituents specified at nodes of the finite element model set the spatial gradation of material properties with isoparametric interpolations inside interface elements and background solid elements to define pointwise material property values. The paper describes applications of the cohesive zone model and the computational scheme to analyze crack growth in a single-edge notch bend, SE(B), specimen made of a TiB/Ti FGM. Cohesive parameters are calibrated using the experimentally measured load versus average crack extension (across the thickness) responses of both Ti metal and TiB/Ti FGM SE(B) specimens. The numerical results show that with the calibrated cohesive gradation parameters for the TiB/Ti system, the load to cause crack extension in the FGM is much smaller than that for the metal. However, the crack initiation load for the TiB/Ti FGM with reduced cohesive gradation parameters (which may be achieved under different manufacturing conditions) could compare to that for the metal. Crack growth responses vary strongly with values of the exponent describing the volume fraction profile for the metal. The investigation also shows significant crack tunneling in the Ti metal SE(B) specimen. For the TiB/Ti FGM system, however, crack tunneling is pronounced only for a metal-rich specimen with relatively smaller cohesive gradation parameter for the metal.     

Simulation of ductile crack growth in thin aluminum panels using 3-D surface cohesive elements

This work describes the formulation and application of a 3-D, interface-cohesive finite element model to predict quasi-static, ductile crack extension in thin aluminum panels for mode I loading and growth. The fracture model comprises an initially zero thickness, interface element with constitutive response described by a nonlinear traction-separation relationship. Conventional volumetric finite elements model the nonlinear (elastic-plastic) response of background (bulk) material. The interface-cohesive elements undergo gradual decohesion between faces of the volumetric elements to create new traction free crack faces. The paper describes applications of the computational model to simulate crack extension in C(T) and M(T) panels made of a 2.3 mm thick, Al 2024-T3 alloy tested as part of the NASA-Langley Aging Aircraft program. Parameters of the cohesive fracture model (peak opening traction and local work of separation) are calibrated using measured load vs. outside surface crack extensions of high constraint (T-stress > 0) C(T) specimens. Analyses of low constraint M(T) specimens, having widths of 300 and 600 mm and various a/W ratios, demonstrate the capabilities of the calibrated model to predict measured loads and outside surface crack extensions. The models capture accurately the strong 3-D effects leading to various degrees of crack front tunneling in the C(T) and M(T) specimens. The predicted crack growth response shows rapid convergence with through-thickness mesh refinement. Adaptive load increment procedures to control the rate of decohesion in the interface elements leads to stable, rapidly converging iterations in the globally implicit solution procedures.     

Removing mesh bias in mixed-mode cohesive fracture simulation with stress recovery and domain integral

To remove mesh bias and provide an accurate crack path representation in mixed-mode investigation, a novel stress recovery technique is proposed in conjunction with a domain integral and element splits. Based on a domain integral and stress recovery technique, a maximum strain energy release rate is estimated to determine a crack path direction. Then, for a given crack path direction, continuum elements are split, and a cohesive surface element is adaptively inserted. One notes that the proposed stress recovery technique provides a more accurate stress field than a standard stress evaluation procedure. The proposed computational framework is verified and validated by solving mode-I and mixed-mode examples. Computational results demonstrate that the domain integral with the stress recovery accurately evaluates a crack path, even with a lower-quality mesh and under a biaxial stress state. Furthermore, the cohesive surface element approach, with the element split in conjunction with the stress recovery and the domain integral, predicts mixed-mode fracture behaviors while removing mesh bias in the crack path representation. Additionally, the condition numbers of stiffness matrices are within the same order of magnitude during cohesive fracture simulation.     

Analysis of the crack growth propagation process under mixed-mode loading

In the present paper, a computational model for crack growth analysis under Mode I/II conditions is formulated. The focus is on two issues – crack path simulation and fatigue life estimation. The finite element method is used together with the maximum principal stress criterion and the crack growth rate equation based on the equivalent stress intensity factor. To determine the mixed-mode stress intensity factors, quarter-point (Q-P) singular finite elements are employed. For verification purposes, a plate with crack emanating from the edge of a hole is examined. The crack path of the plate made of 2024 T3 Al Alloy is investigated experimentally and simulated by using the finite element method with the maximum tangential stress criterion. Then, the validation of the procedure is illustrated by applying the numerical evaluation of the curvilinear crack propagation in the polymethyl methacrylate (PMMA) beam and the Arcan specimen made of Al Alloy for which experimental results are available in the literature. In order to estimate fatigue life up to failure of the plate with crack emanating from the edge of a hole, the polynomial expression is evaluated for the equivalent stress intensity factor using values of stress intensity factors obtained from the finite element analysis. Additionally, the fatigue life up to failure of the Arcan specimen is analyzed for different loading angles and compared with experimental data. Excellent correlations between the computed and experimental results are obtained.     

A cohesive finite element formulation for modelling fracture and delamination in solids

In recent years, cohesive zone models have been employed to simulate fracture and delamination in solids. This paper presents in detail the formulation for incorporating cohesive zone models within the framework of a large deformation finite element procedure. A special Ritz-finite element technique is employed to control nodal instabilities that may arise when the cohesive elements experience material softening and lose their stress carrying capacity. A few simple problems are presented to validate the implementation of the cohesive element formulation and to demonstrate the robustness of the Ritz solution method. Finally, quasi-static crack growth along the interface in an adhesively bonded system is simulated employing the cohesive zone model. The crack growth resistance curves obtained from the simulations show trends similar to those observed in experimental studies     

Experimental and numerical analysis of delamination growth in double cantilever laminated beams

Delamination crack growth in laminated composites is investigated using experiments and finite element (FE) models. Tests are performed on cross-ply graphite/epoxy specimens under static conditions. The load-displacement response is monitored in the tested coupons along with crack length. The FE models employ a cohesive layer that is used to simulate the debonding and crack propagation. The cohesive parameters are calibrated from the experimental load-displacement curves. Crack growth and strain measurements are compared with those from the FE models. The predicted results from the FE models are in good agreement with the test results. The same modeling approach is also used to simulate crack propagation in the transverse direction of a notched laminate. The proposed FE analysis with cohesive layers can simplify fracture toughness assessment in multilayered specimens.     

Two-dimensional and three-dimensional finite element analysis of critical crack-tip-opening angle in 2024-T351 aluminum alloy at four thicknesses

Although the crack-tip-opening angle (CTOA) has been shown to be well suited for modeling stable crack growth and instability for thin-sheet aluminum alloys, its behavior for increasing thickness has not been thoroughly evaluated. This paper presents the results of two-dimensional and three-dimensional finite element based fracture analyses that were performed to characterize the critical CTOA for C(T) specimens made of 2024-T351 aluminum alloy with thicknesses of 2.3, 6.35, 12.7, and 25.4 mm. Computed CTOA, based on a center-node release methodology, was generally higher than experimentally determined surface CTOA measurements for the same thicknesses. For the C(T) specimens analyzed in this work, with the crack length and uncracked ligament generally greater than four times the specimen thickness, the generated global constraint factor data fell within those reported for M(T), DE(T), and SE(B) specimen configurations that also satisfy the above mentioned dimensional guideline. Strengthening the observation that, although critical CTOA is dependent on absolute material thickness, the CTOA characterization process is independent of specimen/loading types and specimen dimensions for cases satisfying this dimensional guideline. The CTOA values generated using 3D finite element analyses were used within a 2D finite element analysis framework to estimate plane strain core (PSC) height values for all evaluated thicknesses. The resulting PSC heights increased with increasing specimen thickness and appear to be on the order of specimen thickness.     

Crack growth resistance behavior of a functionally graded material: computational studies

This paper describes crack growth resistance simulation in a ceramic/metal functionally graded material (FGM) using a cohesive zone ahead of the crack front. The plasticity in the background (bulk) material follows J₂ flow theory with the flow properties determined by a volume fraction based, elastic-plastic model (extension of the original Tamura-Tomota-Ozawa model). A phenomenological, cohesive zone model with six material-dependent parameters (the cohesive energy densities and the peak cohesive tractions of the ceramic and metal phases, respectively, and two cohesive gradation parameters) describes the constitutive response of the cohesive zone. Crack growth occurs when the complete separation of the cohesive surfaces takes place. The crack growth resistance of the FGM is characterized by a rising J-integral with crack extension (averaged over the specimen thickness) computed using a domain integral (DI) formulation. The 3-D analyses are performed using WARP3D, a fracture mechanics research finite element code, which incorporates solid elements with graded elastic and plastic properties and interface-cohesive elements coupled with the functionally graded cohesive zone model. The paper describes applications of the cohesive zone model and the DI method to compute the J resistance curves for both single-edge notch bend, SE(B), and single-edge notch tension, SE(T), specimens having properties of a TiB/Ti FGM. The numerical results show that the TiB/Ti FGM exhibits significant crack growth resistance behavior when the crack grows from the ceramic-rich region into the metal-rich region. Under these conditions, the J-integral is generally higher than the cohesive energy density at the crack tip even when the background material response remains linearly elastic, which contrasts with the case for homogeneous materials wherein the J-integral equals the cohesive energy density for a quasi-statically growing crack.     

A study on the influence of cohesive zone interface element strength parameters on mixed mode behaviour

This paper presents a detailed study of the influence of maximum interfacial stress on interface element analyses for composites delamination. The development of the non-linear cohesive zone ahead of a crack tip is analysed with respect to length, stress distribution and mode ratio. The energy absorbed by interface elements is compared with the crack tip strain energy release rate from fracture mechanics analyses. These studies are performed initially on standard fracture toughness specimens, where mode-ratio is fixed by the applied displacement constraints. Results show close agreement with linear elastic fracture mechanics solutions. A simple ply drop specimen is then modelled, where the mode ratio is not constrained by the boundary conditions, and results are compared with the Virtual Crack Closure Technique. In this case maximum interfacial stress has a far greater influence on the numerical results, due to its significant influence on cohesive zone length, mode ratio and energy absorbed.     

A consistent partly cracked XFEM element for cohesive crack growth

Present extended finite element method (XFEM) elements for cohesive crack growth may often not be able to model equal stresses on both sides of the discontinuity when acting as a crack‐tip element. The authors have developed a new partly cracked XFEM element for cohesive crack growth with extra enrichments to the cracked elements. The extra enrichments are element side local and were developed by superposition of the standard nodal shape functions for the element and standard nodal shape functions for a sub‐triangle of the cracked element. With the extra enrichments, the crack‐tip element becomes capable of modelling variations in the discontinuous displacement field on both sides of the crack and hence also capable of modelling the case where equal stresses are present on each side of the crack. The enrichment was implemented for the 3‐node constant strain triangle (CST) and a standard algorithm was used to solve the non‐linear equations. The performance of the element is illustrated by modelling fracture mechanical benchmark tests. Investigations were carried out on the performance of the element for different crack lengths within one element. The results are compared with previously obtained XFEM results applying fully cracked XFEM elements, with computational results achieved using standard cohesive interface elements in a commercial code, and with experimental results. The suggested element performed well in the tests. Copyright © 2007 John Wiley & Sons, Ltd.     

Investigation of crack tunneling in ductile materials

Crack tunneling has been commonly observed in crack growth experiments on specimens made of ductile materials such as steel and aluminum alloys. The objective of this study is to investigate the crack tunneling phenomenon and study the effects of crack tunneling on the distribution of several mechanics parameters controlling ductile fracture. Three-dimensional (3D) elastic-plastic finite element analyses of stable tearing experiments involving tunneling fracture are carried out. Two model problems based on stable tearing experiments are considered. The first model problem involves a plate specimen containing a stationary, single-edge crack with a straight or tunneled crack front, under remote mode I loading. In the numerical analyses, the crack tip opening displacement, the von Mises effective stress, the mean stress, the stress constraint and the effective plastic strain around straight and tunneled crack fronts are obtained and compared. It is found that crack tunneling produces significant changes in the stress and deformation fields around the crack front. The second model problem involves a specimen containing a stably growing single-edge crack with a straight or tunneled crack front, under remote mode I loading. Crack growth events with a straight or tunneled crack front are simulated using the finite element method, and the effect of crack tunneling on the prediction of the load-crack-extension response based on a CTOD fracture criterion is investigated.     

Numerical prediction of creep crack growth in different geometries using simplified multiaxial void growth model

Abstract

This paper considers the prediction of creep crack growth (CCG) in different fracture mechanics geometries using finite element (FE) analysis based on a material independent simplified multiaxial failure strain model at the crack tip. The comparison is first made by modelling C(T) specimen tests under plane stress and plane strain conditions using creep properties of a C–Mn steel at 360°C. In addition, in order to examine CCG due to different geometries, a single edge notch specimen (SENT), centre cracked tension specimen (CCT) and three-point bending (3PB) specimen have been modelled and analysed. In all cases, it is found, depending on the geometry, that for this steel at low creep temperatures the applied load develops a high reference stress/yield stress (σ_ref/σ_y) ratio, which helps reduce constraint at the crack tip. The predictions are analysed under plane stress/plane strain loading conditions identifying the effects of geometry on cracking rates and the implications for predicting long term test or component failure times exceeding where the applied σ_ref/σ_y<<1.     

Fracture Analysis of Concrete Structural Components Accounting for Tension Softening Effect

This paper presents methodologies for fracture analysis of concrete structural components with and without considering tension softening effect. Stress intensity factor (SIF) is computed by using analytical approach and finite element analysis. In the analytical approach, SIF accounting for tension softening effect has been obtained as the difference of SIF obtained using linear elastic fracture mechanics (LEFM) principles and SIF due to closing pressure. Superposition principle has been used by accounting for non-linearity in incremental form. SIF due to crack closing force applied on the effective crack face inside the process zone has been computed using Green's function approach. In finite element analysis, the domain integral method has been used for computation of SIF. The domain integral method is used to calculate the strain energy release rate and SIF when a crack grows. Numerical studies have been conducted on notched 3-point bending concrete specimen with and without considering the cohesive stresses. It is observed from the studies that SIF obtained from the finite element analysis with and without considering the cohesive stresses is in good agreement with the corresponding analytical value. The effect of cohesive stress on SIF decreases with increase of crack length. Further, studies have been conducted on geometrically similar structures and observed that (i) the effect of cohesive stress on SIF is significant with increase of load for a particular crack length and (iii) SIF values decreases with increase of tensile strength for a particular crack length and load.     

XFEM simulation of stable crack growth using J–R curve under finite strain plasticity

In the present work, extended finite element method (XFEM) has been extended to simulate stable crack growth problems using J–R criterion under finite strain plasticity. In XFEM, a physical representation of crack is not required, and a crack is completely modeled by enrichment functions. The modeling of large deformation is performed using updated Lagrangian approach. The nonlinear equations obtained as a result of large deformation are solved by Newton–Raphson iterative method. Von-Mises yield criterion is used with isotropic hardening to model the finite strain plasticity. The elastic-predictor and plastic-corrector algorithm is employed for stress computation. Three problems i.e. crack growth in compact tension specimen; crack growth in triple point bend specimen and crack growth in bi-metallic triple point bend specimen are solved using J–R curve under plane stress condition to demonstrate the capability of XFEM in crack growth problems.