Three-Dimensional Static and Dynamic Analysis of a Composite Cruciform Structure Subjected to Biaxial Loading: A Discontinuum Approach

A three-dimensional structural integrity analysis using the eXtended Finite Element Method (XFEM) is considered for simulating the crack behaviour of a chopped fibre-glass-reinforced polyester (CGRP) cruciform specimen subjected to a quasi-static tensile biaxial loading. This is the first time this problem is accomplished for computing the stress intensity factors (SIFs) produced in the biaxially loaded area of the cruciform specimen. A static crack analysis for the calculation of the mixed-mode SIFs is carried out. SIFs are calculated for infinite plates under biaxial loading as well as for the CGRP cruciform specimens in order to review the possible edge effects. A ratio relating the side of the central zone of the cruciform and the crack length is proposed. Additionally, the initiation and evolution of a three-dimensional crack are successfully simulated. Specific challenges such as the 3D crack initiation, based on a principal stress criterion, and its front propagation, in perpendicular to the principal stress direction, are conveniently addressed. No initial crack location is pre-defined and an unique crack is developed. Finally, computational outputs are compared with theoretical and experimental results validating the analysis.     

T应力对Ⅰ-Ⅱ复合型裂纹扩展的影响

利用最大周向正应力判据MTS重新分析研究了脆性破坏的Ⅰ-Ⅱ复合型裂纹扩展,其中考虑了平行于裂纹方向的非奇异项T应力。以平板中的斜裂纹处于双向受力为研究对象,通过两个方向力的不同组合以及裂纹与受力方向的夹角变换得到包括纯I型和纯II型在内的Ⅰ-Ⅱ复合型裂纹,分析了T应力对裂纹扩展方向以及断裂时的应力强度因子的影响,并将预测结果与现有的实验数据进行了比较。在此基础上,给出了不同T应力条件下通用的Ⅰ-Ⅱ复合型裂纹扩展条件,可用于给定几何试件的脆性断裂判定。分析结果表明:裂纹尖端非奇异项T应力对裂纹扩展的影响是不可忽略的,尤其是对II型断裂的影响更为明显。     

Applications of normal stress dominated cohesive zone models for mixed-mode crack simulation based on extended finite element methods

In conventional cohesive zone models the traction-separation law starts from zero load, so that the model cannot be applied to predict mixed-mode cracking. In the present work the cohesive zone model with a threshold is introduced and applied for simulating different mixed-mode cracks in combining with the extended finite element method. Computational results of cracked specimens show that the crack initiation and propagation under mixed-mode loading conditions can be characterized by the cohesive zone model for normal stress failure. The contribution of the shear stress is negligible. The maximum principal stress predicts crack direction accurately. Computations based on XFEM agree with known experiments very well. The shear stress becomes, however, important for uncracked specimens to catch the correct crack initiation angle. To study mixed-mode cracks one has to introduce a threshold into the cohesive law and to implement the new cohesive zone based on the fracture criterion. In monotonic loading cases it can be easily realized in the extended finite element formulation. For cyclic loading cases convergence of the inelastic computations can be critical.     

Study of mode I crack dynamic propagation behaviour and rock dynamic fracture toughness by using SCT specimens

To study crack dynamic propagation behaviour and rock dynamic fracture toughness, a single cleavage triangle (SCT) specimen was proposed in this paper. By using these specimens and a drop‐weight test system, impact experiments were conducted, and the crack propagation velocity and the fracture time were measured by using crack propagation gauges. To examine the effectiveness of the SCT specimen and to predict the test results, finite difference numerical models were established by using AUTODYN code, and the simulation results showed that the crack propagation path agrees with the test results, and crack arrest phenomena could happen. Meanwhile, by using these numerical models, the crack dynamic propagation mechanism was investigated. Finite element code ABAQUS was applied in the calculation of crack dynamic stress intensity factors (SIFs) based on specimen dimension and the loading curves measured, and the curves of crack dynamic SIFs versus time were obtained. The fracture toughness (including initiation toughness and propagation toughness) was determined according to the fracture time and crack speeds measured by crack propagation gauges. The results show that the SCT specimen is applicable to the study of crack dynamic propagation behaviour and fracture toughness, and in the process of crack propagation, the propagation toughness decreases with crack propagation velocity, and the crack arrest phenomena could happen. The critical SIF of an arrest crack (or arrest toughness) was higher than the crack propagation toughness but was lower than the initiation toughness.     

Numerical modeling of the nucleation of facets ahead of a primary crack under mode I + III loading

A numerical study of crack front segmentation under mode I + III loading is proposed. Facets initiation ahead of a parent crack is predicted through a tridimensional application of the coupled criterion. Crack initiation shape, orientation and spacing are determined for any mode mixity ratio by coupling a stress and an energy criterion using matched asymptotic expansions. The stress and the energy conditions are computed through a 3D finite element modeling of a periodic network of facets ahead of the parent crack. The initiation shape, loading and spacing of facets depend on the blunted parent crack tip radius. A good estimate of facet orientations is obtained based on the direction of maximum tensile stress. The facet shapes, determined using the stress isocontours, are qualitatively similar to those observed experimentally. The order of magnitude of numerical predictions of facets spacing is very close to experimental measurements.     

Computational modeling of mixed-mode fatigue crack growth using extended finite element methods

The extended finite element method (XFEM) combined with a cyclic cohesive zone model (CCZM) is discussed and implemented for analysis of fatigue crack propagation under mixed-mode loading conditions. Fatigue damage in elastic-plastic materials is described by a damage evolution equation in the cohesive zone model. Both the computational implementation and the CCZM are investigated based on the modified boundary layer formulation under mixed-mode loading conditions. Computational results confirm that the maximum principal stress criterion gives accurate predictions of crack direction in comparison with known experiments. Further popular multi-axial fatigue criteria are compared and discussed. Computations show that the Findley criterion agrees with tensile stress dominant failure and deviates from experiments for shear failure. Furthermore, the crack propagation rate under mixed mode loading has been investigated systematically. It is confirmed that the CCZM can agree with experiments.     

Comparison of the criteria for mixed mode brittle fracture based on the preinstability stress-strain field Part I: Slit and elliptical cracks under uniaxial tensile loading

Predictions for the angle of crack extension, critical load and unstable crack paths based on the criteria of maximum tangential stress (MTS), maximum tangential strain (MTSN) and strain energy density (SED) for angled slit and elliptical cracks under uniaxial tensile loading are compared. The tangential stress associated with the MTS criterion need not be a principal stress and a new approach to this criterion is suggested. A criterion based on maximum tangential principal stress (MTPS) is proposed. Predictions by these two criteria are compared. Some difficulties associated with the application of the SED criterion are indicated. A new basis, which permits a unification of all the criteria in respect of prediction of critical load, is suggested. Some of the results have been compared with data available in the literature.     

Stress intensity factors evaluation for through-transverse crack in slab track system under vehicle dynamic load

The stress intensity factors (SIFs) for through-transverse crack in the China Railway Track System (CRTS II) slab track system under vehicle dynamic load are evaluated in this paper. A coupled dynamic model of a half-vehicle and the slab track is presented in which the half-vehicle is treated as a 18-degree-of-freedom multi-body system. The slab track is modeled as two continuous Bernoulli–Euler beams supported by a series of elastic rectangle plates on a viscoelastic foundation. The model is applied to calculate the vertical and lateral dynamic wheel–rail forces. A three-dimensional finite element model of the slab track system is then established in which the through-transverse crack at the bottom of concrete base is created by using extended finite element method (XFEM). The wheel–rail forces obtained by the vehicle-track dynamics calculation are utilized as the inputs to finite element model, and then the values of dynamic SIFs at the crack-tip are extracted from the XFEM solution by domain based interaction integral approach. The influences of subgrade modulus, crack length, crack angle, friction coefficient between cracked surfaces, and friction coefficient between faces of concrete base and subgrade on dynamic SIFs are investigated in detail. The analysis indicates that the subgrade modulus, crack length and crack angle have great effects on dynamic SIFs at the crack-tip, while both of the friction coefficients have negligible influences on variations of dynamic SIFs. Also the statistical characteristics of varying SIFs due to random wheel–rail forces are studied and results reveal that the distributions of dynamic SIFs follow an approximately Gaussian distribution with different mean values and standard deviations. The numerical results obtained are very useful in the maintenance of the slab track system.     

Higher order tip enrichment of eXtended Finite Element Method in thermoelasticity

An eXtended Finite Element Method (XFEM) is presented that can accurately predict the stress intensity factors (SIFs) for thermoelastic cracks. The method uses higher order terms of the thermoelastic asymptotic crack tip fields to enrich the approximation space of the temperature and displacement fields in the vicinity of crack tips—away from the crack tip the step function is used. It is shown that improved accuracy is obtained by using the higher order crack tip enrichments and that the benefit of including such terms is greater for thermoelastic problems than for either purely elastic or steady state heat transfer problems. The computation of SIFs directly from the XFEM degrees of freedom and using the interaction integral is studied. Directly computed SIFs are shown to be significantly less accurate than those computed using the interaction integral. Furthermore, the numerical examples suggest that the directly computed SIFs do not converge to the exact SIFs values, but converge roughly to values near the exact result. Numerical simulations of straight cracks show that with the higher order enrichment scheme, the energy norm converges monotonically with increasing number of asymptotic enrichment terms and with decreasing element size. For curved crack there is no further increase in accuracy when more than four asymptotic enrichment terms are used and the numerical simulations indicate that the SIFs obtained directly from the XFEM degrees of freedom are inaccurate, while those obtained using the interaction integral remain accurate for small integration domains. It is recommended in general that at least four higher order terms of the asymptotic solution be used to enrich the temperature and displacement fields near the crack tips and that the J- or interaction integral should always be used to compute the SIFs.     

Simulation of Low Velocity Impact Induced Inter- and Intra-Laminar Damage of Composite Beams Based on XFEM

In this paper, the Inter-Fiber Fracture (IFF) criterion of Puck failure theory based on the eXtended Finite Element Method (XFEM) was implemented in ABAQUS code to predict the intra-laminar crack initiation of unidirectional (UD) composite laminate. The transverse crack path in the matrix can be simulated accurately by the presented method. After the crack initiation, the propagation of the crack is simulated by Cohesive Zoom Model (CZM), in which the displacement discontinuities and stress concentration caused by matrix crack is introduced into the finite element (FE) model. Combined with the usage of the enriched element interface, which can be used to simulate the inter-laminar delamination crack, the Low Velocity Impact (LVI) induced damage of UD composite laminate beam with a typical stacking of composite laminates [0₅/90₃]_S is studied. A complete crack initiation and propagation process was simulated and the numerical results obtained by the XFEM are consistent with the experimental results.     

A study of fatigue crack growth with changing loading direction

Round compact specimens made of 1070 steel were experimentally tested under cyclic loading for crack growth. The specimen was first subjected to Mode I loading. After the crack reached a certain length, the external loading direction was changed 50° from the original loading direction. Right after the change of the loading direction, the specimen experienced the combined Mode I/II loading condition. Following a short transient period, the fatigue crack was found to grow in the direction approximately perpendicular to the external loading direction, indicating the recovery of Mode I cracking. A recently developed approach was used to predict the cracking behavior of the specimens. Detailed elastic-plastic stress analysis was conducted using the finite element (FE) method. Both crack growth rate and cracking direction were predicted by employing a critical plane multiaxial fatigue criterion based on the stress-strain response outputted from the FE analysis. The predictions made by using the approach were in excellent agreement with the experimental observations in terms of both crack growth rate and cracking direction. The material constants used in the approach were obtained from testing smooth specimens for crack initiation.     

Mechanical behaviour and fracture evolution of coal specimens containing an over-excavated hole: Experimental study and numerical modelling

Utilising a series of mechanically over-excavated cavities along borehole is a novel technique for enhancing the permeability of soft coal seams and, consequently, gas drainage. The evolution of cracks induced by a wide range of pressure-relief around an over-excavated hole is intrinsically complex. In this study, the mechanical behaviour and crack evolution of the specimens containing an over-excavated hole under uniaxial compression loading were studied by experimental and 3D numerical simulation. The results indicated that the peak strength and elastic modulus of the specimens gradually decrease with increasing cavity diameter and length, which is also verified by the numerical simulation. The inclusion of cylindrical cavities in over-excavated holes results in reduced crack initiation stress and a greater degradation of peak stress and elastic modulus, despite having an equivalent volume to the ellipsoidal cavity. This is likely attributed to the difference in stress concentration between the cylindrical and ellipsoidal cavities. The crack propagation process can be classified into four stages based on the acoustic emission (AE) event counts, initial crack compaction, stable crack propagation, unstable crack propagation and post-peak failure stage. The two AE indices, rise angle and average frequency value, demonstrated that the failure is dominated by tensile crack and gradually transformed to shear crack. Stress redistribution is essential in the initiation and propagation of cracks. Tensile stress concentration leads to cracks forming at the top and bottom of the hole, which propagate in the direction of loading. Compressive stress concentration results in shear cracks forming at the left and right sides of the hole, which propagate diagonally. The failure pattern of the specimen is ultimately determined by a combination of tensile and mixed crack propagation. The experimental and numerical results contribute to a deeper understanding of the crack evolution mechanism of coal seams with over-excavated holes.     

A computational strategy for damage‐tolerant design of hollow shafts under mixed‐mode loading condition

Three‐dimensional numerical analyses, using the finite element method (FEM), have been adopted to simulate fatigue crack propagation in a hollow cylindrical specimen, under pure axial or combined axial‐torsion loading conditions. Specimens, made of Al alloys B95AT and D16T, have been experimentally tested under pure axial load and combined in‐phase constant amplitude axial and torsional loadings. The stress intensity factors (SIFs) have been calculated, according to the J‐integral approach, along the front of a part through crack, initiated in correspondence of the outer surface of a hollow cylindrical specimen. The crack path is evaluated by using the maximum energy release rate (MERR) criterion, whereas the Paris law is used to calculate crack growth rates. A numerical and experimental comparison of the results is presented, showing a good agreement in terms of crack growth rates and paths.     

The Effect of Surface Pit Treatment on Fretting Fatigue Crack Initiation

This paper analyses the effect of surface treatment on fretting fatigue specimen by numerical simulations using Finite Element Analysis. The processed specimen refers to artificially adding a cylindrical pit to its contact surface. Then, the contact radius between the pad and the specimen is controlled by adjusting the radius of the pit. The stress distribution and slip amplitude of the contact surface under different contact geometries are compared. The critical plane approach is used to predict the crack initiation life and to evaluate the effect of processed specimen on its fretting fatigue performance. Both crack initiation life and angle can be predicted by the critical plane approach. Ruiz parameter is used to consider the effect of contact slip. It is shown that the crack initial position is dependent on the tensile stress. For same type of model, three kinds of critical plane parameters and Ruiz method provide very similar position of crack initiation. Moreover, the improved sample is much safer than the flat-specimen.     

Experimental and finite element studies on mode I and mixed mode (I and II) stable crack growth—II. finite element analysis

Finite element studies are presented on both mode I and mixed mode stable crack growth under static loadings through an aluminium (D16AT) alloy. A COD based criterion has been used to predict the load-displacement diagram from initiation to instability. The theoretical predictions are compared with experimental results presented in Part I. Results on computed crack profiles, stress-strain distribution ahead of the crack tip, J integrals, J resistance curves, plastic zones, etc., are included. The study indicates that the load-displacement diagram associated with a mixed mode stable crack growth in a compact tension type of specimen geometry can be predicted reasonably accurately using the criterion of a fixed crack opening displacement at a finite distance behind the crack tip provided the crack is allowed to grow in the direction of initial growth in the finite element analysis. The crack assumes a more blunted profile in a mixed mode than in the mode I at all the stages of stable extension. The distributions of normal stress and strain in the direction perpendicular to the crack extension line, ahead of the current crack tip, have similarities between the mode I and mixed mode, irrespective of loading angle. Both the stress and strain levels increase as the crack extension proceeds. In a mixed mode, the J integral at the onset of crack extension is the lowest compared with the values at the later stages of the extension. Further, the tearing modulus associated with initial kinking is very small; it becomes close to the mode I values at the later stages. The tearing modulus remained approximately constant during the whole mode I stable growth and it had a similar trend subsequent to kinking in a mixed mode. The specific work of crack extension is zero as Δa → 0 and it increases gradually with Δa irrespective of the mode of loading; the actual variation depends on the loading angle. The plastic zone size grows as the stable extension progresses; the growth is approximately the maximum along the crack extension line.     

Effect of strength mis-match and dynamic loading on ductile fracture initiation

It has been well known that ductile fracture of steels is accelerated by triaxial stresses. The characteristics of ductile crack initiation in steels are evaluated quantitatively using a two-parameter criterion based on equivalent plastic strain and stress triaxiality.The present study focuses on the effects of geometrical discontinuity, strength mis-match, which can elevate plastic constraint due to heterogeneous plastic straining, and loading rate on the critical condition for ductile fracture initiation using a two-parameter criterion. Fracture initiation testing has been conducted under static and dynamic loading using circumferentially notched round-bar specimens. In order to evaluate the stress/strain state in the specimens, especially under dynamic loading, a thermal elastic-plastic dynamic finite element (FE) analysis considering the temperature rise due to plastic deformation has been carried out.The tensile tests on specimens with an undermatching interlayer showed that the relationship between the critical equivalent plastic strain to initiate ductile fracture and stress triaxiality was equivalent to that obtained on homogeneous specimens under static loading. Moreover, the two-parameter criterion for ductile fracture initiation is shown to be independent of the loading rate. It was demonstrated that the critical global strain to initiate ductile fracture in specimens with strength mis-match under various loading rate can be estimated based on the local criterion, that is two-parameter criterion obtained on homogeneous specimens under static tension, by mean of FE-analysis taken into account accurately both strength mis-match and dynamic loading effects on stress/strain behaviors.     

求解双材料界面裂纹应力强度因子的扩展有限元法

基于双材料界面裂纹尖端的基本解,构造扩展有限元法(eXtended Finite Element Methods, XFEM)裂尖单元结点的改进函数。有限元网格剖分不遵从材料界面,考虑3种类型的结点改进函数:弱不连续改进函数、Heaviside改进函数和裂尖改进函数,建立XFEM的位移模式,给出计算双材料界面裂纹应力强度因子(Stress Intensity Factors, SIFs)的相互作用积分方法。数值结果表明:XFEM无需遵从材料界面剖分网格,该文的方法能够准确评价双材料界面裂纹尖端的SIFs。     

梯度复合材料裂纹扩展路径和起裂载荷的有限元分析

为了模拟功能梯度材料(FGM)在工程应用中可能会出现的断裂问题并计算相应的开裂载荷,通过编写用户自定义UEL子程序将梯度扩展单元嵌入到ABAQUS软件中模拟功能梯度材料的物理场,并编写交互能量积分后处理子程序计算裂纹尖端的混合模式应力强度因子(SIF),采用最大周向应力准则编写子程序计算裂纹的偏转角,并模拟了裂纹扩展路径,计算了裂纹的起裂载荷。讨论了材料梯度参数对裂纹扩展路径以及起裂载荷的影响规律。通过与均匀材料的对比,验证了功能梯度材料断裂性能的优越性。研究表明:外载平行于梯度方向时,垂直梯度方向的初始裂纹朝着等效弹性模量小的方向扩展,且偏转角在梯度指数线性时出现峰值,并随着组分弹性模量比的增加而变大;当外载和初始裂纹均平行于梯度方向时,材料等效弹性模量和断裂韧性的增加或者梯度指数的减小都导致起裂载荷变大。     

Experimental studies on mixed‐mode dynamic fracture behaviour of aluminium alloy plates with narrow U‐notch

Mixed‐mode dynamic fracture behaviour of cast aluminium alloy ZL205A thin plates with narrow U‐notch was studied by split Hopkinson tensile bar apparatus. Specimens with different loading angles were designed to realize different fracture modes. The same loading condition was maintained during the tests. Recovery specimens show that crack propagates along the notch direction. Force–elongation relations show that with the loading angle increasing, the fracture force increases while the final elongation decreases. Deformation and fracture process was observed by a high‐speed camera. Displacement distribution around the crack was calculated through digital image correlation technique. Based on the photos and displacement results, initiation time of the crack was derived. Besides, two stress components (normal stress and shear stress) applied on the fracture surface were investigated. Results show that crack initiation stresses at different loading angles satisfy the ellipse equation. Pure mode I and II fracture stresses are 425.3 and 236.7 MPa, respectively. Furthermore, specific fracture energy of different specimens was calculated. The energy data vary with loading angle and located on an approximate upward parabolic curve. From the curve, the minimum specific fracture energy of the thin plate specimen is 42.0 kJ/m² under loading angle of 76.3°.     

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.