Evaluating stress intensity factors of a surface crack in lubricated rolling contacts

The three-dimensional finite element method and the least-squares method were used to find the stress intensity factors (SIFs) of a surface crack in a lubricated roller. A steel roller on a rigid plane was modeled, in which a semi-elliptical surface crack is inclined at an angle ψ to the vertical axis. A distance c is set between the crack base and the roller edge. The results indicate that the mode-I SIF reaches the maximum value when the angle θ is equal to 0° (on the roller surface), and the mode-II SIF reaches the absolute maximum value when the angle θ is near or equal to 90° (inside the roller), where θ is the angle of the semi-ellipse from 0° to 180°. The influence of mode-III SIFs in this model is minor since they are much smaller than the mode-I and mode-II SIFs. The SIFs increase greatly when the crack location approaches the uncrowned edge. At this time, a crowned profile can be used to significantly reduce the SIFs near the roller edge. This revised version was published online in July 2006 with corrections to the Cover Date.     

Effect of Specimen Geometry on Stress Intensity Factors of Inclined Crack by Finite Element Method

A rectangular plate with inclined cracks of different crack lengths at different crack inclination angles under biaxial loading condition are being analyzed in mixed mode condition using finite element method (FEM) for the determination of stress intensity factors (SIFs). With increases of the width of the plate and the crack length ratio, SIF increases up to 45° of crack inclination angle and then decreases; maximum value is obtained at 45° of crack inclination angle. With the increasing value of size factor, the value of SIF starts decreasing. The accuracy of the results of the proposed method is validated by comparing with the previously obtained results by theoretical and experimental methods. The FEM results give significant result for the two-dimensional mixed mode loading conditions.     

Mechanics of two-stage crack growth in fretting fatigue

Motivated by experimental observations, we carry out a numerical analysis of the two-stage crack growth under fretting fatigue by using an efficient and accurate boundary element method. To start with, the variation of stress field during a loading cycle is analyzed. Various values of friction coefficient in the contact zone are considered, which is shown to considerably affect the stress field. Then, by assuming crack initiation to occur in the shear mode, a surface-breaking crack is introduced to the specimen at the location of highest shear-stress amplitude. The crack-tip stress intensity factors (SIFs) are calculated for various crack lengths and at various crack angles ranging from 25° to 45° about the contact surface. It is shown that, for a loading ratio of 0.5, the cyclic mode-II SIF amplitude decreases with increasing crack length, whilst its mean value increases. It suggests that the (first-stage) shear crack would sooner or later become dormant, or switch to another mode that can provide continuous support of growth. Then, the first-stage shear crack is manually kinked into a second-stage opening crack, and the follow-on driving force is analyzed. It is shown that the kinking event is only favored after the first-stage crack has grown to a certain length. The present study thus provides insights in the mechanics of two-stage crack growth that has been frequently observed in a typical dovetail joint under fretting fatigue. It also suggests an improved experimental setup to quantitatively investigate the fretting fatigue in dovetail joints.     

Three-dimensional stress intensity factors of a central square crack in a transversely isotropic cuboid with arbitrary material orientations

In this paper, we present the dual boundary element method (dual-BEM) or single-domain BEM to analyze the mixed three-dimensional (3D) stress intensity factors (SIFs) in a finite and transversely isotropic solid containing an internal square crack. The planes of both the transverse isotropy and square crack can be oriented arbitrarily with respect to a fixed global coordinate system. A set of four special nine-node quadrilateral elements are utilized to approximate the crack front as well as the outer boundary, and the mixed 3D SIFs are evaluated using the asymptotic relation between the SIFs and the relative crack opening displacements (COD) via the Barnett–Lothe tensor.Numerical examples are presented for a cracked cuboid which is transversely isotropic with any given orientation and is under a uniform vertical traction on its top and bottom surfaces. The square crack is located in the center of the cuboid but is oriented arbitrarily. Our results show that among the selected material and crack orientations, the mode-I SIF reaches the largest possible value when the material inclined angle ψ₁=45° and dig angle β₁=45°, and the crack inclined angle ψ₂=0° and dig angle β₂=0°. It is further observed that when the crack is oriented vertically or nearly vertically, the mode-I SIF becomes negative, indicating that the crack closes due to an overall compressive loading normal to the crack surface. Variation of the SIFs for modes II and III along the crack fronts also shows some interesting features for different combinations of the material and crack orientations.     

Experimental and Numerical Investigation of Mixed-Mode Interlaminar Fracture of Carbon-Polyester Laminated Woven Composite by Using Arcan Set-up

Composite materials are widely used in marine, aerospace and automobile industries. These materials are often subjected to defects and damages from both in-service and manufacturing process. Delamination is the most important of these defects. This paper reports investigation of mixed-mode fracture toughness in carbon–polyester composite by using numerical and experimental methods. All tests were performed by Arcan set-up. By changing the loading angle, α, from 0° to 90° at 15° intervals, mode-I, mixed-mode and mode-II fracture data were obtained. Correction factors for various conditions were obtained by using ABAQUS software. Effects of the crack length and the loading angle on fracture were also studied. The interaction j-integral method was used to separate the mixed–mode stress intensity factors at the crack tip under different loading conditions. As the result, it can be seen that the shearing mode interlaminar fracture toughness is larger than the opening mode interlaminar fracture toughness. This means that interlaminar cracked specimen is tougher in shear loading condition and weaker in tensile loading condition.     

Mode II stress intensity factors for central slant cracks with frictional surfaces in uniaxially compressed plates

The effect of crack surface friction on mode II stress intensity factor (SIF) of a central slant crack in a plate uniformly loaded in uniaxial compression is quantified. A previously developed two-dimensional finite element analysis was utilised after its modification to accommodate the friction between the crack surfaces. The plane strain state was assumed. A new numerical technique was devised to avoid the iteration procedures, which had to be employed due to the existence of frictional forces.

The crack inclination angle varied between zero and 75° measured from the horizontal direction. The coefficient of friction of the crack surfaces changed from zero to 1. In case of relatively sliding crack surfaces, mode II SIF existed. As is well known, the resulting mode II SIF decreased with increasing the coefficient of friction of the crack surfaces. Further, mode II SIF increased with increasing crack line inclination angle and then decreased after reaching a maximum value. The angle corresponding to that maximum SIF increased as the coefficient of friction of the crack surfaces increased.     

Determination of SIFs, crack-tip coordinates and crack angle of anisotropic materials

This paper investigates the accuracy of a numerical method incorporating an image-correlation experiment for finding the crack-tip coordinates, the axes of the measurement and the mixed-mode stress intensity factors (SIFs) of anisotropic materials. Finite element and experimental simulations in this paper indicate that the proposed linear search method incorporating Powell's method is considerably stable for finding the unknown crack-tip coordinates and measurement axes, even though the initial input is far away from the actual data. Moreover, the displacement field very near the crack tip is not necessary. In the experimental validation, the maximum SIF error of the image-correlation experiment is about 9%, which should be acceptable for the mixed-mode fracture problems.     

Energy release rates of bi-material interface crack including residual thermal stresses: Application of crack tip element method

Crack tip element method is applied to the formulation of the energy release rate associated with interfacial crack growth of laminates with residual thermal stresses using the Timochenko beam model. Special attention is paid to the energy release rates of double cantilever beam and mixed-mode bending tests of bi-material specimens, and mode-I and mode-II energy release rates are formulated including residual thermal stresses. The derived results are verified by the comparison to finite element analysis, and the effect of residual thermal stresses on the mode mixity of the double cantilever beam and mixed-mode bending tests is discussed.     

Numerical and experimental applications of the least-squares method to determine mode-II stress intensity factors for double fillet welded lap joints

Due to its simplicity, the least-squares method provides an efficient means to evaluate the stress intensity factors (SIFs) of cracks in complicated structures. This paper demonstrates numerical and experimental applications of the least-squares method to study mode-II SIFs of double fillet welded lap joints. In the numerical application, double fillet welded lap joints with different geometric parameters, including overlap length, weld leg size, plate thickness and plate length, were systematically analysed by the finite-element method combined with the least-squares method. The computed SIF results were then employed to develop the general formulae of the shearing fracture mode (mode-II) stress intensity factors. To validate the numerical results, three double fillet welded lap joint specimens were tested by a non-contact optical experiment using a common digital camera and a proposed image processing scheme. The measured crack shearing displacements near the crack tip were substituted into the least-squares procedure to obtain the SIFs of the specimens. The numerical and experimental results were in good agreement with the existing numerical results for double fillet welded lap joints provided in the handbook (Murakami, 1987). The non-contact optical experiment makes the field measurement of SIFs possible, which is very useful for fracture analysis or fatigue evaluation of structures like steel bridges, naval structures and offshore structures.     

An experimental investigation of mixed-mode creep crack growth in Jethete M152 at 550°C

Creep crack growth tests have been made on Jethete M152 at 550°C under initially mixed-mode (i.e. K_I/K_II ≈ 1.6) and mode-II crack tip conditions using compact mixed-mode (CMM) specimens. The results of these tests have been compared with mode-I data obtained from compact tension (CT) tests, using a C* approach. The correlation between the mode-I, mode-II and mixed-mode data is reasonably good. However, the scatter band is greater than that obtained from the mode-I results only. The results indicate that the C* approach, which has been used successfully in mode-I situations, may also be useful for predicting creep crack growth in more general situations.     

A fracture mechanics problem of a functionally graded layered structure with an arbitrarily oriented crack crossing the interface

In this paper, the fracture mechanics problem for an arbitrarily oriented crack crossing the interface in a functionally graded layered structure is investigated. The elastic modulus is assumed to be continuous at the interface, but its derivative may be discontinuous. Applying the superposition principle and Fourier integral transform, the stress fields and displacement fields are derived. A group of auxiliary functions defined in both layers are introduced and then the mixed-mode crack problem is turned into solving a group of singular integral equations. The mixed-mode stress intensity factors (SIFs) are obtained by solving the singular integral equations. The influences of the material nonhomogeneity parameter, normalized crack length and crack angle on the SIFs are investigated. It is found that the mixed-mode SIFs can be affected greatly by the crack angle. Moreover, the mixed-mode SIFs usually attain their extremum when the crack tips get to the interface during one crack moves from one layer into another layer. The present work may form the basic work for establishing a multi-layered fracture mechanics model of FGMs with an arbitrarily oriented crack and general mechanical properties.     

Stress intensity factor analysis of elliptical corner cracks in mechanical joints by weight function method

Mixed-mode stress intensity factors at the surface and deepest points of quarter elliptical corner cracks in mechanical joints such as bolted or riveted joints are analyzed by weight function method. The weight function method is an efficient technique to calculate the stress intensity factors using uncracked stress field. The extended form of the weight function method for 2D mixed-mode problems to 3D mixed-mode is presented and the accuracy due to the number of terms included in the weight function is examined. The effects of the amount of clearance between the hole and the bolt or rivet on the stress intensity factors are investigated, and the critical angle causing the mode I stress intensity factor to be maximized is determined by analyzing the variation of the stress intensity factors along incline angle of crack.     

Complex fracture parameters for an interface crack between twohardening materials: a photoelastic study

In this paper, complex stress intensity factors (SIFs) at an interface crack are determined for a range of applied loads, crack lengths and remote mode mixes using automated photoelasticity. The specimen geometries comprise epoxy resin and aluminium alloy halves bonded together, and are loaded in either compact tension in mixed‐mode conditions or in three‐point bend under mode I conditions. In the experiments, full‐field isochromatic data were obtained from the epoxy half using an established phase‐stepping technique. A reworked approach to the determination of the SIFs was developed by combining a least‐squares over‐deterministic method for fitting crack‐tip stress equations to the data and a weighting factor that ensures that only data in the singularity zone are used. For comparison, some of the specimens were tested using a linear‐elastic finite element (FE) analysis and/or by experiment using homogeneous test specimens. Excellent agreement between the experimental and numerical SIF moduli was achieved for remote mode I loadings. However, for good agreement to be made between the phase angle results requires an additional phase term to be added to the FE solution at each load to account for the development of a crack‐tip plastic zone. Further, results for the SIFs from remote mixed‐mode loadings of the compact tension specimen only have a meaningful interpretation in light of small‐scale yielding conditions. It is shown, qualitatively, that the experiments verify some of the predictions made in the literature of asymptotic behaviour at interface crack tips from results of elasto‐plastic FE analyses.     

Calculation of stress intensity factors by the force method

The force method is a simple and accurate technique for calculating stress intensity factors (SIFs) from finite element (FE) models, but it has been scarcely used. This paper shows three important advantages of the force method, which make it particularly attractive for designers and researchers. First, it can be employed without special singular quadratic finite elements at the crack tip. Actually, linear reduced integration elements may be used. Second, the force method can be applied to highly anisotropic materials without requiring knowledge of complicated elasticity relations for the stress field around the crack tip. Third, it can handle mixed-mode fracture problems.     

Mixed Mode Stress Intensity Factor Determination of Multiple Cracks in Hollow Circular Pipe

Failure of pressure vessels and piping due to high temperature applications occurs due to the formation of fatigue cracks caused by cyclic load. It is well known that, the consequences of collapses of pipes causing enormous disruption of daily life. Thus there is a need to design and manufacture the pipes with precision and care. The major cause of crack nucleation in pipes is due to corrosion and internal fluid pressure. The crack-tip stresses are determined using stress intensity factor (SIF). In the present work an attempt has been made to determine the SIF for multiple cracks in a circular pipe subjected to internal fluid pressure. Two surface cracks of same size were introduced at the inner wall of the tube. The crack depth ratio (a/t) ranging between 0.1 and 0.5 and crack aspect ratio (a/c) of 0.6 and 1.0 was considered. Internal fluid pressure of 100 MPa was applied at the inner surface of the pipe and the corresponding SIF was measured. SIF values were calculated with consideration of mode-II and mode-III fracture in order to predict the exact SIF. As available SIF solutions of cracked pipes are limited to mode-I fracture, present work presents the influence of additional influence of mode-II and mode-III fracture. It is observed that, as crack depth ratio increases, SIF also increases considerably for semi-circular cracks. Higher SIF values were observed at the crack surface region [S/S ₀ = ±1] compared to crack middle [S/S ₀ = 0] region. A crossover in SIF was noted at a crack depth ratio of 0.3. At higher crack depths, SIF values decrease at the crack surface region due to additional influence of mode-II and mode-III fracture. In contrast to semi-circular cracks, SIF values are higher at the crack surface region for semi-elliptic cracks irrespective of the crack depths.     

Dual boundary element method and finite element method for mixed‐mode crack propagation simulations in a cracked hollow shaft

Three‐dimensional mixed‐mode crack propagation simulations were performed by means of the dual boundary element method code BEASY and 2 finite element method‐based crack propagation codes: ZENCRACK (ZC) and CRACKTRACER3D (CT3D). The stress intensity factors (SIFs) along the front of an initial semielliptical crack, initiated from the external surface of a shaft, were calculated for 4 different load cases: bending, press fit, shear, and torsion. The methods used for the SIF assessment along the crack front were the J‐integral for BEASY and ZC and the quarter point element stress method for CT3D. Subsequently, crack propagation simulations were performed, with the crack growth rate evaluated by using Paris' law, calibrated for the material at stake (American Society for Testing and Materials A469 steel). The kink angles were evaluated by using the minimum strain energy density and maximum tangential stress criteria for BEASY, the maximum energy release rate and maximum tangential stress for ZC, and the maximum principal asymptotic stress for CT3D. The results obtained in terms of SIFs and crack propagation life show very good agreement among the 3 codes. Also, the shape of the propagated crack, which is significantly out‐of‐plane for the shear and torsion loading, matched very well.     

Stress intensity factor analysis for an interface crack between dissimilar isotropic materials under thermal stress

Thermal stresses, one of the main causes of interfacial failure between dissimilar materials, arise from different coefficients of linear thermal expansion. Two efficient numerical procedures in conjunction with the finite element method (FEM) for the stress intensity factor (SIF) analysis of interface cracks under thermal stresses are presented. The virtual crack extension method and the crack closure integral method are modified using the superposition method. The SIF analyses of some interface crack problems under mechanical and thermal loads are demonstrated. Very accurate mode separated SIFs are obtained using these methods.     

CTOA of a stable crack in a thin aluminum fracture specimen

A crack tip opening angle (CTOA) resistance curve was generated from the moiré interferometry data of thin single edge notched (SEN) and central notched (CN), 2024-T3 aluminum fracture specimens. This CTOA resistance curve, which has a steady state value of 6°, was then used to propagate the cracks in elastic–plastic finite element models of the CN specimen and a CN specimen with a simulated multiple site damage. The CTOA of curved crack growth in a biaxial fracture specimen scattered between 4° and 8° but the resultant crack tip opening displacement, which is the vector sum of the mode-I and the mode-II crack tip sliding displacement, remained a constant 0.18 mm. The CTOA of a rapidly propagating crack in 1.6 mm thick, 7075-T6 SEN specimens increased from 4.5° at a low-crack velocity to a constant 7° at the terminal crack velocity.     

Direct evaluation of stress intensity factors for curved cracks using Irwin's integral and XFEM with high‐order enrichment functions

This paper presents a comprehensive study on the use of Irwin's crack closure integral for direct evaluation of mixed‐mode stress intensity factors (SIFs) in curved crack problems, within the extended finite element method. The approach employs high‐order enrichment functions derived from the standard Williams asymptotic solution, and SIFs are computed in closed form without any special post‐processing requirements. Linear triangular elements are used to discretize the domain, and the crack curvature within an element is represented explicitly. An improved quadrature scheme using high‐order isoparametric mapping together with a generalized Duffy transformation is proposed to integrate singular fields in tip elements with curved cracks. Furthermore, because the Williams asymptotic solution is derived for straight cracks, an appropriate definition of the angle in the enrichment functions is presented and discussed. This contribution is an important extension of our previous work on straight cracks and illustrates the applicability of the SIF extraction method to curved cracks. The performance of the method is studied on several circular and parabolic arc crack benchmark examples. With two layers of elements enriched in the vicinity of the crack tip, striking accuracy, even on relatively coarse meshes, is obtained, and the method converges to the reference SIFs for the circular arc crack problem with mesh refinement. Furthermore, while the popular interaction integral (a variant of the J‐integral method) requires special auxiliary fields for curved cracks and also needs cracks to be sufficiently apart from each other in multicracks systems, the proposed approach shows none of those limitations. Copyright © 2017 John Wiley & Sons, Ltd.     

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.