A self-adaptive finite element approach for simulation of mixed-mode delamination using cohesive zone models

Oscillations observed in the load–displacement response of brittle interfaces modeled by cohesive zone elements in a quasi-static finite element framework are artifacts of the discretization. The typical limit points in this oscillatory path can be traced by application of path-following techniques, or avoided altogether by adequately refining the mesh until the standard iterative Newton–Raphson method becomes applicable. Both strategies however lead to an unacceptably high computational cost and a low efficiency, justifying the development of a process driven hierarchical extension of the discretization used in the process zone of a cohesive crack. A self-adaptive enrichment scheme within individual cohesive zone elements driven by the physics governing the problem, is an efficient solution that does not require further mesh refinements. A two-dimensional mixed-mode example in a general framework with an irreversible cohesive zone law shows that an enriched formulation restores the smoothness of the solution in structures that are discretized in a relatively coarse manner.     

Instability during cohesive zone growth

Tensile microcracking of quasi-brittle materials is studied by means of micromechanics, based on (i) an elasto-damaging cohesive zone model accounting for cohesive softening and (ii) a dilute distribution of non-interacting microcracks of uniform orientation and size. Considering virgin microcracks (initially without cohesive zones), macroscopic tensile load increase results in growth of cohesive zones ahead of stationary (non-propagating) cracks and, subsequently, in crack propagation which, notably, will be encountered before the cohesive zones are fully developed i.e. onset of instable cohesive zone growth will be encountered at a load level (i) at which tractions are still transmitted across the inner edges of the cohesive zones and (ii) at which the separation at the inner edges of the cohesive zones is smaller than its critical value. Focusing on onset of instable cohesive zone growth, the chosen approach allows for accessing quantities characterizing the stability limit (e.g., the intensity of the macroscopic loading and the opening at the inner edges of the cohesive zones), without raising the need for non-linear Finite Element analyses. It is shown that the tensile macrostrength of materials containing virgin microcracks is larger than the one related to cracks with already initially fully developed cohesive zones, and related strength differences are quantified for a wide class of cohesive softening behavior. The proposed model is validated by comparing model predictions with an exact solution (available for the special case of constant cohesive tractions) and with results from reliable Finite Element analyses. The paper will be of interest for engineers involved in testing and/or in modeling of quasi-brittle media including cementitious materials and rock.     

An engineering solution for mesh size effects in the simulation of delamination using cohesive zone models

A methodology to determine the constitutive parameters for the simulation of progressive delamination is proposed. The procedure accounts for the size of a cohesive finite element and the length of the cohesive zone to ensure the correct dissipation of energy. In addition, a closed-form expression for estimating the minimum penalty stiffness necessary for the constitutive equation of a cohesive finite element is presented. It is shown that the resulting constitutive law allows the use of coarser finite element meshes than is usually admissible, which renders the analysis of large-scale progressive delamination problems computationally tractable.     

Discrete cohesive zone model for mixed-mode fracture using finite element analysis

The discrete cohesive zone model (DCZM) is implemented using the finite element (FE) method to simulate fracture initiation and subsequent growth when material non-linear effects are significant. Different from the widely used continuum cohesive zone model (CCZM) where the cohesive zone model is implemented within continuum type elements and the cohesive law is applied at each integral point, DCZM uses rod type elements and applies the cohesive law as the rod internal force vs. nodal separation (or rod elongation). These rod elements have the provision of being represented as spring type elements and this is what is considered in the present paper. A series of 1D interface elements was placed between node pairs along the intended fracture path to simulate fracture initiation and growth. Dummy nodes were introduced within the interface element to extract information regarding the mesh size and the crack path orientation. To illustrate the DCZM, three popular fracture test configurations were examined. For pure mode I, the double cantilever beam configuration, using both uniform and biased meshes were analyzed and the results show that the DCZM is not sensitive to the mesh size. Results also show that DCZM is not sensitive to the loading increment, either. Next, the end notched flexure for pure mode II and, the mixed-mode bending were studied to further investigate the approach. No convergence difficulty was encountered during the crack growth analyses. Therefore, the proposed DCZM approach is a simple but promising tool in analyzing very general two-dimensional crack growth problems. This approach has been implemented in the commercial FEA software ABAQUS^® using a user defined subroutine and should be very useful in performing structural integrity analysis of cracked structures by engineers using ABAQUS^®.     

Accurate simulation of delamination growth under mixed-mode loading using cohesive elements: Definition of interlaminar strengths and elastic stiffness

A methodology for predicting accurately the propagation of delamination under mixed-mode fracture with cohesive elements is proposed. It is shown that changes in the local mode ratio during the evolution of damage under mixed-mode loading can cause errors in the determination of the energy dissipation and result in inaccurate predictions of the global load–displacement response – even under conditions where, according to Linear Elastic Fracture Mechanics, the global mode ratio is constant. To address this difficulty, relations between the interlaminar strengths and the penalty stiffness are proposed which ensure a correct energy dissipation when delamination propagates. The validity of the proposed methodology is demonstrated for different mode ratios by comparison with the corresponding analytical solutions.     

Modeling of delamination using a discretized cohesive zone and damage formulation

Delamination initiation and growth are analyzed by using a discrete cohesive crack model. The delamination is constrained to grow along a tied interface. The model is derived by postulating the existence of a maximum load surface which limits the adhesive forces in the process zone of the crack. The size of this maximum load surface is made dependent on the amount of dissipated crack opening work, such that the maximum load surface shrinks to zero as a predefined amount of work is consumed. A damage formulation is used to reduce the adhesive forces. Mode I, II and III loading or any combined loading is possible. An analytical solution is obtained for a single mode opening and the implications of this result on the governing equations is discussed. The delamination model is implemented in the finite element code LS-DYNA and simulation results are shown to be in agreement with experimental results.     

Simulation of mixed-mode I/III stable tearing crack growth events using the cohesive zone model approach

A cohesive zone model (CZM) approach is applied to simulate mixed-mode I/III stable tearing crack growth events in specimens made of 6061-T6 aluminum alloy and GM 6208 steel. The materials are treated as elastic–plastic following the \(J_{2}\) flow theory of plasticity, and the triangular cohesive law is employed to describe the traction-separation relation in the cohesive zone ahead of crack front. A hybrid numerical/experimental approach is employed in simulations using 3D finite element method. For each material, CZM parameter values are chosen by matching simulation prediction with experimental measurement (Yan et al. in Int J Fract 144:297–321, 2009), of the crack extension-time curve for the \(30^{\circ }\) mixed-mode I/III stable tearing crack growth test. With the same sets of CZM parameter values, simulations are performed for the \(60^{\circ }\) loading cases. Good agreements are reached between simulation predictions of the crack extension-time curve and experimental results. The variations of CTOD with crack extension are calculated from CZM simulations under both \(30^{\circ }\) and \(60^{\circ }\) mixed-mode I/III conditions for the aluminum alloy and steel respectively. The predictions agree well with experimental measurements (Yan et al. in Int J Fract 144:297–321, 2009). The findings of the current study demonstrate the applicability of the CZM approach in mixed-mode I/III stable tearing simulations and reaffirm the connection between CTOD and CZM based simulation approaches shown previously for mixed-mode I/II crack growth events.     

The proper generalized decomposition for the simulation of delamination using cohesive zone model

The use of cohesive zone models is an efficient way to treat the damage especially when the crack path is known a priori. It is the case in the modeling of delamination in composite laminates. However, the simulations using cohesive zone models are expensive in a computational point of view. When using implicit time integration or when solving static problems, the non‐linearity related to the cohesive model requires many iteration before reaching convergence. In explicit approaches, an important number of iterations are also needed because of the time step stability condition. In this article, a new approach based on a separated representation of the solution is proposed. The proper generalized decomposition is used to build the solution. This technique coupled with a cohesive zone model allows a significant reduction of the computational cost. The results approximated with the proper generalized decomposition are very close the ones obtained using the classical finite element approach. Copyright © 2014 John Wiley & Sons, Ltd.     

A damage model for simulation of mixed-mode delamination growth

An interface element capable of modelling delamination progression under mixed-mode loading is presented. The kinematics of the element are based on the concept of regularised displacement discontinuity. This concept allows the interfacial constitutive equations to be formulated in terms of the traction vector of the interface and the corresponding displacement discontinuity. The decohesion within the interface, corresponding to delamination progression, is accomplished by assigning a non-associative perfectly plastic material model including isotropic damage to the interface element. All parameters of the model can be determined from experimental material data. Damage initiation is calibrated against the interlaminar fracture stresses whereas the evolution of damage is calibrated against the mixed-mode fracture toughness. The interface element has been implemented in a finite element code and results for simulations of standard fracture toughness tests are shown. The results display the applicability of the proposed model and the calibration procedure.     

An enriched cohesive zone model for delamination in brittle interfaces

Application of standard cohesive zone models in a finite element framework to simulate delamination in brittle interfaces may trigger non‐smooth load–displacement responses that lead to the failure of iterative solution procedures. This non‐smoothness is an artifact of the discretization; and hence it can be avoided by sufficiently refining the mesh leading to unacceptably high computational costs and a low efficiency and robustness. In this paper, a process‐driven hierarchical extension is proposed to enrich the separation approximation in the process zone of a cohesive crack. Some numerical examples show that instead of mesh refinement, a more efficient enriched formulation can be used to prevent a non‐smooth solution. Copyright © 2009 John Wiley & Sons, Ltd.     

Aspects of cohesive zone models and crack growth in rate-dependent materials

Various mathematical aspects of cohesive zone models are explored in detail with an emphasis on the asymptotic behavior at each end of the cohesive zone. The formulation presented is quite general in that a wide range of cohesive zone material behaviors can be considered, including time dependent ones, and the zone and crack can be stationary or propagating. Certain complexities arise when the zone is viscous and is propagating. This case is considered in detail with explicit asymptotic and numerical results presented for a power-law creep behavior.     

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.     

Mode I fracture of adhesive joints using tailored cohesive zone models

Cohesive zone models are explored in order to study cleavage fracture in adhesive bonded joints. A mode I cohesive model is defined which correlates the tensile traction and the displacement jump (crack faces opening) along the fracture process zone. In order to determine the traction-separation relation, the main fracture parameters, namely the cohesive strength and the fracture energy, as well as its shape, must be specified. However, owing to the difficulties associated to the direct measurement of the fracture parameters, very often they are obtained by comparing a measured fracture property with numerical predictions based on an idealized traction separation relation. Likewise in this paper the cohesive strength of an adhesive layer sandwiched between elastic substrates is adjusted to achieve a match between simulations and experiments. To this aim, the fracture energy and the load-displacement curve are adopted as input in the simulations. In order to assess whether or not the shape of the cohesive model may have an influence on the results, three representative cohesive zone models have been investigated, i.e. exponential, bilinear and trapezoidal. A good agreement between experiments and simulations has been generally observed. However, a slight difference in predicting the loads for damage onset has been found using the different cohesive models.     

On damage accumulations in the cyclic cohesive zone model for XFEM analysis of mixed-mode fatigue crack growth

Predicting mixed-mode fatigue crack propagation is an important and troublesome issue in structure assessment for decades. In the present paper an extended finite element method (XFEM) combined with a new cyclic cohesive zone model (CCZM) is introduced for simulating fatigue crack propagation under mixed-mode loading conditions, which has been implemented in the commercial general purpose software ABAQUS. The algorithm allows introducing a new crack surface at arbitrary locations and directions in a finite element mesh, without re-meshing. The cyclic cohesive zone model is based on the known S–N curves and Goodman diagram for metallic materials and validated by uniaxial tension results. Furthermore, the sensitivity of the model parameter is investigated for mixed-mode fatigue. The virtual crack closure technique has been extended to the cohesive zone model and proposed to calculate the energy release rate for the generalized Paris’ law. Finally, the crack propagation rate and direction under mixed-mode fatigue loading conditions are studied.     

Constitutive models for cohesive zones in mixed-mode fracture of plain concrete

Discrete mixed-mode fracture (modes I and II) of plain concrete is investigated using a coupled and an uncoupled cohesive zone constitutive model in a finite element context. Fracture surfaces are confined to inter-element boundaries that are not necessarily coincident with the actual fracture surfaces. For this reason, traction components on the cohesive zone do not correspond to actual values either. In this work is demonstrated that only the coupled model is able to cope with these spurious traction components, that must decrease with crack opening. It is shown also that, in this regard, the key variable is the plastic potential adopted in the integration of tractions. Three mixed-mode fracture examples were tested in this work: a three-point single-edge notched beam, double-edge notched plates under variable lateral and normal deformation and four-point double-edge notched beams. A good fitting with experiments was obtained only for the coupled model. Mode II parameters can change in a large range without noticeable change in results, at least in the tested examples.     

A cohesive zone model for predicting delamination suppression in z-pinned laminates

This paper presents a cohesive zone model based finite element analysis of delamination resistance of z-pin reinforced double cantilever beam (DCB). The main difference between this and existing cohesive zone models is that each z-pin bridging force is governed by a traction-separation law derived from a meso-mechanical model of the pin pullout process, which is independent of the fracture toughness of unreinforced laminate. Therefore, two different traction-separation laws are used: one representing the toughness of unreinforced laminate and the other the enhanced delamination toughness owing to the pin bridging action. This approach can account for the large scale bridging effect and avoid using concentrated pin forces, thus removing the mesh dependency and permitting more accurate analysis solution. Computations were performed using a simplified unit strip model. Predicted delamination growth and load vs. displacement relation are in excellent agreement with the prediction by a complete model, and both models are in good agreement with test measured load vs. displacement relation. For a pinned DCB specimen, the unit strip model can reduce the computing time by 85%.