Numerical verification of stress intensity factor solution for clamped single edge notched tension (SENT) specimens

Stress intensity factor solutions for clamped single edge notched tension (SENT) specimens, including a closed‐form function recently proposed by Zhu along with a function by CanmetMATERIALS referenced in the British Standard BS 8571, have been assessed. Solutions for an SENT specimen with a daylight‐to‐width ratio of 10 have been compared with new finite element results generated in this work to assess their accuracies. The results of this study show that the polynomial proposed by Zhu differs by no more than 0.23% compared with the numerical results over the range of 0.2 ≤a/W ≤ 0.7. The CANMET function differs by no more than 0.69% over the same range.     

A model for calculating geometry factors for a mixed-mode I–II single edge notched tension specimen

In the present study, a novel approach is presented to obtain closed-form solutions for the geometry factors, which are used to determine the stress intensity factors for various configurations. A single edge notched tension specimen with an angled-crack is used as an example to demonstrate the applicability, simplicity and flexibility of the new approach. Several values for crack inclination angles, plate widths and crack lengths, including micro-cracks, are considered in the analysis. The new approach is validated through comparison with existing analytical and numerical solutions as well as experimental results.     

Stress intensity factor for a cracked specimen under compression

For a cracked specimen under compression, a set of complex stress functions is proposed and by using the boundary collocation method, the unknown coefficients of these complex stress functions are determined. Based on the calculation results of the boundary collocation method, the formulas of the stress intensity factor for a cracked specimen under compression are obtained, and by using these formulas, the influence of confining stress on stress intensity factor is analyzed.     

A direct method for calculating the stress intensity factor in BEM

The proposed algorithm employs singular crack tip elements in which the stress intensity factor appears as a degree of freedom. The additional degrees of freedom are compensated by constraint conditions which originate from imposing continuity across elements and a contour integration formula. The two benchmark problems indicate the proposed algorithm can accurately predict the stress intensity factor and the distribution of the primary and secondary variables in fracture problems.     

Finite element analysis of crack mouth opening displacement compliance in crack length evaluation for clamped single edge tension specimens

In the unloading compliance method developed for clamped single edge tension (SE(T)) specimens, six crack mouth opening displacement (CMOD)‐based compliance equations (i.e. a/W = f(BCE′)) were proposed for the crack length evaluation without clearly clarifying the corresponding predictive accuracies. In addition, the effective elastic modulus (E_e) that reflects the actual state of stress should also be introduced in the crack length evaluation for SE(T) specimens, because the actual state of stress in the remaining ligament of the test specimen is neither plane stress (E) nor plane strain (E′). In this study, two‐dimensional (2D) plane strain and three‐dimensional (3D) finite element analyses (FEAs) are carried out to investigate predictive accuracies of the six compliance equations. In both 2D and 3D FEA, specimens with a wide range of crack lengths and geometric configurations are included. For a given specimen, the value of E_e that presents the equivalent stress state in the remaining ligament is calculated on the basis of 3D FEA data. A set of formulae for the clamped SE(T) specimen is proposed that allows to evaluate E_e from the corresponding CMOD compliance. This approach is verified using numerical data. The observations of the numerical verification suggest that the use of E_e instead of E or E′ in CMOD‐based compliance equations markedly improves the accuracy of the predicted crack length for clamped SE(T) specimens.     

Stress intensity factors for corner cracks in single‐edge notch bend specimen by a three‐dimensional weight function method

A three‐dimensional (3D) weight function method is employed to calculate stress intensity factors of quarter‐elliptical corner cracks at a semi‐circular notch in the newly developed single‐edge notch bend specimen. Corner cracks covering a wide range of geometrical parameters under pin‐loading and remote tension conditions are analysed. Stress intensity factors from the 3D weight function analysis agree well with ABAQUS‐Franc3D finite element results. An engineering similitude approach previously developed for the half‐elliptical surface crack in single‐edge notch bend specimen is also applied to the present corner crack configuration. The results compare well with those from the present weight function analysis.     

Stress intensity factor solution for a semi-elliptical crack in an arbitrarily distributed stress field

An equation for the stress intensity factor (SIF) for semi-elliptical crack has been developed. It is based on the Newman-Raju's solution for the crack in a plate under bending or tension. The equation can be applied when a stress distribution is described by a power function. Using the approach outlined, the SIF for a surface crack in a T-butt welded connection has been estimated. The results obtained can be used in a fracture-mechanics-based fatigue analysis.     

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.     

Measuring residual stress and the resulting stress intensity factor in compact tension specimens

The measurement of residual stress through the remaining ligament of a compact tension specimen was studied. In the crack compliance method, a slot or notch is successively extended through the part, and the resulting strain is measured at an appropriate location. By using a finite element simulation of a specimen preloaded beyond yield, three techniques for determining the original residual stress from the measured strains were compared for accuracy and sensitivity to measurement errors. A common beam-bending approximation was substantially inaccurate. The series expansion method proved to be very versatile and accurate. The fracture mechanics approach could determine the stress intensity factor caused by the residual stresses with a very simple calculation. This approach offers the exciting possibility of determining the stress intensity factor prior to a fatigue or fracture test by measuring strains during the specimen preparation.     

Stress intensity factors for surface cracks in single‐edge notch bend specimen by a three‐dimensional weight function method

Stress intensity factors for half‐elliptical surface cracks at a semi‐circular notch in a recently developed single‐edge notch bend specimen are determined for a wide range of geometrical parameters using a three‐dimensional weight function method. Two load cases of pin loading and uniform remote tension are considered. The results are in good agreement with abaqus/franc3d finite element analysis. It is found that the Ziegler–Newman engineering similitude approach (programmed into the Fatigue Crack Growth Structural Analysis life‐prediction code) produces good results for a wide range in a/c ratios. Expressions by multi‐variable curve fitting to the weight function results are presented for easy engineering applications.     

Application of finite element method for determination of stress intensity factor and plastic zone geometry in an aluminium alloy sheet under uniaxial tension

High strength materials have gained prominence in the fields of aero-structures, space missiles, ship-building, pressure vessels etc. However, high strength materials are often characterised by low values of crack resistance or fracture toughness. Knowledge of stress intensity factor (SIF) is essential to predict their fracture toughness. SIF values can be obtained both theoretically and experimentally. Theoretical methods include analytical techniques as well as the finite element method (FEM). The former is used for simpler geometries and the latter for complicated geometries of engineering structures. The SIF as a function of crack size in an aluminium alloy 2024-T₃ (Al-4·5% Cu, 1·5% Mg, 0·6% Mn) sheet was determined by a computer method. These values were obtained directly from the stresses as well as indirectly from strain energy release rateG andJ integral. The results agree well with the normalised values obtained from an ASTM formula. The size and shape of the plastic zone at the crack tip have been determined as a function of nominal stress for a fixed crack length. The plastic zone has the form of two ellipsoids with their maximum spreads oriented around 69° to the crack axis.     

An efficient stress intensity factor solution scheme for corner cracks at holes under bivariant stressing

This paper summarizes the development of an efficient stress intensity factor (SIF) solution scheme applicable to a corner crack (CC) in a rectangular section subjected to arbitrary stressing on the crack plane. A general bivariant weight function (WF) formulation developed previously for a CC in a plate was extended to address a CC at a hole. Two supplemental algorithms were developed to achieve a substantial reduction in the computational time necessary for practical application. The new SIF solution scheme was validated by comparison with more than 180 three‐dimensional (3D) boundary element (BE) solutions.     

Influence of contact compliance on dynamic stress intensity factor variation during an impact test

Influence of the contact compliance on magnitude of oscillations of dynamic stress intensity factor (DSIF) during an impact test has been investigated numerically. It has been shown that although this magnitude is mainly determined by geometry of the specimen (namely, by combination of its relative length and relative crack depth), changes in contact stiffness affect the magnitude as well. For the range of specimen configurations and contact stiffnesses considered, the smallest DSIF oscillations were obtained for the impact specimen with relative length 5.5 and relative crack length 0.3.     

Theoretical and experimental determination of magnetic stress intensity factors of a crack in a double cantilever beam specimen

This paper presents the results of an experimental and theoretical investigation of the magnetic fracture behaviour of double cantilever beam (DCB) specimens. DCB tests were conducted on ferritic stainless steel SUS430 in the bore of a superconducting magnet at room temperature. A simple experimental technique using strain gauges was used to determine the stress intensity factor. The experiments show the predicted increase in the stress intensity factor with increasing magnetic field. The theoretical analysis is based on a beam‐plate theory for magnetoelastic interactions in a soft ferromagnetic material. Numerical calculations are carried out, and the stress intensity factor is obtained for several values of magnetic field. A comparison of the stress intensity factor is made between theory and experiment, and the agreement is good for the magnetic field considered.     

Stochastic critical stress intensity factor response of single edge notched laminated composite plate using displacement correlation method

Abstract

The second-order statistics of critical stress intensity factor (SIF) of single edge notched fiber reinforced composite plates with random system properties and subjected to uniaxial tensile loadings is investigated. This paper is an extension of reference (Lal and Kapania, 2013) by the present authors by considering more number of input random system parameters for higher accuracy. A C⁰ finite element method based on a higher-order shear deformation plate theory using displacement correlation method via isoparametric quarter point element is proposed for basic formulation. A stochastic finite element method using first-order perturbation technique and Monte Carlo simulation (MCS) is employed to examine the mean, coefficient of variance, and probability density faction of critical first mode SIF. The effect of different fiber orientations, crack length, plate thickness, a number of layers, and the lamination schemes with random system properties on the statistics of SIF of single edge crack laminated composite plate is evaluated. The tensile failure load is predicted using Hashin’s failure criteria. The present approach is validated with results available in literature and by employing independent MCS.     

Analysis of the stress intensity factor dependence with the crack velocity using a lattice model

In this work, the influence of crack propagation velocity in the stress intensity factor has been studied. The analysis is performed with a lattice method and a linear elastic constitutive model. Numerous researchers determined the relationship between the dynamic stress intensity factor and crack propagation velocity with experimental and analytical results. They showed that toughness increases asymptotically when the crack tip velocity is near to a critical. However, these methods are very complex and computationally expensive; furthermore, the model requires the use of several parameters that are not easily obtained. Moreover, its practical implementation is not always feasible. Hence, it is usually omitted. This paper aims to capture the physics of this complex problem with a simple fracture criterion. The selected criterion is based on the maximum principal strain implemented in a lattice model. The method used to calculate the stress intensity factor is validated with other numerical methods. The selected example is a finite 2D notched under mode I fracture and different loads rates. Results show that the proposed model captures the asymptotic behaviour of the SIF in function of crack speed, as reported in the aforementioned models.     

Free out-of-plane vibration of cracked curved beams on elastic foundation by estimating the stress intensity factor

Abstract

This paper is concerned with evaluating stress intensity factors (SIFs), for a cracked curved beam of rectangular cross section, applying an approach which allows us to estimate the strain energy release rate. The beam is located on an elastic foundation. The out-of-plane vibration of the beam is investigated. This approach requires an additional factor namely correction factor, on the basis of the energy release zone slope to approximate the SIFs. The initial curvature of the beam, however, adds some complication in using this factor. The second part of this study is investigating a numerical approach, namely differential quadrature element method (DQEM), to gain the natural frequencies of the cracked beam. This method is applied to show the application of the SIFs to calculate the compliance of the cracked section for modeling the crack. The other method which is used to obtain the natural frequencies is the finite element method (FEM). The results of these two methods are found to be in good agreement, which shows the precision of the stress intensity factors of the cracked beam.     

Weight functions and stress intensity factors for pin‐loaded single‐edge notch bend specimen

A recently developed pin‐loaded single‐edge notch bend specimen provides an alternative to the single‐edge notch tension specimen commonly used for small‐crack growth testing. In this paper, weight functions for pin‐loaded single‐edge notch bend specimen are derived by using two methods, the classical analytical weight function method and the newly developed numerical weight function complex variable Taylor series expansion method. Excellent agreement between the two methods is achieved. Based on these weight functions, accurate stress intensity factors for two load cases, that is, pin‐loading and Dugdale loading, which is required for plasticity‐induced crack‐closure analysis based on the strip‐yield model, are determined.     

On the numerical evaluation of the anvil force for accurate dynamic stress intensity factor determination

To evaluate precisely the dynamic fracture toughness of a brittle material in the tests with short time-to-fracture, both tup and anvil forces have to be known. Unfortunately, the anvil force is rarely registered by the standard impact testing equipment. The method for numerical evaluation of the support reactions by using registered tup force and the calculated specimen modal parameters is proposed. It assumes that the contact between the specimen and the supports can be described by the quasi-static Hertz’s theory. Both linearized and nonlinear relations for the specimen-support contact compliance are considered. The efficiency of the method has been verified by processing the results of two three-point-bend impact tests reported by Böhme and Kalthoff. The influence of the various calculation parameters (number of eigenmodes taken into account, time step size) and the specimen geometry (length of the specimen overhangs) on the accuracy of determination of the anvil force and dynamic stress intensity factor variation with time is investigated.     

XFEM analysis of the effects of voids,inclusions and other cracks on the dynamic stress intensity factor of a major crack

This paper is devoted to the extraction of the dynamic stress intensity factor (DSIF) for structures containing multiple discontinuities (cracks, voids and inclusions) by developing the extended finite element method (XFEM). In this method, four types of enrichment functions are used in the framework of the partition of unity to model interface discontinuity within the classical finite element method. In this procedure, elements that include a crack segment, the boundary of a void or the boundary of an inclusion are not required to conform to discontinuous edges. The DSIF is evaluated by the interaction integral. After the effectiveness of the implemented XFEM program is verified, the effects of voids, inclusions and other cracks on the DSIF of a stationary major crack are investigated by using XFEM. The results show that the dynamic effects have an influence on the path independence of the interaction integral, and these voids, inclusions and other cracks have a significant effect on the DSIF of the major crack.