Fatigue fracture in plates in tension and out-of-plane shear

Straight cracks near a stiffening element, or curved cracks, in a pressurized shell can be subjected to out-of-plane tearing stresses in addition to normal tensile stresses due to the membrane stresses in the shell. To predict the rate of fatigue crack growth in such situations a theory and a crack growth rate correlation are needed. Such loadings are modelled as a superposition of plane stress tensile fracture (mode I) and Kirchhoff plate theory shearing fracture (mode 2). Finite element analyses using shell elements are used to compute the energy release rate and stress intensity factors associated with the loading. Three fatigue crack growth rate experiments were carried out on sheets of 2024-T3 aluminium alloy loaded in tension and torsion. The first set of experiments is constant amplitude fatigue crack growth tests. The second consists of experiments where crack closure is artificially eliminated to determine the rate of crack growth in the absence of crack face contact. The third is a set of constant stress intensity factor amplitude tests. The results all show that as the crack grows extensive crack face contact occurs, retarding crack growth. In the absence of crack face contact, however, the addition of out-of-plane shear loading increases the crack growth rate substantially.     

Modelling considerations for stress intensity factor solutions at pin‐loaded holes

This work summarizes investigations into stress intensity factor solutions for straight, through cracks at pin‐loaded holes in thin sheets. As shown in this work, several assumptions contribute to the fidelity of a stress intensity factor solution that includes the distribution of contact pressure on the pin‐hole interface, the friction coefficient at the pin‐hole interface, the crack initiation angle, and stiffness mismatch. These assumptions lead to higher or lower stress intensity factor solutions as demonstrated by results generated from advanced finite element analyses of the relevant geometries. Results shown here contribute to the development of a realistic and conservative set of assumptions for stress intensity factor solutions. Conclusions drawn from this work are applicable to cracks originating at pin‐loaded holes in plates and lugs.     

On bars with cracks

Within the framework of elementary strength-of-materials theories, bars with cracks subjected to tension or torsion are considered. Simple formulas for stress intensity factors are derived leading to results which are close to values obtained on the basis of the theory of elasticity.     

Buckling of thin‐walled cylindrical shells under axial compression

Lightweight thin‐walled cylindrical shells subjected to external loads are prone to buckling rather than strength failure. The buckling of an axially compressed shell is studied using analytical, numerical and semi‐empirical models. An analytical model is developed using the classical shell small deflection theory. A semi‐empirical model is obtained by employing experimental correction factors based on the available test data in the theoretical model. Numerical model is built using ANSYS finite element analysis code for the same shell. The comparison reveals that the analytical and numerical linear model results match closely with each other but are higher than the empirical values. To investigate this discrepancy, non‐linear buckling analyses with large deflection effect and geometric imperfections are carried out. These analyses show that the effects of non‐linearity and geometric imperfections are responsible for the mismatch between theoretical and experimental results. The effect of shell thickness, radius and length variation on buckling load and buckling mode has also been studied. Copyright © 2009 John Wiley & Sons, Ltd.     

Non‐planar mixed‐mode growth of initially straight‐fronted surface cracks,in cylindrical bars under tension,torsion and bending,using the symmetric Galerkin boundary element method‐finite element method alternating method

In this paper, the stress intensity factor (SIF) variations along an arbitrarily developing crack front, the non‐planar fatigue‐crack growth patterns, and the fatigue life of a round bar with an initially straight‐fronted surface crack, are studied by employing the 3D symmetric Galerkin boundary element method‐finite element method (SGBEM‐FEM) alternating method. Different loading cases, involving tension, bending and torsion of the bar, with different initial crack depths and different stress ratios in fatigue, are considered. By using the SGBEM‐FEM alternating method, the SIF variations along the evolving crack front are computed; the fatigue growth rates and directions of the non‐planar growths of the crack surface are predicted; the evolving fatigue‐crack growth patterns are simulated, and thus, the fatigue life estimations of the cracked round bar are made. The accuracy and reliability of the SGBEM‐FEM alternating method are verified by comparing the presently computed results to the empirical solutions of SIFs, as well as experimental data of fatigue crack growth, available in the open literature. It is shown that the current approach gives very accurate solutions of SIFs and simulations of fatigue crack growth during the entire crack propagation, with very little computational burden and human–labour cost. The characteristics of fatigue growth patterns of initially simple‐shaped cracks in the cylindrical bar under different Modes I, III and mixed‐mode types of loads are also discussed in detail.     

圆柱壳非圆大开孔的应力集中研究

本文以薄圆柱壳大开孔应力集中问题的理论解为基础,利用保角映射方法对圆柱壳非圆大开孔的应力集中问题进行研究。在给出映射函数的基础上,对承受不同外部载荷下开椭圆大孔圆柱壳孔边应力集中系数进行了数值计算,并与相应的圆柱壳小开孔理论解进行了比较。结果表明：大开孔解答更具有合理性。     

Cracked shells under skew-symmetric loading

In this paper, the general problem of a shell containing a through crack in one of the principal planes of curvature and under general skew-symmetric loading is considered. By employing a Reissner type shell theory which takes into account the effect of transverse shear strains, all boundary conditions on the crack surfaces are satisfied separately. Consequently, unlike those obtained from the classical shell theory, the angular distributions of the stress components around the crack tips are shown to be identical to the distributions obtained from the plane and anti-plane elasticity solutions. Extensive results are given for axially and circumferentially cracked cylindrical shells, spherical shells, and toroidal shells under uniform in-plane shearing, out of plane shearing, and torsion. Taking advantage of the fact that the problem is formulated for “specially” orthotropic materials, the effect of orthotropy on the results is also studied in some detail.     

Non‐linear analysis of shells with arbitrary evolving cracks using XFEM

A new formulation and numerical procedures are developed for the analysis of arbitrary crack propagation in shells using the extended finite element method. The method is valid for completely non‐linear problems. Through‐the‐thickness cracks in sandwich shells are considered. An exact shell kinematics is presented, and a new enrichment of the rotation field is proposed which satisfies the director inextensibility condition. To avoid locking, an enhanced strain formulation is proposed for the 4‐node cracked shell element. A finite strain plane stress constitutive model based on the logarithmic corotational rate is employed. A cohesive zone model is introduced which embodies the special characteristics of the shell kinematics. Stress intensity factors are calculated for selected problems and crack propagation problems are solved. Copyright © 2004 John Wiley & Sons, Ltd.     

Multiaxial fatigue behaviour of A356‐T6

Aluminum alloy A356‐T6 was subjected to fully reversed cyclic loading under tension, torsion and combined loading. Results indicate that endurance limits are governed by maximum principal stress. Fractography demonstrates long shear mode III propagation with multiple initiation sites under torsion. Under other loadings, fracture surfaces show unique initiation sites coincidental to defects and mode I crack propagation. Using the replica technique, it has been shown that the initiation life is negligible for fatigue lives close to 10⁶ cycles for combined loading. The natural crack growth rate has also been shown to be comparable to long cracks in similar materials.     

Modeling arbitrary crack propagation in coupled shell/solid structures with X‐FEM

In this paper, the extended finite element method (X‐FEM) formulation for the modeling of arbitrary crack propagation in coupled shell/solid structures is developed based on the large deformation continuum‐based (CB) shell theory. The main features of the new method are as follows: (1) different kinematic equations are derived for different fibers in CB shell elements, including the fibers enriched by shifted jump function or crack tip functions and the fibers cut into two segments by the crack surface or connecting with solid elements. So the crack tip can locate inside the element, and the crack surface is not necessarily perpendicular to the middle surface. (2) The enhanced CB shell element is developed to realize the seamless transition of crack propagation between shell and solid structures. (3) A revised interaction integral is used to calculate the stress intensity factor (SIF) for shells, which avoids that the auxiliary fields for cracks in Mindlin–Reissner plates cannot satisfy exactly the equilibrium equations. Several numerical examples, including the calculation of SIF for the cracked plate under uniform bending and crack propagation between solid and shell structures are presented to demonstrate the performance of the developed method. Copyright © 2015 John Wiley & Sons, Ltd.     

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.     

Fatigue crack growth of a welded tube–flange connection under bending and torsional loading

In this contribution the results of an experimental investigation into the fatigue crack growth of welded tube-to-plate specimens of steel StE 460 under bending, torsion, and combined in-phase and out-of-phase bending/torsion loading are presented. The tests were performed at stress ratios of R = −1 and R = 0. The residual stresses were reduced by thermal stress relief. The fatigue crack development is compared with the prediction on the crack growth rates of Paris. Individual stress intensity factors for the semielliptical surface cracks in the tube-flange specimens are approximated on a weight function analogy using the published solutions of other workers.     

Exact characteristic equations for free vibrations of thin orthotropic circular cylindrical shells

This paper presents an analytical procedure and closed-form vibration solutions with analytically determined coefficients for orthotropic circular cylindrical shells having classical boundary conditions. This analysis is based upon the Donnell-Mushtari shell theory. This is the simplest thin shell theory and its results for the lowest frequencies of a closed cylinder may not be as accurate. It is known that the exact procedure is complicated for orthotropic shells and this complexity has apparently prevented most researchers from getting results. Using the separation of variables method, the closed-form natural frequencies are successfully obtained in this work. They are found in a compact form. Moreover, the characteristics of the eigenvalues are examined. The exact solutions are validated through numerical comparisons with available solutions in literatures and the semi-analytical differential quadrature finite element method (S-DQFEM) solutions calculated by the authors.     

Crack closure effect on stress intensity factors of an axially and a circumferentially cracked cylindrical shell

Crack-face closure occurs when a shell or plate containing a through-the-thickness crack is subjected to a bending load, which leads to lower stress-intensity factors than those expected from non-closure assumption. This article presents a theoretical analysis of the effect of crack-face closure on the stress intensity factors of an axially and a circumferentially cracked cylindrical shell subjected to bending moment respectively. The presented analysis extends the shallow shell theories of Delale and Erdogan by incorporating the effect of crack-face closure. In keeping consistent with the shear deformation shell theory, crack-face closure is modeled by a line contact at the compressive edges of the crack face. The unknown contact force is computed by solving a mixed-boundary value problem iteratively, i.e. along the crack length, either the normal displacement of the crack face at the compressive edges is equal to zero or the contact pressure is equal to zero. The results show that the distribution of the contact force along the crack is generally nonuniform. Furthermore, it is found that, similar to the case of spherical shells, crack closure may occur over the full length or only some segments of the crack in cylindrical shells, depending on the geometry of the shell and the nature (direction) of applied bending load. Comparisons of the stress intensity factor ratios between the closure solutions and the non-closure solutions reveal that the crack-face closure influences significantly the magnitude of the stress intensity factors and it tends to reduce the maximum stress intensity factor. The closure effect of crack face on the stress intensity factors is highest when the shell radius becomes very large for a given crack length and shell thickness.     

Crack face pressure loading of semielliptical cracks located along the bore of a hole

The finite element-alternating method is used to obtain Mode I stress intensity factors for semielliptical surface cracks centered along the bore of a hole in a large plate of finite thickness. The variation in stress intensity factor around the crack perimeter is provided for two loading configurations: remote uniaxial tension and a crack face pressure described by a third order polynomial. It is suggested that the tabulated solutions for the crack face pressure loading represent “general” results which can be used with linear superposition to compute stress intensity factors for many other practical loading configurations. Two example problems describe application of the superposition procedure with the crack face pressure results.     

Analytical and numerical investigation of the stiffness matrix for edge‐cracked circular shafts

This paper examines two engineering methods of evaluating the stress intensity factors for cracked beams and bars subjected to a combined loading and proposes innovative formulations, as far as the circular cross section is concerned. Based on the definition of the stress intensity factors, the compliance matrix is determined as the inverse of the stiffness matrix, modelling the cracked section of a beam through a line‐spring approximation with interactive forces computed within fracture mechanics. A comparative evaluation of numerical predictions based on the proposed methods is also performed with methods available from the literature. Results for free vibration analyses of beams with transverse non‐propagating open cracks are presented and compared in order to estimate the accuracy and efficiency of the proposed methods, where a good agreement is generally found. More specifically, two different coupling effects are herein analysed for circular beams subjected to a combined bending, axial and shear loading, first, and a combined bending, shear and torsion loading, subsequently.     

A full‐discontinuous Galerkin formulation of nonlinear Kirchhoff–Love shells: elasto‐plastic finite deformations,parallel computation,and fracture applications

Because of its ability to take into account discontinuities, the discontinuous Galerkin (DG) method presents some advantages for modeling cracks initiation and propagation. This concept has been recently applied to three‐dimensional simulations and to elastic thin bodies. In this last case, the assumption of small elastic deformations before cracks initiation or propagation reduces drastically the applicability of the framework to a reduced number of materials. To remove this limitation, a full‐DG formulation of nonlinear Kirchhoff–Love shells is presented and is used in combination with an elasto‐plastic finite deformations model. The results obtained by this new formulation are in agreement with other continuum elasto‐plastic shell formulations. Then, this full‐DG formulation of Kirchhoff–Love shells is coupled with the cohesive zone model to perform thin body fracture simulations. As this method considers elasto‐plastic constitutive laws in combination with the cohesive model, accurate results compared with the experiments are found. In particular, the crack path and propagation rate of a blasted cylinder are shown to match experimental results. One of the main advantages of this framework is its ability to run in parallel with a high speed‐up factor, allowing the simulation of ultra fine meshes. Copyright © 2012 John Wiley & Sons, Ltd.     

STRESS INTENSITY FACTORS FOR SURFACE CRACKS AT A HOLE BY A THREE-DIMENSIONAL WEIGHT FUNCTION METHOD WITH STRESSES FROM THE FINITE ELEMENT METHOD

Stress intensity factors for semielliptical surface cracks emanating from a circular hole are reported in this paper. The three-dimensional weight function method with three-dimensional finite element solutions for the uncracked stress distribution is used for the analysis. Two different loading conditions, i.e. remote tension and wedge loading, are considered for a wide range of geometrical parameters. Both single and double surface cracks are studied and compared with other solutions available in the literature. Typical crack opening displacements are also provided.     

An assumed displacement hybrid finite element model for linear fracture mechanics

This paper deals with a procedure to calculate the elastic stress intensity factors for arbitrary-shaped cracks in plane stress and plane strain problems. An assumed displacement hybrid finite element model is employed wherein the unknowns in the final algebraic system of equations are the nodal displacements and the elastic stress intensity factors. Special elements, which contain proper singular displacement and stress fields, are used in a fixed region near the crack tip; and the interelement displacement compatibility is satisfied through the use of a Lagrangean multiplier technique. Numerical examples presented include: central as well as edge cracks in tension plates and a quarter-circular crack in a tension plate. Excellent correlations were obtained with available solutions in all the cases. A discussion on the convergence of the present solution is also included.     

A weight function method for mixed modes hole‐edge cracks

A weight function approach is proposed to calculate the stress intensity factor and crack opening displacement for cracks emanating from a circular hole in an infinite sheet subjected to mixed modes load. The weight function for a pure mode II hole‐edge crack is given in this paper. The stress intensity factors for a mixed modes hole‐edge crack are obtained by using the present mode II weight function and existing mode I Green (weight) function for a hole‐edge crack. Without complex derivation, the weight functions for a single hole‐edge crack and a centre crack in infinite sheets are used to study 2 unequal‐length hole‐edge cracks. The stress intensity factor and crack opening displacement obtained from the present weight function method are compared well with available results from literature and finite element analysis. Compared with the alternative methods, the present weight function approach is simple, accurate, efficient, and versatile in calculating the stress intensity factor and crack opening displacement.