Consideration of the mechanical behaviour of small fatigue cracks

The mechanical behaviour of small fatigue cracks is investigated for a low, medium and high strength material. At first an elastic consideration is performed which give a good impression how the stress fields change with crack size. In part 2 a full elastic-plastic analysis of short cracks is performed using a new numerical scheme to simulate the growth of shear bands emanating from the crack tip. The influence of material and loading paramters as well as of the crack size on the plastic crack tip opening displacement is discussed. It is also investigated how it is possible to get a conservative estimate of the crack tip deformation at small cracks.     

Crack tip displacements of microstructurally small cracks in 316L steel and their dependence on crystallographic orientations of grains

The paper presents an analysis of the effect of the grain orientations on a short Stage I surface crack in a 316L stainless steel. The analysis is based on a plane‐strain finite element crystal plasticity model. The model consists of 212 randomly shaped, sized and oriented grains that is loaded monotonically in uniaxial tension to a maximum load of 1.12R_p0.2 (280 MPa). The influence of random grain structure on a crack is assessed by calculating the crack tip opening (CTOD) and sliding displacements (CTSD) for single crystal and polycrystal models, considering also different crystallographic orientations. In the single crystal case the CTOD and CTSD may differ by more than one order of magnitude. Near the crack tip slip is activated on all the slip planes whereby only two are active in the rest of the model. The maximum CTOD is directly related to the largest Schmid factors. For the more complex polycrystal cases it is shown that certain crystallographic orientations result in a cluster of soft grains around the crack‐containing grain. In these cases the crack tip can become a part of the localized strain, resulting in a large CTOD value. This effect, resulting from the overall grain orientations and sizes, can have a greater impact on the CTOD than the local grain orientation. On the other hand, when a localized soft response is formed away from the crack, the localized strain does not affect the crack tip directly, resulting in a small CTOD value. The resulting difference in CTOD can be up to a factor of 4, depending upon the crystallographic set. Grains as far as 6xCracklength significantly influence the crack tip parameters. It was also found that among grains with favourable orientation the CTOD increased with the size of such a grain. Finally, a significant change in CTOD and CTSD was observed when extending the crack into the second grain and placing it in the primary or the conjugate slip plane.     

Experimental investigation of crack growth direction in multiple cracks

In this paper, the interaction between multiple cracks in crack growth direction is studied in an aluminium alloy under static and fatigue loading. Self similar as well as non‐self‐similar crack growth has been observed which depends on the relative crack positions defined by crack offset distance and crack tip distance. On the basis of experimental observations, the criterion for crack coalescence and crack growth direction are expressed in terms of the crack positions defined by crack offset and crack tip distances. The criterion presented in this study can be used to determine the limiting value of crack tip and crack offset distance and to determine the mode in which cracks coalesce during their growth process. Experimental results and crack interaction criterion presented under various crack positions and size conditions could be used to derive a new evaluation method of crack growth in multiple crack geometry.     

Cyclic crystal plasticity analyses of stationary, microstructurally small surface cracks in ductile single phase polycrystals

ABSTRACT This paper explores the effects of microstructural heterogeneity on the cyclic crack tip opening and sliding displacements for stationary, microstructurally small transgranular surface cracks in a single phase metallic polycrystal using planar double slip crystal plasticity computations. Crack tip displacements are examined under plane strain conditions for stationary cracks of different lengths relative to grain size as a function of the applied nominal strain amplitude for tension-compression and cyclic shear. Nominal strain amplitudes range from well below to slightly above the nominal cyclic yield strength for each type of loading condition. Results indicate the complex nature of the crack tip sliding and opening displacements as functions of nominal strain amplitude and orientation of the nearest neighbour grains, the influence of the free surface in promoting the cyclic opening displacement even for cracks in the first surface grain, the rather restricted limits of applicability of linear elastic fracture mechanics, and very interesting crack tip plasticity effects which include crack tip displacement ratcheting or progressive accumulation, even for completely reversed, proportional applied loading. Results are compared for cases with and without crack face friction.     

Evaluation of energy release rate-based approaches for predicting delamination growth in laminated composites

A variety of energy release rate-based approaches are evaluated for their accuracy in predicting delamination growth in unidirectional and multidirectional laminated composites. To this end, a large number of unidirectional and multidirectional laminates were tested in different bending and tension configurations. In all cases, the critical energy release rate was determined from the tests in the most accurate way possible, such as by compliance calibration or the area method of data reduction. The mode mix from the tests, however, was determined by a variety of different approaches. These data were then examined to determine whether any of the approaches yielded the result that toughness was a single-valued function of mode mix. That is, for an approach to have accurate predictive capabilities, different test geometries that are predicted to be at the same mode mix must display the same toughness. It was found that variously proposed singular field-based mode mix definitions, such as the =0 approach or basing energy release rate components on a finite amount of crack extension, had relatively poor predictive capabilities. Conversely, an approach that used a previously developed crack tip element analysis and which decomposed the total energy release rate into non-classical components was found to have excellent predictive capabilities. It is postulated that this approach is more appropriate for many present-day laminated composites.     

Fatigue growth prediction of center slant crack in rectangular plate

This paper presents a numerical prediction model of mixed‐mode crack fatigue growth in a plane elastic plate. It involves a formulations of fatigue growth of multiple crack tips under mixed‐mode loading and a displacement discontinuity method with crack‐tip elements (a boundary element method) proposed recently by Yan is extended to analyse the fatigue growth process of multiple crack tips. Due to an intrinsic feature of the boundary element method, a general growth problem of multiple cracks can be solved in a single‐region formulation. In the numerical simulation, for each increment of crack extension, remeshing of existing boundaries is not necessary. Crack extension is conveniently modelled by adding new boundary elements on the incremental crack extension to the previous crack boundaries. At the same time, the element characters of some related elements are adjusted according to the manner in which the boundary element method is implemented. As an example, the present numerical approach is used to analyse the fatigue growth of a centre slant crack in a rectangular plate. The numerical results illustrate the validation of the numerical prediction model and can reveal the effect of the geometry of the cracked plate on the fatigue growth.     

Analysis of crack tip plasticity for microstructurally small cracks using crystal plasticity theory

Crack tip plastic zone sizes and crack tip opening displacements (CTOD) for stationary microstructurally small cracks are calculated using the finite element method. To simulate the plastic deformation occurring at the crack tip, a two-dimensional small strain constitutive relationship from single crystal plasticity theory is implemented in the finite element code ANSYS as a user-defined plasticity subroutine. Small cracks are modeled in both single grains and multiple grains, and different crystallographic conditions are considered. The computed plastic zone sizes and CTOD are compared with those found using conventional isotropic plasticity theory, and significant differences are observed.     

THE SIGNIFICANCE OF CRACK TIP DEFORMATION FOR SHORT AND LONG FATIGUE CRACKS

Abstract— The behaviour of physical short mode I cracks under constant amplitude cyclic loading was investigated both numerically and experimentally. A dynamic two-dimensional elastic-plastic finite element technique was utilised to simulate cyclic crack tip plastic deformation. Different idealisations were investigated. Both stationary and artificially advanced long and short cracks were analysed. A parameter which characterises the plastically deformed crack tip zone, the strain field generated within that zone and the opening and closure of the crack tip were considered. The growth of physically short mode I cracks under constant amplitude fully reversed fatigue loading was investigated experimentally using conventional cast steel EN-9 specimens. Based on a numerical analysis, a crack tip deformation parameter was devised to correlate fatigue crack propagation rates.     

About cracks, dunce caps and a new way to stop cracks

Recently, the 'method of tensile triangles' has been introduced for optimizing the shape of notches by adding material at overloaded regions but also to remove unloaded material from an oversized design proposal.
In this work, we apply the method to demonstrate that the unloaded region in the vicinity of a crack has the shape of spindle-shaped hole, which looks like two dunce caps mirrored at the crack line. Also, these shapes can be predicted by the 'method of tensile triangles' without any FEM-effort. Furthermore, we show a new way to stop cracks by deviating the crack tip into a shape-optimized pattern leading to a compressive stress that closes the crack tip. This procedure is now used in chemical engineering.     

Deformation behaviour at the tip of a physically short fatigue crack due to a single overload

A two-dimensional elastic–plastic finite element analysis was utilized to investigate the transition behaviour of a physically short fatigue crack following the application of a single overload cycle. The deformation accommodated at the tip of a crack artificially advancing with a fully reversed load was considered. The development of the cyclic crack tip opening displacement was computed and then modelled to include the effects of the stress level of the base cycles, overload pattern and crack length at which the transient cycle was applied. The cyclic crack tip opening displacement was initially of a relatively high value. It decreased and then increased to match the behaviour under the base load cycles. The extent and location of both the minimum and matching points were dependent on the overload crack length and the stress compared with the material’s yield stress. In the case of the yield stress being exceeded by the overload, the minimum and the-return-to-normality points are identical. A previously developed crack tip deformation parameter was invoked to predict relevant experimental fatigue growth rates of short cracks reported in the literature.     

A reappraisal of transition elements in linear elastic fracture mechanics

This article offers a detailed comparison of the transition elements described by P.P. Lynn and A.R. Ingraffea [International Journal for Numerical Methods in Engineering 12,1031–1036] and C. Manu[Engineering Fracture Mechanics 24,509–512]. The source of a numerical phenomenon in using Manu's transitionelement (TE) is explained. The effect of eight-noded TEs with differentquarter-point elements (QPE) on the calculated stress intensity factors (SIFs) isinvestigated. Strain at the crack tip is shown to be singular for any ray emanating from the crack tip within an eight-noded TE, but strain has bothr ^–1/2andr ^–1singularities, withr ^–1/2dominating for large TEs. Semi-transition elements (STEs) are defined and shown to have a marginal effect on the calculated SIFs. Nine-nodedtransition elements are formulated whose strain singularity is shown to be the same as that of eight-noded TEs. Then the effect of eight-noded and nine-noded TEs with collapsed triangular QPEs, and rectangular and nonrectangular quadrilateral eight-noded and nine-noded QPEs, is studied, and nine-noded TEs are shown to behave exactly like eight-noded TEs with rectangular eight-noded and nine-noded QPEs and to behave almost the same with other QPEs. The layered transition elements proposed by V. Murti and S.Valliapan [Engineering Fracture Mechanics 25, 237–258] areformulated correctly. The effect of layered transition elements is shown by two numerical examples.     

Numerical simulation of stress-strain state near crack tip in a compact tensile specimen

A computational scheme has been developed and a numerical simulation of the stress-strain state near the crack tip is performed at different levels of the stress intensity factor using a compact tensile specimen as an example. The authors analyze the influence of the finite element size near the crack tip and compare the results obtained in different codes (software packages) for different crack geometries. __________ Translated from Problemy Prochnosti, No. 1, pp. 134–140, January–February, 2009.     

A conservative integral for determining stress intensity factors of a bimaterial notch

This work presents regular and singular asymptotic solutions for non-planar quasi-circular cracks. Regular asymptotic solutions, which do not give rise to hyper-singular stresses near the crack tip, are developed in the general three-dimensional setting. Singular asymptotic solutions are considered for axisymmetric problems only, because those problems do not involve hyper-singularity. The validity of asymptotic solutions for planar and non-planar cracks is investigated by comparing them with detailed numerical and analytical solutions. Also asymptotic solutions are applied to analysis of quasi-static crack growth in three dimensions.     

A537钢疲劳裂纹扩展单次拉伸超载效应及裂尖形变,裂纹闭合行为

研究了恒定ΔＫ条件下,单次拉伸超载对Ａ５３７钢疲劳裂纹扩展速率的影响,并利用激光散斑技术原位研究超载前后的裂尖应变场,裂纹闭合效应。结果表明：超载后裂纹闭合效应呈增强趋势,裂尖应变呈下降趋势。伸超载有阻滞裂纹扩展的作用。