Multiple penny-shaped cracks interaction in a finite body and their effect on stress intensity factor

In this paper we investigate the stress intensity factors (SIFs) of multiple penny-shaped cracks in an elastic solid cylinder under mode I (axial tension) loading. The cracks are located symmetrically and in parallel to one another in the isotropic cylinder. The fractal-like finite element method (FFEM) is employed to study the interaction of multiple cracks and to demonstrate the efficiency of the FFEM for multiple crack problems. The results show that the SIF values of the inner cracks, which are denoted as crack number 1,2,3,…,(n+1)/2 of a stack of n parallel cracks, are lower than the SIF values of a single crack by between 16% and 48%. Also, the outermost crack, that is the crack closest to the boundaries of a multiple cracked body, has the highest SIF values and is, therefore, likely to fail first.     

A finite element modelling for directly determining intensity factors of piezoelectric materials with cracks

Recently, authors(Cao et al., Acta Aeronautica et Astronautica Sinica 25(5): 470–472, 2004) extended the singular crack element originally introduced by Wang et al. (Eng Fract Mech 37(6):1195–1201, 1990) for evaluating the stress intensity factors (SIFs). Extensive studies have proved the versatility and accuracy of the element. This study is to show the versatility of the element for piezoelectric materials. In this paper, electric potential and displacement fields near a crack tip of piezoelectric materials are first used to construct a finite element version for directly determining intensity factors of piezoelectric materials with cracks. A singular finite element is constituted and a new method to calculate intensity factors of piezoelectric materials with cracks is obtained without any post-processing procedures. Detailed derivations are given and the results obtained with present method are good agreement with those of theoretical results, the FEM data by ANSYS and singular electromechanical crack tip elements. The results to the different selections of the structural dimensions are carried out. Numerical examples demonstrate the accuracy and validity of the novel element of present method.     

Mode I stress intensity factor estimate for a half-penny shaped crack in a trilayer structure by reduction to a bilayer model

The stress intensity factor (SIF) of a half-penny shaped crack normal to the interface in the top layer of a three-layer bonded structure is obtained by the finite element method for a wide range of parameters. To obtain a simple estimate of the SIF, the method of reduction of an idealized cracked trilayer domain to that of a corresponding bilayer domain has been introduced based on the notion of an equivalent homogeneous material substitution for the two bottom layers. The results obtained are utilized in estimating the SIF of a small crack at the interface in a trilayer structure subjected to an indentation load based on the stress calculations in a corresponding uncracked structure. The simplification method may be useful in predicting brittle failure initiating from interfacial flaws in layered structural components with complex geometries that would normally require extensive computational modeling.     

Stress intensity factor computation using the method of fundamental solutions

In this paper, we study the application of the method of fundamental solutions to the computation of stress intensity factors in linear elastic fracture mechanics. The displacements are approximated by linear combinations of the fundamental solutions of the Cauchy–Navier equations of elasticity and the leading terms for the displacement near the crack tip. The applicability of two formulations of the method is demonstrated on two mode I crack problems, where it is shown that accurate approximations for the stress intensity factors can be obtained with relatively few degrees of freedom. Parts of this work were undertaken while the first author was a Visiting Professor in the Department of Mathematical and Computer Sciences, Colorado School of Mines, Golden, Colorado 80401, U.S.A.     

Numerical methods for determination of stress intensity factors of singular stress field

The asymptotic solution of the singular stress field near a singular point is generally comprised of one or more singular terms in the form of Kr^λ-1f_ij(θ). Based on the asymptotic solution of the singular stress field and the common numerical solution (stresses or displacements) obtained by an ordinary tool such as the finite element method or boundary element method, a simple and effective numerical method is developed to calculate stress intensity factors for one and two singularities. Three examples show that the stress intensity factors evaluated using the method proposed in this paper are very accurate.     

A finite element based interior collocation method for the computation of stress intensity factors and T-stresses

A new, simple and efficient method for simultaneous estimation of the mixed-mode stress intensity factors (SIFs) and T-stresses using finite element computations is proposed in this paper. The current work is based on the formation of overdetermined system of equations using the displacement components near the crack tip. The proposed method can be easily implemented in the existing finite element codes. The results obtained from the present investigation for plane stress problems are validated by comparing with the published results and found to be in very good agreement with them.     

On fracture analysis using an element overlay technique

In this paper, an element overlay technique (s-FEM [Comput. Struct. 43 (1992) 539]) is applied to various two dimensional linear fracture problems. When s-FEM is adopted, local finite element model concerning cracks can be built independently from the global finite element mesh for modeling overall structure. The local model is superposed on the global one. Therefore, it is tractable to introduce cracks in an existing finite element model. The accuracy of s-FEM is critically examined and it is found that the size of local mesh region needs to be larger than or roughly equal to that of an element in the global mesh.     

Stress intensity factor predictions: Comparison and round-off error

Practical steps required to obtain robust finite element triangular meshes for crack path and stress intensity calculation purposes are evaluated, and techniques to use their predictions to calculate fatigue lives, including load interaction effects, are discussed. These steps address: (a) how to simulate efficiently 2D crack paths under bi-axial loading using automatic remeshing schemes; (b) how to choose the best method to calculate stress intensity factors along the crack path; and (c) how the numerical problems associated with excessive FE mesh refinement along the crack path may affect predictions. Various modeling strategies are compared using different crack geometries and mesh refinements to quantify their performance, particularly when the elements around the crack tip are very small compared with the elements far from it. It is shown that, contrary to many other stress analysis applications, excessive mesh refinement may significantly degrade the calculation accuracy in crack problems. A limit for the elements size ratio is clearly established.     

Application of the substructured finite element/extended finite element method (S-FE/XFE) to the analysis of cracks in aircraft thin walled structures

The substructured finite element/extended finite element (S-FE/XFE) approach is used to compute stress intensity factors in large aircraft thin walled structures containing cracks. The structure is decomposed into a ‘safe’ domain modeled with classical shell elements and a ‘cracked’ domain modeled using three-dimensional extended finite elements. Two applications are presented and discussed, supported by validation test cases. First a section of stiffened panel containing a through-thickness crack is investigated. Second, small surface cracks are simulated in the case of a generic ‘pressure membrane’ with realistic crack configurations. These two semi-industrial benchmarks demonstrate the accuracy, robustness and computational efficiency of the substructured finite element/extended finite element approach to address complex three-dimensional crack problems within thin walled structures.     

Stress intensity factors in spot welds

This paper looks at stress intensity factors of cracks in resistance spot welded joints. Stress intensity factors have been used in the past to predict fatigue crack propagation life of resistance spot welds. However, the stress intensity factors from all previous work was based on assumed initial notch cracks at the nugget, parallel to the sheets. Physical evidence shows, however, that fatigue cracks in spot welds propagate through the thickness of the sheets rather than through the nugget. In this work, stress intensity factors of assumed notch cracks and through thickness cracks in tensile shear (TS) and modified coach peel (MCP) specimens were determined by the finite element method. The finite element results from the assumed notch cracks were compared with the results in the literature and were found to be in agreement with the results from Zhang’s equations [Int. J. Fract. 88 (1997) 167]. The stress intensity factors of assumed notch cracks were found to be different from those of through thickness cracks. To date, no analytic equations for stress intensity factors of through thickness cracks in spot welds have been published. In the current work, simple equations are proposed to estimate the K_I and K_II values of through thickness cracks in TS and MCP specimens.     

Stress intensity factor analyses of interface cracks between dissimilar anisotropic materials using the finite element method

Delamination along an interface between dissimilar materials is the primary cause of failure in microstructures like electronic packages, micro-electro-mechanical systems (MEMS), and so on. Fracture mechanics is a powerful tool for the evaluation of delamination. However, many materials used in microstructures such as composite materials and single crystals are anisotropic materials. Stress intensity factors of an interface crack between dissimilar anisotropic materials, which were proposed by Hwu, are useful for evaluating the reliability of microstructures. However, numerical methods that can analyze the stress intensity factors of an interface crack between anisotropic materials have not been developed. We propose herein a new numerical method for the analysis of an interface crack between dissimilar anisotropic materials. The stress intensity factors of an interface crack are based on the generalized plane strain condition. The energy release rate is obtained by the virtual crack extension method in conjunction with the finite element method for the generalized plane strain condition. The energy release rate is separated into individual modes of the stress intensity factors K_I, K_II, and K_III, using the principal of superposition. The target problem to be solved is superposed on the asymptotic solution of displacement in the vicinity of an interface crack tip, which is described using the Stroh formalism. Analyses of the stress intensity factors of center interface cracks between semi-infinite dissimilar anisotropic media subjected to concentrated self-balanced loads on the center of crack surfaces and to uniform loads are demonstrated. The present method accurately provides mode-separated stress intensity factors using relatively coarse meshes for the finite element method.     

Stress intensity factors for corner cracks emanating from fastener holes under tension

In this paper, previous work associated with the stress intensity factor for corner cracks at fastener holes in finite thickness plates is briefly reviewed. The stress intensity factors for two symmetric quarter-elliptical corner cracks subjected to remote tension are evaluated by using both the quarter-point displacement and J-integral methods based on three-dimensional finite element analyses. The geometry ratios analyzed cover a wide range, i.e. depth ratio a/t: 0.2–0.95, aspect ratio a/c: 0.2–5, and hole radius ratio r/t: 0.5–3. Analysis of the J-integral path independence and mutual comparison of the stress intensity factor results between the two methods demonstrate that the present results are of good numerical accuracy. Deviation of the present results from some other solutions found in the literature is also revealed, particularly from Newman and Raju's equations. It is shown that the difference among these results obtained by the different methods is generally within a reasonable bound of error, but Newman and Raju's equations systematically underestimate (up to 15%) the stress intensity factor for cracks of depth ratio larger than 0.8.     

Stress intensity factors for functionally graded solid cylinders

This paper presents the mode I stress intensity factors for functionally graded solid cylinders with an embedded penny-shaped crack or an external circumferential crack. The solid cylinders are assumed under remote uniform tension. The multiple isoparametric finite element method is used. Various types of functionally graded materials and different gradient compositions for each type are investigated. The results show that the material property distribution has a quite considerable influence on the stress intensity factors. The influence for embedded cracks is quite different from that for external cracks.     

梯度复合材料应力强度因子计算的梯度扩展单元法

推导了一种适用于梯度复合材料断裂特性分析的梯度扩展单元,采用细观力学方法描述材料变化的物理属性,通过线性插值位移场给出了4节点梯度扩展元随空间位置变化的刚度矩阵,并建立了结构的连续梯度有限元模型.通过将梯度单元的计算结果与均匀单元以及已有文献结果进行对比,证明了梯度扩展有限元(XFEM)的优越性,并进一步讨论了材料参数对裂纹尖端应力强度因子(SIF)的影响规律.研究结果表明:随着网格密度的增加,梯度单元的计算结果能够迅速收敛于准确解,均匀单元的计算误差不会随着网格细化而消失,且随着裂纹长度和属性梯度的增大而增大;属性梯度和涂层基体厚度比的增大导致涂覆型梯度材料的SIF增大;裂纹长度的增加和连接层基体厚度比的减小均导致连接型梯度材料的SIF增大.     

Stress intensity factor analysis of friction sliding at discontinuity interfaces and junctions

A stress intensity factor (SIF) analysis for two-dimensional fractures with frictional contact (crack friction) is presented. This analysis is carried out using the symmetric-Galerkin boundary element method, and a modified quarter-point crack tip element. As in case of non-contact fracture, it is shown that highly accurate SIFs can be obtained, even with the simple Displacement Correlation SIF technique. Moreover, with the modified crack tip element, the mesh on the crack does not need to be excessively refined in order to achieve high accuracy. This meshing advantage is especially important in the context of the nonlinear frictional contact problem, as the computing time for the iterative process strongly depends on the number of elements used. Several numerical examples are presented and the SIF results are compared with available analytical or reference solutions. This research was supported in part by the University of South Alabama Research Council, and by the Applied Mathematical Sciences Research Program of the Office of Mathematical, Information, and Computational Sciences, U.S. Department of Energy under contract DE-AC05-00OR22725 with UT-Battelle, LLC.     

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.     

Stress intensity factor solutions for cracks in finite-width three layer laminates with and without residual stress effects

Approximate stress intensity factor solutions for cracks in finite-width three layer laminates, with the crack located in the middle layer, were derived on the basis of force-balance between the applied stress and the modified Westergaard form of normal stress distribution ahead of the crack tip. This yielded a simple and closed form equation for the stress intensity factor that included the effects of the ratio of the moduli of the layers and the relative layer thicknesses. A comparison of the stress intensity factor values from this equation and with finite element data indicated that the difference between these two data sets was small for most of the crack lengths and the modulus ratio of the layers. The maximum difference occurred at crack lengths approaching the interface and at high moduli ratios, but was less than 10%, in general. The equations were also modified to incorporate the effects of residual stresses that arise during cooling after laminate processing, on the stress intensity factor. A comparison of the analytical data with the finite element data obtained by imposing thermal and mechanical boundary loads on the laminate specimens indicated a good agreement. The present closed form approximate solutions may be useful in fracture analyses of finite-width laminates containing cracks.     

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^®.     

Stress intensity factor analysis of a three-dimensional interface crack between dissimilar anisotropic materials

A new numerical method to calculate the stress intensity factors (SIFs) of a three-dimensional interface crack between dissimilar anisotropic materials was developed. In this study, the M-integral method was employed for mode separation of the SIFs. The moving least-square method was utilized to calculate the M-integral. Using the M-integral with the moving least-square method, SIFs can be automatically calculated with only the nodal displacements from the finite element method (FEM). Here, SIFs analyses of some typical three-dimensional problems are demonstrated. Excellent agreement was achieved between the numerical results obtained by the present method and the corresponding results proposed by other researchers. In addition, the SIFs of a single-edge crack, a through crack, and a semi-circular crack between two anisotropic solids in three-dimensional structures were analyzed.     

Dislocation-based semi-analytical method for calculating stress intensity factors of cracks: Two-dimensional cases

Determination of the stress intensity factors of cracks is a fundamental issue for assessing the performance safety and predicting the service lifetime of engineering structures. In the present paper, a dislocation-based semi-analytical method is presented by integrating the continuous dislocation model with the finite element method together. Using the superposition principle, a two-dimensional crack problem in a finite elastic body is reduced to the solution of a set of coupled singular integral equations and the calculation of the stress fields of a body which has the same shape as the original one but has no crack. It can easily solve crack problems of structures with arbitrary shape, and the calculated stress intensity factors show almost no dependence upon the finite element mesh. Some representative examples are given to illustrate the efficacy and accuracy of this novel numerical method. Only two-dimensional cases are addressed here, but this method can be extended to three-dimensional problems.