Extended finite element method and fast marching method for three-dimensional fatigue crack propagation

A numerical technique for planar three-dimensional fatigue crack growth simulations is proposed. The new technique couples the extended finite element method (X-FEM) to the fast marching method (FMM). In the X-FEM, a discontinuous function and the two-dimensional asymptotic crack-tip displacement fields are added to the finite element approximation to account for the crack using the notion of partition of unity. This enables the domain to be modeled by finite elements with no explicit meshing of the crack surfaces. The initial crack geometry is represented by level set functions, and subsequently signed distance functions are used to compute the enrichment functions that appear in the displacement-based finite element approximation. The FMM in conjunction with the Paris crack growth law is used to advance the crack front. Stress intensity factors for planar three-dimensional cracks are computed, and fatigue crack growth simulations for planar cracks are presented. Good agreement between the numerical results and theory is realized.     

Abaqus implementation of extended finite element method using a level set representation for three-dimensional fatigue crack growth and life predictions

A three-dimensional extended finite element method (X-FEM) coupled with a narrow band fast marching method (FMM) is developed and implemented in the Abaqus finite element package for curvilinear fatigue crack growth and life prediction analysis of metallic structures. Given the level set representation of arbitrary crack geometry, the narrow band FMM provides an efficient way to update the level set values of its evolving crack front. In order to capture the plasticity induced crack closure effect, an element partition and state recovery algorithm for dynamically allocated Gauss points is adopted for efficient integration of historical state variables in the near-tip plastic zone. An element-based penalty approach is also developed to model crack closure and friction. The proposed technique allows arbitrary insertion of initial cracks, independent of a base 3D model, and allows non-self-similar crack growth pattern without conforming to the existing mesh or local remeshing. Several validation examples are presented to demonstrate the extraction of accurate stress intensity factors for both static and growing cracks. Fatigue life prediction of a flawed helicopter lift frame under the ASTERIX spectrum load is presented to demonstrate the analysis procedure and capabilities of the method.     

A mixed augmented Lagrangian-extended finite element method for modelling elastic–plastic fatigue crack growth with unilateral contact

The complete modelling of fatigue crack growth is still an industrial challenging issue for numerical methods. A new technique for the finite element modelling of elastic–plastic fatigue crack growth with unilateral contact on the crack faces is presented. The extended finite element method (X-FEM) is used to discretize the equations, allowing for the modelling of arbitrary cracks whose geometries are independent of the finite element mesh. This paper presents an augmented Lagrangian formulation in the X-FEM framework that is able to deal with elastic–plastic crack growth with treatment of contact. An original formulation, which takes advantages of two powerful numerical methods, is presented. Next the numerical issues such as contact treatment and numerical integration are addressed, and finally numerical examples are shown to validate the method. Copyright © 2007 John Wiley & Sons, Ltd.     

Modelling multiple cohesive crack propagation using a finite element–scaled boundary finite element coupled method

This paper presents an extension of the recently-developed finite element–scaled boundary finite element (FEM–SBFEM) coupled method to model multiple crack propagation in concrete. The concrete bulk and fracture process zones are modelled using SBFEM and nonlinear cohesive interface finite elements (CIEs), respectively. The CIEs are automatically inserted into the SBFEM mesh as the cracks propagate. The algorithm previously devised for single crack propagation is augmented to model problems with multiple cracks and to allow cracks to initiate in an un-cracked SBFEM mesh. It also addresses crack propagation from one subdomain into another, as a result of partitioning a coarse SBFEM mesh, required for some mixed–mode problems. Each crack in the SBFEM mesh propagates when the sign of the Mode-I stress intensity factor at the crack tip turns positive from negative. Its propagation angle is determined using linear elastic fracture mechanics criteria. Three concrete beams involving multiple crack propagation are modelled. The predicted crack propagation patterns and load–displacement curves are in good agreement with data reported in literature.     

Theoretical analysis of 4-ENF tests for mode II fracturing in wood by finite element method

In this note, the four-point bend end notched flexure tests of wood of the specimen with an I-shaped cross-section were simulated by the finite element method. It was suggested that the relation between the mode II energy release rate and crack length was appropriately obtained by the data reduction method proposed in a previous work [Yoshihara H. Mode II R-curve of wood measured by 4-ENF test. Engng Fract Mech 2004;71:2065-77].     

Adaptive and hierarchical modelling of fatigue crack propagation

A methodology is developed to simulate adaptively and hierarchically fatigue crack growth in structural components. Cracks are modelled, by overlaying portions of the finite element mesh free of cracks with a discontinuous finite element field containing unconstrained double nodes along the discontinuity. Crack propagation is simulated by advancing the crack front in the superimposed mesh only keeping the underlying mesh fixed. Adaptivity in time and space domain together with the hierarchical nature of the method ensure both economical and reliable simulation of crack propagation. Numerical results of fatigue crack growth in the attachment lug were found to be, in good agreement with the experimental data.     

Three-dimensional, parallel, finite element simulation of fatigue crack growth in a spiral bevel pinion gear

This paper summarizes new results for predicting crack shape and fatigue life for a spiral bevel pinion gear using computational fracture mechanics. The predictions are based on linear elastic fracture mechanics theories combined with the finite element method, and incorporating plasticity-induced fatigue crack closure and moving loads. We show that we can simulate arbitrarily shaped fatigue crack growth in a spiral bevel gear more efficiently and with much higher resolution than with a previous boundary-element-based approach [Spievak LE, Wawrzynek PA, Ingraffea AR, Lewicki DG. Simulating fatigue crack growth in spiral bevel gears. Engng Fract Mech 2001;68(1):53-76] using the finite element method along with a better representation of moving loads. Another very significant improvement is the decrease in solution time of the problem by employing a parallel PC-cluster, an approach that is becoming more common in both research and practice. This reduces the computation time for a complete simulation from days to a few hours. Finally, the effect of change in the flexibility of the cracking tooth on the location and magnitude of the contact loads and also on stress intensity factors and fatigue life is investigated.     

Shape prediction and stability analysis of Mode-I planar cracks

This paper presents a numerical technique for simulating stable growth of Mode-I cracks in two and three dimensions, using energy release rate and its derivatives. The crack growth model used in the numerical simulation is based on the concept of maximizing potential energy of the system released as cracks evolve. Therefore, a series of quadratic programming (QP) problems with linear constraints and bounds are solved to simulate stable growth of Mode-I planar cracks. The derivative of energy release rate provides a stability condition for crack growth in structures and can be regarded as a discretized influence function that represents the strength of the interaction among crack extensions at different crack tips in 2-D and different locations along a crack front in 3-D. The energy release rate and its derivative are accurately calculated by the analytical virtual crack extension method [Engng. Fract. Mech. 59 (1998) 521; 68 (2001) 925] in a single analysis. Numerical examples are presented to demonstrate the capabilities of the proposed approach. Examples include a central crack subjected to wedge forces in a 2-D finite plate, a system of interacting thermally induced parallel cracks in a two-dimensional semi-infinite plane and a 3-D penny-shaped crack embedded in a large cylinder, pressurized in a central circular region.     

Three‐dimensional non‐planar crack growth by a coupled extended finite element and fast marching method

A numerical technique for non‐planar three‐dimensional linear elastic crack growth simulations is proposed. This technique couples the extended finite element method (X‐FEM) and the fast marching method (FMM). In crack modeling using X‐FEM, the framework of partition of unity is used to enrich the standard finite element approximation by a discontinuous function and the two‐dimensional asymptotic crack‐tip displacement fields. The initial crack geometry is represented by two level set functions, and subsequently signed distance functions are used to maintain the location of the crack and to compute the enrichment functions that appear in the displacement approximation. Crack modeling is performed without the need to mesh the crack, and crack propagation is simulated without remeshing. Crack growth is conducted using FMM; unlike a level set formulation for interface capturing, no iterations nor any time step restrictions are imposed in the FMM. Planar and non‐planar quasi‐static crack growth simulations are presented to demonstrate the robustness and versatility of the proposed technique. Copyright © 2008 John Wiley & Sons, Ltd.     

An assessment of stress intensity factors for surface flaws in a tubular member

In the safety assessment of pressure vessels and pipes with circumferential surface cracks, it is often necessary to consider fatigue crack propagation and fracture among the possible modes of failure. The stress intensity factors at crack tips are important parameters for estimating residual life and criticality. The purpose of this paper is to present a method to calculate the mode I stress intensities for semi-elliptical cracks in pipes. This method uses the finite element technique to analyse a crack but does not require the crack to be modelled explicitly. This method is ideal for use with either fatigue life calculations or use with structural optimisation processes. Accurate results are obtained using only a relatively small number of degrees of freedom without the need to explicitly mesh cracks. In this paper a range of examples are presented to demonstrate the accuracy of this method.     

几何非线性扩展有限元法及其断裂力学应用

该文将扩展有限元方法应用到几何非线性及断裂力学问题中,并研制开发了扩展有限元Fortran程序。扩展有限元法其计算网格与不连续面相互独立,因此模拟移动的不连续面时无需对网格进行重新剖分。该文推导了几何非线性扩展有限元法的公式,在常规有限元位移模式中,基于单位分解的思想加进一个阶跃函数和二维渐近裂尖位移场,反映裂纹处位移的不连续性,并用2个水平集函数表示裂纹;采用拉格朗日描述方程建立了有限变形几何非线性扩展有限元方程;采用多点位移外推法计算裂纹应力强度因子并通过最小二乘法拟合得到更精确的结果。最后给出的大变形算例表明该文提出的几何非线性的断裂力学扩展有限元方法和相应的计算机程序是合理可行的,而且对于含裂纹及裂纹扩展的问题,扩展有限元法优于传统的有限元法。     

Automated simulation of fatigue crack propagation for two-dimensional linear elastic fracture mechanics problems by boundary element method

In this paper, automated simulation of multiple crack fatigue propagation for two-dimensional (2D) linear elastic fracture mechanics (LEFM) problems is developed by using boundary element method (BEM). The boundary element method is the displacement discontinuity method with crack-tip elements proposed by the author. Because of 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. Local discretization on the incremental crack extension is performed easily. Further the new adding elements and the existing elements on the existing boundaries are employed to construct easily the total structural mesh representation. Here, the mixed-mode stress intensity factors are calculated by using the formulas based on the displacement fields around crack tip. The maximum circumferential stress theory is used to predict crack stability and direction of propagation at each step. The well-known Paris’ equation is extended to multiple crack case under mixed-mode loadings. Also, the user does not need to provide a desired crack length increment at the beginning of each simulation. The numerical examples are included to illustrate the validation of the numerical approach for fatigue growth simulation of multiple cracks for 2D LEFM problems.     

Enriched finite elements and level sets for damage tolerance assessment of complex structures

The extended finite element method (X-FEM) has recently emerged as an alternative to meshing/remeshing crack surfaces in computational fracture mechanics thanks to the concept of discontinuous and asymptotic partition of unity enrichment (PUM) of the standard finite element approximation spaces. Level set methods have been recently coupled with X-FEM to help track the crack geometry as it grows. However, little attention has been devoted to employing the X-FEM in real-world cases. This paper describes how X-FEM coupled with level set methods can be used to solve complex three-dimensional industrial fracture mechanics problems through combination of an object-oriented (C++) research code and a commercial solid modeling/finite element package (EDS-PLM/I-DEAS^®). The paper briefly describes how object-oriented programming shows its advantages to efficiently implement the proposed methodology. Due to enrichment, the latter method allows for multiple crack growth scenarios to be analyzed with a minimal amount of remeshing. Additionally, the whole component contributes to the stiffness during the whole crack growth simulation. The use of level set methods permits the seamless merging of cracks with boundaries. To show the flexibility of the method, the latter is applied to damage tolerance analysis of a complex aircraft component.     

Automatic 3-D mode I crack propagation calculations with finite elements

An algorithm is presented which allows for fully automatic linear elastic low cycle fatigue (LCF) crack propagation calculations of mode I plane cracks in large structures by means of the finite element technique. The bulk of the algorithm consists of an automatic procedure to introduce the geometry of a plane crack with an arbitrary crack front in an existing three-dimensional (3-D) mesh. Once the K-distribution for the initial crack has been calculated, the use of the superelement technique reduces the computing time for the subsequent cycles by a factor of up to 40 or more. Two industrial examples illustrate the accuracy and effectiveness of the method. © 1998 John Wiley & Sons, Ltd.     

An iterative algorithm for modeling crack closure and sliding

In this paper, a simple and efficient iterative algorithm is adopted to model crack closure and sliding with the displacement discontinuity method (DDM). The problem of a subsurface crack in a half-plane under indentation loading considered by Elvin and Leung (Elvin N, Leung C. A fast iterative boundary element method for solving closed crack problems. Engng Fract Mech 1999;63:631-48) and DeBremaecker and Ferris (DeBremaecker J-Cl, Ferris MC. A comparison of two algorithm for solving closed crack problems. Engng Fract Mech 2000;66:601-05) is reexamined using the iterative DDM. The cases of a partially closed crack with both frictionless and frictional contacts are considered. Benchmark results for the stress intensity factors and the interfacial crack mechanisms for a subsurface crack are presented and compared with the results obtained from the fast iterative algorithm of Elvin and Leung and those from the PATH algorithm of DeBremaecker and Ferris.     

An adaptive multiscale method for crack propagation and crack coalescence

This work presents a new multiscale technique for the efficient simulation of crack propagation and crack coalescence of macrocracks and microcracks. The fully adaptive multiscale method is able to capture localization effect mesh independently. By modeling macrocracks and microcracks, the extended finite element method offers an accurate solution and captures cracks and their propagation without changing the mesh topology. Propagating and coaliting cracks of different length scales can therefore be easily modeled and updated during the computation process. Hence, the presented method is an efficient and accurate option for modeling cracks of different length scales. This is demonstrated in several numerical examples showing the interaction of microcracks and macrocracks. Copyright © 2012 John Wiley & Sons, Ltd.     

A continuous-discontinuous model for crack branching

A new continuous-discontinuous model for fracture that accounts for crack branching in a natural manner is presented. It combines a gradient-enhanced damage model based on nonlocal displacements to describe diffuse cracks and the extended finite element method (X-FEM) for sharp cracks. Its most distinct feature is a global crack tracking strategy based on the geometrical notion of medial axis: the sharp crack propagates following the direction dictated by the medial axis of a damage isoline. This means that, if the damage field branches, the medial axis automatically detects this bifurcation, and a branching sharp crack is thus easily obtained. In contrast to other existing models, no special crack-tip criteria are required to trigger branching. Complex crack patterns may also be described with this approach, since the X-FEM enrichment of the displacement field can be recursively applied by adding one extra term at each branching event. The proposed approach is also equipped with a crack-fluid pressure, a relevant feature in applications such as hydraulic fracturing or leakage-related events. The capabilities of the model to handle propagation and branching of cracks are illustrated by means of different two-dimensional numerical examples.     

DETERMINATION OF THE MOST APPROPRIATE MESH SIZE FOR A 2-D FINITE ELEMENT ANALYSIS OF FATIGUE CRACK CLOSURE BEHAVIOUR

Abstract— A two-dimensional elastic-plastic finite element analysis is performed for plane stress conditions with 4-node isoparametric elements to examine closure behaviour of fatigue cracks, giving special attention to the determination of the most appropriate mesh sizes. It is found that a smaller mesh size does not always give more accurate simulation results in the fatigue crack closure analysis, unlike a conventional structural analysis. A unique, most-appropriate mesh size exists for a given loading condition that will provide numerical results which agree well with experimental data. The most appropriate mesh size can be determined approximately in terms of the theoretical reversed plastic zone size. In particular, the ratio of the most appropriate mesh size to the theoretical reversed plastic zone size is nearly constant for a given stress ratio in the so-called crack-length-fixed method proposed in this study. By using the concept of the most appropriate mesh size, the finite element analysis can predict fatigue crack closure behaviour very well.     

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.     

Growth prediction of two interacting surface cracks of dissimilar sizes

When multiple cracks approach one another, the stress intensity factor changes due to the interaction of the stress field. This causes variation in the crack growth rate and shape of cracks. In particular, when cracks are parallel to the loading direction, their shape becomes non-planar due to the mixed mode stress intensity factor. In this study, the growth of interacting surface cracks was simulated by using the S-version finite element method, in which a local detailed finite element mesh (local model) is superposed on a coarse finite element model (global model) representing the global structure. First, simulations were performed for fatigue crack growth experiments and the method validity was shown. Second, simulations were conducted for various relative sizes and spacings of twin cracks. It was shown that the offset distance and the relative size were both important parameters to determine the interaction between two surface cracks; the smaller crack stopped growing when the difference in size was large. It was possible to judge whether the effect of interaction should be considered based on the correlation between the relative spacing and relative size.