Rapid parametric analysis of SEN(T) specimens using algorithmic modelling: Evaluation of strain energy density and notch stress intensity factors

The aim of this paper is to present a methodology to rapidly evaluate the strain energy density (SED) and the notch stress intensity factor (NSIF) of a wide range of sharp V-notched SEN(T) specimens. A dislocation based method is used to find the solution of the boundary value problem. As a post-processing stage, computation of the local strain energy density over a circular sector surrounding the point of singularity is performed. NSIFs are then assessed by means of the strain energy approach (SEA) for several opening angles and specimen widths. Comparisons of local strain energy results with full-term solutions obtained by finite element analysis (FEA) are provided in order to validate the method and to establish the limitations of the NSIF approach for the case under consideration. The procedure presented in this work is shown to provide accurate results for the range of notch depth to specimen width ratios a/L < 0.4. The validity of the single-parameter characterisation when the boundary effect becomes significant is also discussed.     

The Equivalent Strain Energy Density approach re-formulated and applied to sharp V-shaped notches under localized and generalized plasticity

In the case of a rounded notch, the stress and strain at the notch tip can be determined by the traditional Neuber rule or by the Equivalent Strain Energy Density (ESED) approach, as formulated by Glinka and Molski. In the latter case the elastoplastic strain energy density at the notch tip is thought of as coincident with that determined under purely elastic conditions. For sharply V‐shaped notches this approach is not directly applicable, since the strain energy density at the notch tip tends toward infinity both for a material obeying an elastic law and a material obeying a power hardening law. By using the notch stress intensity factors, the present paper suggests a re‐formulation of the ESED approach which is applied no longer at the notch tip but to a finite size circular sector surrounding the notch tip. In particular we have adopted the hypothesis that, under plane strain conditions, the value of the energy concentration due to the notch is constant and independent of the two constitutive laws. When small scale yielding conditions are present, such a hypothesis immediately results in the constancy of the strain energy averaged over the process volume. As a consequence, plastic notch stress intensity factors valid for sharp V‐shaped notches can be predicted on the basis of the linear elastic stress distributions alone.     

State‐of‐the‐art review on the local strain energy density concept and its relation to the J‐integral and peak stress method

The local average strain energy density (SED) approach has been proposed and elaborated by Lazzarin for strength assessments in respect of brittle fracture and high‐cycle fatigue. Pointed and rounded (blunt) V‐notches subjected to tensile loading (mode 1) are primarily considered. The method is systematically extended to multiaxial conditions (mode 3, mixed modes 1 and 2). The application to brittle fracture is documented for PMMA flat bar specimens with pointed or rounded V‐notches inclusive of U‐notches. Results for other brittle materials (ceramics, PVC, duraluminum and graphite) are also recorded. The application to high‐cycle fatigue comprises fillet‐welded joints, weld‐like shaped and V‐notched base material specimens as well as round bar specimens with a V‐notch. The relation of the local SED concept to comparable other concepts is investigated, among them the Kitagawa, Taylor and Atzori–Lazzarin diagrams, the Neuber concept of fictitious notch rounding applied to welded joints and also the J‐integral approach. Alternative details of the local SED concept such as a semicircular control volume, microrounded notches and slit‐parallel loading are also mentioned. Coarse FE meshes at pointed or rounded notch tips are proven to be acceptable for accurate local SED evaluations. The peak stress method proposed by Meneghetti, which is based on a notch stress intensity factor consideration combined with a globally even coarse FE mesh and is used for the assessment of the fatigue strength of welded joints, is also presented.     

Estimation of elastic‐plastic strain response at two‐dimensional notches

It is widely recognized that the accuracy of notch fatigue calculations can be improved significantly when those calculations are based on the elastic‐plastic response strain at the notch root, as opposed to the remotely applied loads or stresses. Two of the most widely used approximations for this response are Neuber's rule and Glinka's equivalent strain energy density method. In the present work, a survey of some of the many published evaluations of these methods was first conducted, and then, additional detailed comparisons with elastic‐plastic finite element analyses for a series of semicircular and V‐shaped notch configurations were performed. Based on the observed limitations of both the Neuber and Glinka approaches, and with the guidance of the elastic‐plastic finite element results, a new (and more robust) approach for the estimation of notch response strains is proposed. This approach calls for the definition of a generalized notch response curve (GNRC), which is dependent on both the material stress–strain curve and the notch geometry. Once defined, the GNRC allows the determination of the response strain for any applied stress.     

Fracture investigation of U‐notch made of tungsten–copper functionally graded materials by means of strain energy density

The averaged strain energy density over a well‐defined control volume was employed to assess the fracture of U‐notched specimens made of tungsten–copper functionally graded materials under prevalent mode II loading. The boundary of control volume was evaluated by using a numerical method. Power law function was employed to describe the mechanical properties (elasticity modulus, Poisson's ratio, fracture toughness and ultimate tensile stress) through the specimen width. The effect of notch tip radius and notch depth on notch stress intensity factors and mode mixity parameter χ were assessed. In addition, a comparison based on fracture load between functionally graded and homogeneous W–Cu was made. Furthermore, in this research, it was shown that the mean value of the strain energy density over the control volume can be accurately determined using coarse meshes for functionally graded materials.     

A generalised notch stress intensity factor for U-notched components loaded under mixed mode

A novel notch stress intensity factor (NSIF) for U-notched specimens loaded under mixed mode is examined in this article. The concept is based on the averaged strain energy density criterion, or alternatively on the cohesive zone model, as well as the equivalent local mode approach. To a certain extent, it is a generalisation of Glinka’s NSIF for mode I, where σ_tip is replaced by σ_max.The applicability of a fracture criterion based on this new NSIF is checked against 171 fracture tests with PMMA (at −60 °C) performed on U-notched specimens, with different notch root radii and loaded under mixed mode. The asymptotic behaviour of the new NSIF as the notch becomes a crack (when the notch root radius tends to zero) or when the notch disappears (when the notch root radius tends to infinity) is also discussed.     

Significance of the elastic peak stress evaluated by FE analyses at the point of singularity of sharp V-notched components

The paper presents an expression useful to estimate the notch stress intensity factor (NSIF) from finite element analyses carried out by using a mesh pattern with a constant element size. The evaluation of the NSIF from a numerical analysis of the local stress field usually requires very refined meshes and then large computational effort. The usefulness of the presented expression is that (i) only the elastic peak stress numerically evaluated at the V‐notch tip is needed and no longer the whole stress–distance set of data; (ii) the adopted meshes are rather coarse if compared to those necessary for the evaluation of the whole local stress field. The proposed expression needs the evaluation of a virtual V‐notch tip radius, i.e. the radius which would produce the same elastic peak stress than that calculated by FEM at the sharp V‐notch tip by means of a given mesh pattern. Once such a radius has been theoretically determined for a given geometry, the expression can be applied in a wide range of notch depths and opening angles.     

Fatigue-relevant stress field parameters of welded lap joints: pointed slit tip compared with keyhole notch

The notch stress intensity factor (NSIF) based analytical frame is applied to the slit tips (or weld roots) of welded joints with inclusion of the T-stress component. This T-stress can be determined from FE models evaluating the ligament stresses close to the pointed slit tip. An alternative analytical frame is presented for the corresponding keyhole notches based on analytical solutions from the literature, which are applied to the ligament stresses.
In the slit tip models, the mean local strain energy density (SED) with inclusion of the T-stress effect is determined analytically and numerically in comparison, using two different fatigue-relevant control radii,  R ₀= 0.28 mm and  R ₀= 0.15 mm, the former value well proven for thick-sheet welded joints made of structural steel. The latter smaller value is tentatively proposed for thin-sheet welded joints, in the direction suggested in the recent literature where a reduction of the microstructural support length for laser beam welds and resistance spot welds is recommended. The FEM-based and analytical stress concentration factors (SCF) for the lap joint keyhole model and also the SED values for the corresponding pointed slit tips are found to be in good agreement. The  J -integral consisting of the first and second component (the latter containing the T-stress) is compared with the corresponding SED values.     

Brittle failures from U- and V-notches in mode I and mixed, I + II, mode: a synthesis based on the strain energy density averaged on finite-size volumes

A large bulk of static test results carried out on notched specimens are presented in a unified way by using the mean value of the strain energy density (SED) over a given finite-size volume surrounding the highly stressed regions. In plane problems, when cracks or pointed V-notches are considered, the volume becomes a circle or a circular sector, respectively, with R _C being the radius. R _C depends on the fracture toughness of the material, the ultimate tensile strength and the Poisson's ratio. When the notch is blunt, the control area assumes a crescent shape and R _C is its width as measured along the notch bisector.
About 900 experimental data, taken from recent literature, are involved in the local SED-based synthesis. They have been obtained from (a) U- and V-notched specimens made of different materials tested under mode I loading; (b) U- and V-notched specimens made of polymethyl-metacrylate (PMMA) and an acrylic resin, respectively, tested in mixed, I + II, mode; (c) U-notched specimens made of ceramics materials tested under mode I.
The local SED values are normalized to the critical SED values (as determined from unnotched specimens) and plotted as a function of the R / R _C ratio. A scatter band is obtained whose mean value does not depend on R / R _C, whereas the ratio between the upper and the lower limits are found to be about equal to 1.6. The strong variability of the non-dimensional radius R / R _C (ranging here from about zero to around 1000) makes stringent the check of the approach based on the mean value of the local SED on a material-dependent control volume.     

Multiaxial fatigue of V‐notched steel specimens: a non‐conventional application of the local energy method

The paper deals with the multi‐axial fatigue strength of notched specimens made of 39NiCrMo3 hardened and tempered steel. Circumferentially V‐notched specimens were subjected to combined tension and torsion loading, both in‐phase and out‐of‐phase, under two nominal load ratios, R=?1 and R= 0, also taking into account the influence of the biaxiality ratio, λ=τ_a/σ_a. The notch geometry of all axi‐symmetric specimens was a notch tip radius of 0.1 mm, a notch depth of 4 mm, an included V‐notch angle of 90° and a net section diameter of 12 mm. The results from multi‐axial tests are discussed together with those obtained under pure tension and pure torsion loading on plain and notched specimens. Furthermore the fracture surfaces are examined and the size of non‐propagating cracks measured from some run‐out specimens at 5 million cycles. Finally, all results are presented in terms of the local strain energy density averaged in a given control volume close to the V‐notch tip. The control volume is found to be dependent on the loading mode.     

A superposition approach to the stress fields for various blunt V‐notches

This paper deals with the problems of blunt V‐notch with various notch shapes. The purpose is to develop a new method capable of obtaining more accurate solutions for the stress fields around a blunt V‐notch tip under opening and sliding modes. The key method is to use the principle of superposition for linear elastic materials. On the basis of the superposition method and the conventional stress fields for a sharp V‐notch, the stress fields useful for any shapes of blunt V‐notch is proposed. The notch stress intensity factors are estimated by the numerical analysis with finite element analysis, and then the effectiveness and validation of the proposed superposition approach are discussed by comparison with the results from the literature.     

Fatigue tests of notched specimens made from butt joints at steel

The weld toe as well as the weld root of joints acts as a geometrical notch, which decreases the fatigue strength of welded components. Local approaches used for fatigue assessment account for the local stress concentration when referring to the notch stress as a fatigue parameter. This applies also to the approaches based on the notch stress intensity factor like, for example, the averaged strain energy density, neglecting the actual notch radius and considering a sharp notch as a simplification. A uniform S‐N curve valid for different types of welded joints and failure locations was derived from re‐analyses of fatigue test results as documented in literature. The fatigue tests described in this paper aimed at validating that energy‐based S‐N curve by dedicated tests on artificially notched specimens. At first, four parameters were investigated in order to estimate their influence on the fatigue strength and to select appropriate notch geometries for the final step of the test campaign. The advantages of these tests are that both the exact notch geometry and the local stress range at the notch, including misalignment effects, were identified and considered in experimental data analysis. This paper presents the results of the rather comprehensive testing activities and comparisons with the design‐S‐N curve mentioned, yielding unexpected fatigue behaviour. This can be explained by the short crack propagation life.     

A numerical method for evaluation of J‐integral in plates made of functionally graded materials with sharp and blunt V‐notches

The main purpose of the paper is to propose a numerical method for evaluation of J‐integral in plates made of functionally graded materials (FGM) with sharp and blunt V‐notches under Mode I loading. The material properties have been assumed to be varied exponentially along the specimen width (notch direction). Using the proposed method, the effect of material gradient on the J‐integral for two cases of sharp and blunt V‐notches has been studied. The results have shown that in FGMs with sharp V‐notches, the J‐integral is not proportional to . So, the parameter J_L is path dependent. It has been observed that the material gradient has larger effect on the J‐integral in sharp V‐notch compared with that in blunt V‐notch.     

Concurrent ratcheting and stress relaxation at the notch root of steel samples undergoing asymmetric tensile loading cycles

The current study intends to develop a framework model to assess ratcheting and stress relaxation at the notch root of 1045 steel samples over asymmetric loading cycles. The framework involves the Ahmadzadeh‐Varvani (A‐V) kinematic hardening rule to control ratcheting progress and Neuber rule to accommodate for local stress and strain components at the vicinity of notch root. Plastic strain at notch root was first coupled with its counterpart in the A‐V model to establish a relation between local stress and backstress components. Calculated local stress and strain values at turning points enabled the A‐V model to assess ratcheting strain over each loading cycle. The stepwise drop in stresses at peak‐valley tips of hysteresis loops at the notch root was associated to coupled framework of the A‐V model and Neuber rule through constancy in local strain while ratcheting progressed over each cycle. This relaxed out the local stresses at tips of hysteresis loops to position on Neuber hyperbolic curve. Predicted ratcheting values at notch root of various diameters closely agreed with those of measured in steel samples over stress cycles.     

Comparative analysis of fatigue life predictions in central notched specimens of Al–Mg–Si alloys

The fatigue behaviour of an Al–Mg–Si alloy was studied using notched specimens. Fatigue tests were conducted at two stress ratios R= 0 and R= 0.4 on thin plates with a central hole. Constant and block variable loading amplitudes were applied to the specimens using a servo‐hydraulic machine. The applicability of the local strain approach method to the prediction of the fatigue life was investigated for this type of discontinuity. Two methods, the equivalent strain energy density approach and a modified stress–strain intensity field approach, were used to predict the fatigue strength. For the second one an elastic–plastic finite element analysis was carried out in order to obtain the local strain and stress distributions near the notch root. Based on Miner's rule an equivalent stress was used to correlate the fatigue lives for the variable amplitude histories. The experimental results were compared with the predicted results obtained by the two methods investigated and better agreement was found with the stress–strain field intensity approach, while the strain energy approach gave more conservative results. Miner's rule gives a good correlation between the variable amplitude and constant amplitude results.     

Generalized stress intensity factors due to steady and transient thermal loads with applications to welded joints

This paper deals with the elastic and plastic stress fields induced by thermal loads in the vicinity of sharp V‐notch tips in plates. Under the hypothesis of steady‐state heat transfer and plane‐strain conditions, the thermal and mechanical problem requires the numerical solution of an ordinary differential equation (ODE) system, obtained by extending the ‘stress function approach’. The intensity of the stress distributions ahead of V‐notch tips can be expressed in terms of thermal notch stress intensity factors (thermal NSIFs), as for external loads. The problem becomes much more demanding in the presence of transient thermal loads. The residual asymptotic stress distribution arising from the solidification of a fusion zone during an arc welding process is obtained by considering different boundary conditions. An aluminium butt‐welded joint is analysed after having modelled the weld toe region as a sharp V‐notch. A finite element (FE) simulation of the welding process is carried out by means of SYSWELD code (version 2004.1) modelling the arc welding torch by means of Goldak's source. Near the weld toe, the intensity of the residual stress field is given in terms of elastic or elastic—plastic generalized NSIFs.     

Local fatigue strength parameters for welded joints based on strain energy density with inclusion of small-size notches

A fatigue strength parameter for (seam-)welded joints is presented which is based on the averaged elastic strain energy density (SED) criterion applied to full circle and semicircular ‘control volumes’, the latter centred by the expected crack path. The parameter is applicable both at weld toes and weld roots, at least in the medium-cycle and high-cycle fatigue range where elastic conditions are prevailing. Based on a rectangular slit-plate model representing the weld root and analysed by the finite element method, the effect of the following influencing conditions is investigated: tension loading (mode 1) and shear loading (mode 2), slit-parallel tension loading acting on a rounded slit tip, pointed slit tip versus small-size key-hole at the slit tip, semicircle and narrow sector versus full circle or full sector SED evaluations, distortional SED versus total SED under plane strain conditions. The following conclusions are drawn from the numerical results. The SED approach should be based on the full circle or full sector evaluation of the total SED, with R₀ = 0.28 mm for steels. In cases of a markedly unilateral angular SED distribution, the semicircle evaluation centred by the expected crack path is more appropriate. The use of small-size reference notches instead of pointed notches provides no advantage. The endurable remote stresses for fatigue-loaded welded joints according to the SED approach are well in correspondence with those according to the fictitious notch rounding approach. High accuracy of the results can already be achieved with a rough meshing at the pointed notches.     

Fracture assessment of Brazilian disc specimens weakened by blunt V-notches under mixed mode loading by means of local energy

The main purpose of this research is to re-analyse experimental results of fracture loads from blunt V-notched samples under mixed mode (I + II) loading considering different combinations of mode mixity ranging from pure modes I to II. The specimens are made of polymethyl-metacrylate (PMMA) and tested at room temperature. The suitability of fracture criterion based on the strain energy density (SED) when applied to these data is checked in the paper. Dealing with notched samples, characterized by different notch angles and notch root radii, the SED criterion used in combination with the concept of local mode I, valid in the proximity of the zone of crack nucleation, permits to provide a simple approximate but accurate equation for the SED in the control volume. This proposal unifies predictions for the experimental results obtained under modes I, II and mixed mode loading.     

Some remarks on the Neuber rule applied to a control volume surrounding sharp and blunt notch tips

The paper deals with the small scale yielding estimation of nonlinear stresses and strains at the root of sharp and blunt notches through the mechanical model of antiplane shear loadings. The frame stems from the relation existing between the elastic and plastic averaged strain energy densities evaluated over the control volume drawn by the energy contour lines ahead of the notch tip. The analysis proves that there exist different relationships in terms of point‐wise elastic and plastic stresses and strains at the notch tip depending whether the notch is sharp (small notch tip radius) or blunt. For sharp notches, the analysis confirms previous results obtained by the present authors, according to which . This equation accounts for the influence of the material law through the hardening exponent n. Differently, when the notch can be regarded as blunt, calculations over the control volume give , in agreement with the Neuber rule.     

On the second non-singular stress term of the V-notch solution: a new engineering solution

The non-singular stress terms are expressed by means complex eigenvalues and their corresponding complex coefficients for a number of sharp V-notches with varying notch opening angles. According to the literature the complex part of the solution introduces in the stress field equations an oscillatory function depending also on the logarithm of the radial distance from the notch tip. The intensity of the non-singular term depends on two parameters contrary to the conventional representation of the singular term the intensity of which is expressed by the notch stress intensity factor (NSIF). The aim of this paper is to investigate whether the stress field and the strain energy density can be described with sufficient accuracy by the real part of the Williams’ solution, neglecting the complex part of the eigenvalue and the corresponding complex coefficient. This engineering proposal strongly simplifies the problem allowing to define a real, unique, non-singular NSIF ( $\text{ H }_\mathrm{ns}$ ) which governs the intensity of the non-singular part of the stress field.