Finite element analysis of crack propagation in three-dimensional solids under cyclic loading

This paper is concerned with an efficient computational procedure for analyzing crack propagation in solids. The method is general; however, its application to semi-elliptical surface cracks in thick plates is discussed in particular. The strain energy release rate G for a crack in mode I is a function of the crack geometry, the direction of crack propagation and the state of loading. When G is known, the stress intensity factor K_I can easily be obtained. In this paper the strain energy of the plate is computed numerically for a wide range of crack geometries using the finite element method. A 20-node isoparametric solid element is employed in modelling the structure. Certain special techniques for increasing the computational efficiency of the method, such as multilevel subdivision of the structure (substructuring) and condensation of degrees of freedom that are not needed in the crack propagation analysis, are emphasized. In fact, analysis of a large number of crack geometries requires only insignificantly more computational efforts than treating a single crack. Certain other aspects of the finite element modelling are also discussed.Two methods for replacing the computed discrete values of strain energy by continuous functions are presented. These functions are expressed in terms of the two half-axes defining the geometry of the elliptical crack and they are determined using a least square technique. G and K_I are easily deduced from these functions. As an example, a semi-elliptical, part-through, surface crack in a thick nickel steel plate is analyzed. The crack is subjected to a combination of axial and bending loading, applied cyclically. From the finite element calculations of the strain energy and the stress intensity factors which are computed accordingly, crack propagation along the two half-axes of the ellipse is calculated by utilization of a formula suggested by Paris. The results are checked against laboratory fatigue tests. The method has proved to be very efficient and accurate, and due to its generality it can also be applied to complicated geometries and complex states of loading.