Beruflich Dokumente
Kultur Dokumente
Fracture Mechanics
Dr. K. R. Jayadevan
Professor
GEC Thrissur
Introduction
FM can also be used to predict the rate at which
a crack can approach a critical size in fatigue or by
environmental influences.
Or to determine the conditions in which a
rapidly propagating crack can be arrested.
Historical Perspective
Bridges after
industrial revolution
Fracture Mechanics as an
engineering discipline
was evolved
Comet jetliner -1952
max = nom 12 a/
as --> 0 ,
infinite stress at the crack tip
Griffith, A. A. (1920)
Size effect on Glass fibers
(Griffith's expt)
Actual strength of materials
is much less than theoretical
strength ?
Presence of defects
dE d d
Griffith's law: = =0
dA dA dA
Rice, J. (1968)
J-integral ; Non-linear fracture mechanics
MPa m1/2
Fracture Toughness
6.9 MPa
4340 steel
LEFM:
SIF, K(,a) = Kc
Kc fracture foughness,
a material property
Scope of Fracture Mechanics
KIc vs Failure Mechanism
2a
FAILURE
STRESS
Collapse
Limit load
Analyses
e
tur
Nonlinear
ac
Fracture
Fr
Mechanics
e
ittl
Br
LEFM
Ductile Fracture
Applied Stress
Fracture based
design
Strength of Materials
approach
Yield Strength
Applied Stress
Fracture Mechanics
approach
1
LEFM EPFM
K
K Ic
1 / FS
Engg
design SM
regime
0 1 / FS max 1
y
Applications
Fatigue :
da
=C K n Paris Law Threshold SIF
dN
(K)th
da Environmental
=D Kn assisted cracking
dt
ac
Crack length
Damage Tolerance
ad
approach :
ao
Aircrafts, Railways,
t t
offshore structures ...
td tc
Time
Broad areas in FM
Micro-mechanics of Fracture
Mixed-mode Fracture
Nano Fracture
Reference books
Fracture Mechanics T.L. Anderson
E E s
c =
xo
2a
A = 1 +
b
a
A = 1 + 2 ,
=
b2
a
a
When a >> b A = 2
f = s
4a
Griffiths energy balance
(Griffith, 1924)
Based on First law of Thermodynamics :
dE d dWs d dWs
= + = 0 =
dA dA dA dA dA
ie., for fracture to occur, the energy stored in the structure must be
sufficient to overcome the surface energy of the material.
2 a 2 B
1/ 2 = o
2 E s E
f =
a d 2 a
=
dA E
dWs
valid only for brittle matls = 2 s
dA
Modified Griffiths equation
Apply only for brittle matls
1/ 2
2 E ( s + p )
f =
a
s - Surface energy per unit area
release rate
G = or Crack Driving Force
dA G is a measure of the energy available
for an increment of crack extension
dWs 2 a
Gc = = 2w f G=
dA E
wf = s + p
Expression for G
The potential energy
of an elastic body, = U Wext U SE stored in the body
Wext W.D. by external forces
1 dU P d 1 dU dP
G= = G= =
B da P 2 B da P B da 2 B da
2
P dC
for both cases : G= , C=
2B da P
dU dU
ie., G is same for both Load & Disp control : Also =
da P da
Instability & R-curve
Stable crack growth:
dG dR
G=R &
da da
Unstable dG dR
>
da da
Ga for CCP
2 (for brittle matls)
Ga for DCB
Material behaviour
Crack & loading confgn
(ductile matls)
Load Vs Displacement Control
ij =
k
r
f ij A m r m/2 g m
m=0 ij
k a constant
fij a dimensionless funtion of
1
As r 0,
r
; u r
(Stress singularity)
Fracture Modes
A crack can experience three types of loading
Load is normal to the crack plane
Tends to open the crack
In-plane shear loading
Tends to slide one crack face
with respect to the other
Out-of-plane shear loading
Each mode causes stress singularity
k, fij depends on mode of loading
Stress Intensity Factor
(Irwin, 1957)
KI 3
xx = cos 1 sin sin
2r 2 2 2
KI 3
yy = cos 1 + sin sin
2r 2 2 2
KI 3
xy = cos sin cos
2r 2 2 2
[ ]
KI r
ux = cos 1sin2
2 2 2 2 = 3 4 for plane strain
(3 4 )
[ ]
KI r = for plane stress
uy = sin 1cos 2 (1 + )
2 2 2 2
Relation between SERR & SIF
(Irwin, 1957)
G Net change in energy release rate for a (global)
K Characterises the crack-tip field (local)
U
for Linear Elastic case: G= lim
a 0 a fixed load
x = a
1
U = dU ( x)
x =0
; dU ( x) = 2 Fy ( x) u y ( x) = yy ( x) u y ( x) dx
2
( + 1) K I (a + a ) a x K I (a)
uy = ; yy =
2 2x
a
lim ( + 1) K I (a ) K I (a + a ) a x
G= a 0
4 a 0
x
dx
2 2 2
K 2I E' = E Plane stress KI K II
K III
G= ' E : G= ' '
E E' =
1 2
Plane strain
E E 2
Singularity dominated zone
Region where Williams eqns describe the crack-tip fields.
KI
for =0, xx = yy =
2r
xy = 0
K proportional to load
K =O a ( ) MPa m
SIF - solutions
Closed form K solns are derived for simple geometries:
2
K I = a K I = 1 . 12 a K I = a
Replace by for pure mode-II loading
K I = y ' y ' a
K II = y ' x ' a
Effect of finite size
2W a
1/ 2
K I = a tan
a 2W
Based on FEM:
a 1 / 2 a
2
a
4
Semi-elliptical crack
Internal pressure
K I( a ) = K I( b ) K I( c )
= K I( b ) 0
K (a)
I =K (b)
I
Arbitrary loading
6PL
max = 2 F M approach:
BH
S M approach:
Pd
Pressure vessel : h=
2t
S M approach: F M approach:
y 2t
max P y K =1.12 max a
FS FS d
K Ic
K =K Ic or K=
Take: FS
2t K Ic
K Ic =30 MPa m , y =450 MPa , F S =3, P
d=1m , t =2 cm , a=1 cm F S d 1.12 a
SM : = y FM : K (, a) = Kc
b) CT (edge crack) K I = 1 . 12 a
2
c) Penny shaped crack K I = a
Tutorial - I
4.What is the order of the elastic crack tip field near the tip?
1
Stress : (singular)
r
Displacement: r (non-singular)
K Ic =50~150 MPa m
KI
xx = yy =
2r
r
Tutorial - I
7. A large plate with a small central hole is loaded as shown ? Is design safe for
= 10 Mpa, if a = 1 mm, Kc = 50 Mpa m1/2, y = 300 Mpa.
SM approach
design is safe
a
FM approach
for an edge crack: K I = 1 . 12 a
KI = 59.54 Mpa m1/2 > Kc = 30 Mpa m1/2
design is unsafe !!
Nonlinear Effects
Plasticity corrections
(Irwin, 1958)
2
First-order : r y=
1 KI
2 ys (Plane stress)
ry ry
KI
Second order : YS rp = yy dr = dr
0 0 2r
2
r y=
1 KI
ys
(Plane stress)
r y=
1 KI
6 ys
(Plane strain)
a eff = a + ry
K eff = a eff a eff
Strip Yield Model
(Dugdale ; Baranblatt, 1962)
A long slender crack-tip plastic zone
in a non-hardening material
in plane stress.
r y=
KI
8 ys
&
K eff = a sec
2 YS
Comparison of Plastic Zone Corrections
Plastic zone shape
Applying Von-Mises
yield criterion:
e = y on
Elastic soln
Mode-I plastic zones from FEM
Elastic-plastic boundary
from LEFM
K( , a) Stress Intensity Factor
K dominant region
R
Inelastic region
boundary of D
inelastic region
SSY condition
outer boundary of
K-dominant
region
R < D, or B
2
Fracture Criterion
R
1 KI
2 ys
K( , a) = Kc
K as a failure criterion
K defines the crack tip field
A critical K value
Kc Fracture Toughness
( Material constant)
a KI
As r 0, yy = xx = =
2r 2r
a
2a Assuming singularity zone, rs = ,
50
2
1 K I
set ry=rs in p , ry =
6 ys
2 2
50 K I* K I*
= 2.65
a=
6 ys
ys
ASTM standard for KIc :
2 the limit of LEFM is:
K
*
a, B, (W a) 2.5 I K I* = 0.35 YS a
ys
ensure P Ensure nominal LE
behaviour
Applications
Pressure vessel :
Minimum Flaw size, given the max pressure
a=
y
K Ic
- geometry dependent
parameter
Importance of Location 4340 steel air frame
K Ic =50 MPa m , y =1680 MPa , F S =4
Pressure vessel :
Edge crack :
Influence of Material 2
ac=
1
K Ic
1.25
2c
Pressure vessel /
t
Pipelines : a
Part-through-wall
surface crack
Type A
Type B
Type B is more
2ac critical !
Type C
2cc
Leak-before-brake condition (Type A)
Introduction to EPFM
Limitations of EPFM
Crack tip opening Displacement, CTOD ()
In general,
Based on Strip yield model: 2
Burdeking & Stone (1966) KI G
= =
2 m ys E m ys
[ ]
2
KI 1
= 1
ys E 6 2 ys m ~1-2 (p p)
(for Griffith's problem)
CTOD definition
Rice, 1968
FE measurements
Vp
'
r : Plastic rotational factor 0.44
p m ys E r p W a a
J Contour Integral
Rice (JAM, 1968) Rices J-integral
J = w dy T i
u i
x
ds
ij
w= ij d ij ; T i= ij n j
0
Assumptions :
Homogenious hyper-elastic matl
Rice showed that : Small strains
Time independent processes
Plane stress & disp fields
J is path-independent &
Crack face parallel to X
No body force
J = Energy release rate. Traction free crack surfaces
Nonlinear energy release rate
(Rice 1968)
d
J = = U W ext
dA
for unit thickness,
A=a
*
dU dU
J= = or
da P da
P
J=
0
a P
dP =
0
P
a
d
For a linear elastic matl :
2
KI
J = G and J= '
E
HRR Solution
J Stress intensity parameter ( Hutchinson; Rice & Rosengren, JMPS, 1968)
ij= 0 2
EJ
0 I n r
n1
ij n , In Integration constant,
depends on n and p/p
n
0
ij=
EJ
E 02 I n r
n1
ij n ,
, -- Dimensionless fns of n and
depends on p/p
(Hutchinson, 1968)
HRR - significance
Importance of HRR soln:
LEFM
singularity
J-integral defines the amplitude HRR
of HRR singularity singularity
J =
1 U
B a
=nc c
For deep crack, nc << c
U = M d
0
M c
J =
0
c
a M
2
dM M d c
b 0
In general: Uc
J= is a dimensionless constant
Bb
J CTOD relationship
For LEFM : J =G=m YS
This applies beyond validity of LEFM.
J = YS
=d n J / o - dn is dimensionless constant
=1
=1
E dJ R
T R= 2
0 da
Deformation J : U D=U D P , a
J D=
1 U D
B a
If R << D
J( , a) = Jc boundary of D
process zone
J
ij
'
1 E J
=F ij 2 ,
0 0r
ij
'
E J a
=F 3ij , ,
0 20 r i
ij
0
=F 3ij
E' J
2
0r
,
Stage 2 : Rising R-curve, under SSY
J R =J R a
J-R curve is a material property
Crack-tip Constraint under Large-scale Plasticity
McClintock(1971)
Plane strain,
Non-hardening matl
Slip-line analyses
a = 1 mm
K, J along with T-stress as the second parameter Hancock & coworkers, 1990
ij=
KI
2r [ T 0 0
f ij 0 0 0
0 0 T ]
Fracture toughness strongly increases with negative T
T-stress strongly affects shape and size of crack tip plastic zone
KI
ij= f ij T 1i 1j
2r
T=
P
f
B aW W
a
, where =
T a
KI
is the biaxiality parameter
J Q Theory (ODowd and Shih, 1991)
yy yy T=0 r 0
Q at =0 and =2
0 J
Q & T are related under SSY
Evolution of Q
depends on crack depth
J-Q theory
J c =J c Q
Application of
J-Q toughness locus
Micro-mechanics of Fracture
Fracture mechanisms in metals
2
1
1. Ductile fracture
2. Cleavage fracture
3. Intergranular fracture
3 4. Fatigue
Ductile fracture
1 Inclusions in a
ductile matrix
2 Void nucleation 3 Void growth
4 Strain localisation
between voids
5 Necking between voids 6 Void coalescence
and fracture
Void Growth and Coalescence
Once voids form, further plastic strain and hydrostatic stress cause the
voids to grow and eventually coalesce.
KIt
ij t = f ij
2r
Time dependent Same quasi.static fns Time
Independent of time
Fracture initiation :
D
K I t =K Ic Dynamic fracture toughness
Rate sensitivity effect on Fracture toughness
p
H(t)
t
!!! Maximum K d 2.5 K stat !!!
Schematic illustration of explosive damage in Pan Am
Aircraft from the Lockerbie tragedy:
F
J=
V
[
J =lim 0 W T dy ij n j
ui
x
ds ]
ij
1 ui ui
t
where, W = ij d ij = ij ij dt ; T=
0 0
2 t t
P(t) = t +
t2
P(t)
Crack tip
element size
5 10 m
E = 200 GPa
= 0.3
= 7,800 kg/m3
.
Kdc K variations
Sharp increase
in
. Kdc around
K = 106 MPa m1/2/s
Proposed dynamic
crack initiation
model is verified
.
Experimental data from
Owen et al., 1998
Numerical
Owen results
qualitatively
agree with
experimental
results.
.
Reeling
Pipe Geometry
D = 400 mm
D / t = 20 t = 20 mm
L = 1200 mm
a / t = 0.1 - 0.5
c / R = 0.04 - 0.3
a = 2 and 10 mm
2c = 25 - 378 mm
Finite Element Model
Crack
Loading
end
1/4th of the pipe model
Mid-
section 20 noded brick elements
30 40,000 d.o.f
Crack front radius :
0.025 mm Abaqus FE package
Plane
KIc strain
t
Tutorial-II
J-integral
5. Definition of CTOD?
7. HRR field
Name the variables?
What is the order of singularity?
ij= 0 2
EJ
0 I n r
n1
ij n ,
In Integrationconstant,
, n, o matl constants
depends on n and p/p
Ramberg-Osgood relationship
Deformation plasticity
Proportional loading
Small strain