2008 International

ANSYS Conference

3-D Crack Propagation Modeling and

Analysis: Turbocharger components under
TMF loading

Ragupathy Kannusamy, Shailendra Bist

Honeywell Turbo Technologies

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Introduction
• Turbine Housing
– Also called turbine scroll contains the radial turbine wheel and directs gas
into it.
– Mostly made of cast iron alloys for turbocharger applications.
– During operation these components experience severe thermo
mechanical (TM) load.
– Severe TM loading can lead to cracks initiating and propagating with
accumulation of cycles.
– Presence of a crack is not necessarily a failure unless it leads to loss of
functionality (gas leakage, wheel rub etc) or is externally visible.
– Knowledge of how cracks grow (path) and how fast they grow (growth
rate) is important.
– Methods/tools that can help predict path and growth rate of cracks:

• Help design products quantitatively as opposed to a ‘better than’

approach.
• Increase confidence during testing phase.
• Lead to more reliable products.
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Introduction

Inlet gas
temp.
Temp (% of Inlet).

Stress S1 (% of Max).
Stress S1.
Metal
temp.

No of Cycles. A typical free floating Turbine housing.

A typical accelerated test duty cycle.

Typical housing failures via cracking.

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Challenges
• Several LEFM based, Mode I (planar) crack growth modeling codes and
methods are popular and commercially available.
• However, due to the nature of loading and complexity of geometry above
assumptions are not applicable to our case
• Large scale and even cross sectional yielding can occur in certain locations.
– Cracks have been observed to exhibit mixed mode growth behavior (turning and
kinking)
– Thermal loads can only be accounted for via an indirect approach in the above case.
• A conventional displacement (K) based approach is also an implementation
challenge in 3D
– To capture the singularity in strain at the crack tip a focused/collapsed mesh is
needed.
– Creating such a mesh at the crack front at each crack increment is near impossible
in an automated manner.

• Developing an automated 3-d mixed mode crack growth code capable of

dealing with elastic-plastic condition is a technical challenge !

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Background of J-integral Approach

• J-integral is a path independent fracture mechanics parameter which

predicts energy release rate and intensity of deformation at crack
front (CF) for linear and nonlinear material behavior.

• W is strain energy and it is a point function. It varies from point to

point within body of the component [13]
• ANSYS calculates J values using volume integral in terms of rings of
elements at the crack front.
• The highest energy release rate is calculated for virtual crack
extension angle for all the CF nodes and new crack front is extended
in the direction of max energy value.

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Crack Growth Rate using Paris Law :

Evaluation of Crack growth vs Cycles : Constant Amplitude Approach

- During fatigue crack growth under LEFM assumptions, the relation

between incremental crack growth and load cycles can be represented by
Paris law. (1 − v 2 ) K 2
Plane Strain.
da
dN
m
(
= C (ΔK ) = C ΔJ )
m
J=
E
K2 Plane Stress
E
- C and m are material properties and need to be evaluated (ASTM D647) .
- However, under large scale yielding condition, J-integral approach needs to be
directly implemented. This also involves non standard testing for estimating fcg
material properties.

Crack growth calculation based on block technique:

⎛ da ⎞ ⎛ da ⎞ ⎛ da ⎞
Δa = ⎜ ⎟ 1 ⎜
N + ⎟ 2 ⎜
N + ⎟ N 3 + ....
⎝ dN ⎠1 ⎝ dN ⎠ 2 ⎝ dN ⎠3
N is cycles per Block
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FCG methodology implementation

Spectrum File

Create a model
Thermal & Stress Identify initial with crack Preprocessing,
Calculate next
analysis for the crack surface and Solution and
crack increment
given load location and crack front Post processing
size (∆a)
spectrum orientation. information (ANSYS)
(CAD)
Global DB and RST files
Report new
• Sub model creation, crack feature crack front
No Stopping
location and criterion
insertion handled by CAD. crack surface reached?
• Meshing, preprocessing, analysis and information.
path/growth prediction handled by ANSYS.
• Logic and links implemented via in-house Yes
scripts (APDL and CAD package).
• Process is fully automated after initial set-up. Report Result
• Can handle both elastic or elastic-plastic
analysis.

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Validation runs: Qualitative

Expected crack
path.

• Cruciform specimen.
– Uniaxial mechanical loading.
Predicted crack path (cruciform specimen
– Fully elastic, R = 0.1
under uniaxial loading).

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Validation runs: Qualitative.

Expected crack
path.

• Cruciform specimen.
– Biaxial mechanical loading.
Predicted crack path (cruciform specimen under
– Fully elastic, R = 0.1
biaxial loading).

Gives more confidence to J integral approach implementation and mixed mode

capability !

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Validation runs: Quantitative.

Applied Load
Geometry details:
Length = 200mm
Width = 100 mm
Thickness = 20 mm
Loads:
Max. Load = 250 Mpa
.
Min. Load = 62.5 Mpa Full Model with Crack

R = 0.25
Material Properties:
E = 72400 Mpa
‫ = ע‬0.33
Paris law constants:
M=3.7
C=1.515e-14
Cycles per block (CPB) =
5000
First crack radius = 3 mm
Sub model with
Fixed in all 3 directions Crack

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Validation runs: Quantitative.

Crack Front Profile Plot

30

25
Depth of Plate (mm)

20

15

10

0
0 5 10 15 20 25 30
Width of Plate (mm)

Transition from surface crack to through crack automated using a c/s stress
based criterion.
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Validation runs: Quantitative.

Crack Length vs. Cycles

25
NASGRO ∆c
FE approach-Sub-model

Crack length, mm
20
Crack Length (mm)

FE approach-Full Model

15

10

∆a Crack depth, mm
0
0 5000 10000 15000 20000 25000 30000 35000

Cycles, Np

1. Differences in NASGRO and FE approaches are due to location of crack increment size.
2. NASGRO calculates next crack increment by considering only ∆a from free surface whereas
ANSYS takes highest ∆a value from the crack front. This leads to more conservative results.

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Crack path prediction : real geometry

Turbine Housing.

Real life crack geometry. V Band

Connection.
Center/bearing
Housing.

Mounting base.

• CFD to obtain thermal B.Cs in the components.

• Elastic material properties used.
• In-house thermal shock cycle simulated.
• Global stress results used for crack path prediction.

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Results : Sub-models after each

iteration

Actual crack path after tests.

Predicted crack path.

Qualitative agreement between real life and analysis!

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Results : Real life design comparison.

-34 design is 50% better in terms of fcg life!

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Productivity gain: C(t) Specimen

100

80
Manual Process
Automated Process
60

.
100 minutes
40
45 minutes
30 minutes
20 45 minutes
25minutes
25 minutes
2.5 minutes
0.5 minute 1 minute 0.5 minute
Model creation in FE model creation with Results extraction and Crack Total cycle time for simulation
crack front in ANSYS. growth Calculation for a of one crack increment
CAD.
given load spectrum. (excluding solution)

The developed methodology reduces the crack growth

analysis time of test specimen by more than 90%

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Next steps:

• Elevated temperature fcg testing being currently conducted using M(t)

specimen.
• In-house custom fcg test being developed for validation purposes.
• Algorithms being further refined for robustness, accuracy and speed.
• Further validation work is ongoing using literature cases.
• Ansys Collaboration :
• Bugs with CINT fixed in V11.0 SP1.
• Thermal effects included in J calculation in V12.0 preview version.
– Tested and validated by HTT.
• Need Ansys to implement J calculation using tetrahedral elements.
• Need option for J value decomposition. (JI, JII, JIII)

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Conclusion:

• The J integral (energy) approach to fcg modeling was effectively used to

develop a 3-d mixed mode capable process/methodology.
• J integral approach has several benefits over K based approach:
– Ease of implementation as meshing requirments at cf are much
more relaxed.
– Capable of dealing with large scale yielding problems.
– Directly account for thermal loading.
• Automation via scripts make the process feasible in a production
environment. ( ~ 500 designs analyzed/year)
• Some baseline validation runs show good promise for the methodology.
• Qualitative validation using fcg material test data will pose its own
challenges. (non isothermal Vs isothermal, LEFM vs NLFM, closure
effects etc)

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References

1. H.A Richard, M Fulland and M sander, Theoretical Crack Path Prediction, Fatigue
Fracture Engg. Mater Struct. 28, 3-12, 2005
2. Shih, C. F., B. Moran, and T. Nakamura, “Energy Release Rate Along a Three-
Dimensional Crack Front in a Thermally Stressed Body,” International Journal of
Fracture, vol. 30, pp. 79–102, 1986.
3. Daniel Bromberg, Guido Dhondt, Automatic crack-insertion for arbitrary crack
growth, Engineering Fracture Mechanics, 9 January 2007 ( Publication is in Press)
4. A.F Liu, Structural Life Assessment Methods, ASM International
5. L.P Pook, Crack Paths, WIT Press, 2002
6. L.P Pook, Metal Fatigue, What is , Why it matters, Springer,2007
7. H A. Richard, Computational simulation and experimental results on 3D crack growth
in a 3PB specimen with a inclined plane, Key Engineering Material, Vol 251-252
(2003) pp 85-90
8. ANSYS Manuals,
9. NASGRO 5.1 Manuals
10. J. H Kuang, Crack initiation direction for a crack under mixed mode loading, Inter.
Journal of Fracture, 73 33 -37, 1995
11. L. P Pook, H.A Richard, Crack paths, Engineering Fracture Mechanics, may, 2007
12. D.M Parks, Application of Domain Integral Methods using Tetrahedral elements to
determine SIF values, Engg. Fracture Mechanics, 66 (2000), 455-482.

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Special mention :

Authors would like to thank:

- Dr. Grama Bhashyam & Dr. Guoyu Lin of Ansys Inc for enabling key
capabilities in Ansys to support fcg methodology implementation.

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