Elements of Fracture Mechanics

Elements of Fracture Mechanics

Jonah H. Lee
Department of Mechanical Engineering University of Alaska Fairbanks

Jonah H. Lee

Fracture Mechanics

Elements of Fracture Mechanics

Grifth Crack Theory

Figure: 8.1: Through-thickness crack in a large plate.

The potential energy (strain energy - work done) of a plate with a crack (s = energy/area, J/m2 ): PE with crack U surface energy strain energy = = = PE w/o crack Dec. PE + Inc. surface energy U0 2 a2 t + 4a t s E area s = 2 (2a t) s V /2 /E a2 t
Jonah H. Lee Fracture Mechanics

Elements of Fracture Mechanics

Grifth Crack Theory - continued

Equilibrium condition: 2 2 at U = 4ts = 0. a E Equilibrium but unstable, crack will grow (negative second derivative) For plane stress = for plane strain = is the applied stress. 2Es a(1 2 ) 2Es a

Jonah H. Lee

Fracture Mechanics

Elements of Fracture Mechanics

Effect of Plastic Deformation

Materials with limited plastic deformation, fracture energy surface energy (glasses). Materials with extensive plastic deformation, fracture energy (metals, polymers): = 2E(s + P ) = a s , so 2Es P ( ) a s a/; (Eq. 7.9): c = E a0 2Es P (1 + ) a s surface energy

P = plastic deformation energy

(Eq. 7.27): a =applied stress, max 2a

Let c (theoretical cohesion) = max (maximum stress due to stress concentration): a = 1 2 Es ( )= a a0 2Es ( ) a 8a0

plastic deformation P increase of : crack tip blunting.

Jonah H. Lee Fracture Mechanics

Elements of Fracture Mechanics

Energy Source and Release Rate

Elastic energy per unit crack area (a t): G For unit thickness (t = 1), G

U , (J/m2 ). (at)

U (a 1) At the point of instability, the elastic energy release rate (crack driving force N/m) reaches a critical value Gc (a material property), fracture occurs = From before: = 2E(s + P ) a EG , a G = 2(s + P )

Jonah H. Lee

Fracture Mechanics

Elements of Fracture Mechanics

Critical Energy Release Rate (Fig. 8.2)

Jonah H. Lee

Fracture Mechanics

Elements of Fracture Mechanics

Determination of Critical Energy Release Rate

Let da=increase in crack length, d=displacement increment due to P, work done 1 1 P2 (by P)=dW = Pd, V =stored elastic strain energy= P or (M =stiffness); 2 2 M Surface energy is needed for that crack to extend and comes from: G = = dU d dV =P da da da work done by external force - release of strain energy

Fixed grip (displacement control) condition, d = 0, load drops from P1 to P2 , P2 P1 = stiffness drops from M1 to M2 but 1 = 2 = M1 M2 ( Critical energy release rate Gc = where Pmax =load at fracture.
Jonah H. Lee Fracture Mechanics

U 1 (1/M) ) = P 2 a 2 a

1 2 (1/M) P 2 max a

Elements of Fracture Mechanics

Stress Analysis of Cracks

Figure: 8.3

Mode I - opening or tensile mode. Mode II - sliding or in-plane shear mode. Mode III - tearing or antiplane shear mode.

Jonah H. Lee

Fracture Mechanics

Elements of Fracture Mechanics

Figure: 8.5

Example of crack-tip stress in y -direction obtained using theory of elasticity (Airy stress functions): K 3 y = cos 1 + sin sin 2 2 2 2r Singular stress at r = 0. K =f (, a) stress-intensity factor, with dimensions Pa m1/2 .

Jonah H. Lee

Fracture Mechanics

Elements of Fracture Mechanics

Figure: 8.7 - Stress-intensity-factor (K ) solutions for a central (a) and edge (b) crack.

KI = Y

Pa1/2 tW
Jonah H. Lee Fracture Mechanics

Elements of Fracture Mechanics

Design philosophy, e.g., Fig. 8.7a: K = Kc = a Kc Material selection Design stress

a Allowable aw size (NDT)

Jonah H. Lee

Fracture Mechanics

Elements of Fracture Mechanics

Crack-Tip Plastic-Zone Size Estimation

At = 0, y = K / 2r , at yielding, y = ys , plastic-zone size=ry is a function of a.) Plane stress: ry 1 K2 1 K2 ; Plane strain: ry 2 2 2 ys 6 ys

K2 (K 2 2ys

Effective K for an innite plate with a small central notch (Eq. 8-45) a Keff = 1/2 1 2 1 2 ys
Jonah H. Lee Fracture Mechanics

Elements of Fracture Mechanics

Fracture-Mode Transition: Plane Stress Versus Plane Strain

Figure: 8.15 - Effect of relative plastic zone size to plate thickness (ry /t) Figure: 8.14 - Variation in fracture toughness with plate thickness

Kc =fracture toughness varies with plate thickness (higher at plane stress, lower at plane strain) (Fig. 8.14). KIC =plane-strain fracture toughness remains constant after thickness t2 , or, small ry /t (Figs. 8.14 and 8.15). Plane strain fracture (at, smooth), plane stress fracture (slant, rough).
Jonah H. Lee Fracture Mechanics

Elements of Fracture Mechanics

Plane-Strain Fracture-Toughness (KIC ) Testing - ASTM E3990-90

Figure: 8.18 - Example of load-displacement curves during KIC testing.

Figure: 8.7(e) - KI for 3-point bending.

Jonah H. Lee Fracture Mechanics

Elements of Fracture Mechanics

Test sample initially fatigue loaded to extend the machined notch to a prescribed amount a; e.g., three-point bend bar, Fig. 8.7(e): KI = Y Test done using displacement control. Measure specimen load P and (crack-opening) displacement until fracture. Applied stress is found via (maximum) load P using P curve (Fig. 8.18) formula for K for a particular geometry is then used. Restrictions: t and a 2.5 KIC ys
2

6Ma1/2 tW 2

Jonah H. Lee

Fracture Mechanics

Elements of Fracture Mechanics

Plane Stress and Related Models

Figure: 8.13(b) - Dugdale plastic zone strip model where plastic zones R extend as thin strips from each end of the crack. 2c is the initial crack length.

Cohesive-zone model (Fig. 8.13) R/c = 2 2 ( ) 8 ys

J-integral based on simple elastic-plastic analysis using a deformation plasticity theory (path-independent).

Jonah H. Lee

Fracture Mechanics