Beruflich Dokumente
Kultur Dokumente
Florent Galland
PhD Student
David Roche
Support engineer
II.
IV. Examples :
Damage tolerance sensitivity analysis, crack propagation analysis.
2009 ANSYS, Inc. All rights reserved.
Application context and difficulties Fracture mechanics science was born in the 20th century and for many applications, is still an open problem. Accident of the German train ICE in 1998:
Application context and difficulties Simulating fatigue crack growth: an opening challenge for the commercial finite element analysis softwares. A wide range of industrial applications are concerned by 3D fatigue crack growth simulations. aeronautic, aerospace, military engineering, nuclear structures applications...
High need of robust automatic numerical tools for 3D fatigue crack growth
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Simulation context
The initiation stage can represent a large part of the life span During the stable propagation stage the crack speed grows exponentially with the crack size The crack grows unstably until the ductile fracture
G=
W p A
The energy release rate is the quantity of dissipated energy per unit of newly created fracture surface area
G Gc
Reference: A. A. Griffith, The phenomena of rupture and flow in solids, Philosophical Transactions of the Royal Society of London, Harrison and Sons 1921
2009 ANSYS, Inc. All rights reserved.
r singularity
crack
Advantages
Preciseevenwith coarsemesh (G method) Robustness (pathindependency)
Drawbacks
Implementation
1 J = qi , j kl klij kj uk ,i dV V 2
Easeofuse
Reference: JR. Rice, A path independent integral and the approximate analysis of strain concentration by notches and cracks, Journal of applied mechanics 35, 379-386, 1968
2009 ANSYS, Inc. All rights reserved.
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Stressintensityfactor(Pa*m)
2,00E+06
k2numerical
1,00E+06 0,00E+00 1,00E+06
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Angleindegrees
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FRACTURE MESHING
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A workflow has been developed using the Ansys V12 schematic approach, and allows for fracture computation in workbench
2009 ANSYS, Inc. All rights reserved.
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Reference: Chong Rhee and Salama, Mixed-mode stress intensity factor solutions of a warped surface flaw by three-dimensional finite element analysis, Engineering fracture mechanics 28, Elsevier 1987
2009 ANSYS, Inc. All rights reserved.
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K2 Paper
K3
Reference: Chong Rhee and Salama, Mixed-mode stress intensity factor solutions of a warped surface flaw by three-dimensional finite element analysis, Engineering fracture mechanics 28, Elsevier 1987
2009 ANSYS, Inc. All rights reserved.
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Finally, a response surface and an optimization are computed to determine the most critical locations of the crack
2009 ANSYS, Inc. All rights reserved.
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Industrial example: Cracked turbine blade Identify the most critical locations of the crack:
Parameterize the position of the crack Create a Design of Experiments Automatic solving for several positions of the crack
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Industrial example: Cracked turbine blade Identify the most critical locations of the crack:
Response surface:
G atthefreesurface
G inthebulk
Postprocess the variations of the energy release rate G versus the location of the crack
2009 ANSYS, Inc. All rights reserved.
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Industrial example: Cracked turbine blade Identify the most critical locations of the crack:
Optimization: Screening for candidates locations giving G > GC :
For which location does the energy release rate G exceed a certain criterion Gc?
2009 ANSYS, Inc. All rights reserved.
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Industrial example: Cracked helicopter flanged plate An open problem: The helicopter round-robin challenge
Initiated in 2002 by the American helicopter community to benchmark the fatigue crack growth simulation methods.
- Complicated 3D part - Complicated variable loading - High number of cycles
2009 ANSYS, Inc. All rights reserved.
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Industrial example: Cracked helicopter flanged plate An open problem: The helicopter round-robin challenge
Objective: solve fatigue crack propagation analysis with minimal user intervention
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da = C.K m dn
Free crack front shape: No assumption on the front nature
Kth
K ( MPa. m )
Kc
Newcrackfront
Initial front
Reference: P.C Paris et al., A rational analytic theory of fatigue, The trend in engineering 13, 528-34, 1961 S. Pommier, Principaux mcanismes physiques de fissuration par fatigue en mode 1, ENS Cachan, 2009
2009 ANSYS, Inc. All rights reserved.
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Draw the initial crack in a submodel of the interest zone and initialize the 3D curve with that geometry
Solve the problem, compute the new crack front position, send back parameters to workbench
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Industrial example: Cracked helicopter flanged plate Scripting workbench: Automatic propagation loop
DesignModeler Refreshthe 3Dcurves Updatethe geometry Mechanical Meshthe model Setupthe boundary conditions Mechanical APDL Solvethe model Computethe crackadvance (Parislaw)
JScript
APDL
Python
2009 ANSYS, Inc. All rights reserved.
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Industrial example: Cracked helicopter flanged plate Postprocess the crack growth:
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Industrial example: Cracked helicopter flanged plate Postprocess the crack at the final step:
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Industrial example: Cracked helicopter flanged plate Ensure the solution validity all along the propagation:
Mesh quality:
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Industrial example: Cracked helicopter flanged plate Postprocess the crack front evolutions:
The obtained front shapes are in fairly good agreement with experimental results
Reference: J.C. Newman et al., Crack growth predictions in a complex helicopter component under spectrum loading, Fatigue & Fracture of Engineering Materials & Structures 29 (11), 949-958, Blackwell Publishing Ltd 2006
2009 ANSYS, Inc. All rights reserved.
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Industrial example: Cracked helicopter flanged plate Postprocess the crack front evolutions:
The obtained front shapes are in fairly good agreement with experimental results
Reference: J.C. Newman et al., Crack growth predictions in a complex helicopter component under spectrum loading, Fatigue & Fracture of Engineering Materials & Structures 29 (11), 949-958, Blackwell Publishing Ltd 2006
2009 ANSYS, Inc. All rights reserved.
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Concluding remarks
Direct computation of the mixed mode stress intensity factor is possible in Ansys V12 Fracture mechanics problem can be solved entirely in workbench, thanks to a new workflow It gives the opportunity of using all the workbench project page features. Solve problems with:
Contact Confined plasticity, thermal loading Submodelling Parametric update Design of experiment
Performing fatigue crack growth analysis on realistic 3D industrial parts is now possible
2009 ANSYS, Inc. All rights reserved.
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