Brief History of Fracture

and Fracture Mechanics and Fracture Mechanics

10,000 BC
Cavemen found that rocks could be fractured Cavemen found that rocks could be fractured
to make shape edges for cutting/killing tools
2
100 BC
Roman/Greek engineers built large stone Roman/Greek engineers built large stone
structures for buildings/bridges/aqueducts
3
1500
Leonardo da Vinci conducted fracture test Leonardo da Vinci conducted fracture test
on iron wire and found failure load ~ 1/ L
L
4
1913
Inglis used Theory of Elasticity to determine Inglis used Theory of Elasticity to determine
exact stress field for an elliptical hole in a plate
under remote tensile stress under remote tensile stress
Maximum stress at notch root:
o
max
= S (1 + 2 a/b)
max
( )
o
max
= S [1 + 2 \(a/)]
o
max
= S + 2 S\(a/)
5
1919
Boston Molasses Tank Disaster Boston Molasses Tank Disaster
Built before ASME Boiler and Pressure Vessel Codes (1914-15)
6
1920-24
A A Griffith considers cracks in brittle materials A. A. Griffith considers cracks in brittle materials,
such as glass
Father of Fracture Mechanics
7
GRIFFITH FRACTURE THEORY
E b l i I li l i f lli i l h l Energy balance using Inglis solution for elliptical hole:
Tensile strength of freshly drawn glass fiber is much
greater than that of old or aged glass fiber
Tensile strength decreases with glass fiber length Tensile strength decreases with glass fiber length
Tensile strength is very variable from sample to
l h t ti ti l i sample much statistical variance
8
1940-45
Welded Liberty ship failures due to pre existing Welded Liberty ship failures due to pre-existing
flaws and stress concentrations
At D k At S At Dock: At Sea:
9
1954-55
Passenger jet Comet experiences two in flight Passenger jet Comet experiences two in-flight
failures: airframe design research intensified
Worlds first commercial jet airliner
COMET AIRCRAFT
10
CATASTROPHIC FAILURE OF COMET FUSELAGE
1954-55 1954 55
11
1957
G R I i i t d th t i t it f t K G. R. Irwin introduces the stress-intensity factor, K
o
ij
= K/(2tr) f
ij
(u) + H.O.T.
Father of (Modern) Fracture Mechanics
12
Crack-Tip Stress-Intensity Factor is Corner-Stone
f F t M h i of Fracture Mechanics
13
Brief History of Fracture and Fracture Mechanics
(continued)
1961 Paris and Anderson proposes da/dN = f (AK)
(continued)
1961 Paris and Anderson proposes da/dN f (AK)
1961 Neuber develops K
o
K
c
= K
T
2
concept
1963 Wells develops the CTOD fracture concept
1968 Ri ( d E h lb ) d l th J i t l t 1968 Rice (and Eshelby) develops the J integral concept
1968 Hutchinson shows o c E = o
e
2
for HRR
*
field
e
f
1968 Elber discoveries fatigue crack-closure behavior
(
*
HRR Hutchinson, Rice and Rosengren elastic-plastic stress field)
14
1967
Failure of Silver Bridge at Point Pleasant, WV g ,
Built in 1928
Bridge collapse was due to failure of single eyebar.
Statically-determinate structure!!!
15
1970
U S Air Force develops damage-tolerance concept U.S. Air Force develops damage tolerance concept
(H. Wood, C. Tiffany and J. Lincoln)
16
Damage-Tolerance Concept Controls Aircraft Design
a
o
Failure of F-111 aircraft from
surface crack in wing-box
a = 0 05 in = 1 3 mm
Initial flaw size:
a
o
= 0.05 in = 1.3 mm
17
1979-86
Raju and Newman developed many K solutions Raju and Newman developed many K solutions
for three-dimensional cracked bodies
K = S (ta/Q)
1/2
F(|, a/c, a/ t, c/ r, c/ w)
Raju and Newman (1979-86)
FEA (h-version)
~10,000 dof (0.5 r / t 2)
Fawaz and Andersson (2000-04)
FEA (p-version)
~100,000+ dof (0.1 r / t 10)
2w
18
1988
Aloha Airlines in-flight fuselage failure initiates Aloha Airlines in flight fuselage failure initiates
Aging Aircraft programs at FAA/NASA/DoD
Aloha Airlines Boeing 737 April 28, 1988
19
1999
Hsu et al (Boeing-Long Beach) applies CTOA and FEA Hsu et.al. (Boeing-Long Beach) applies CTOA and FEA
method to predict failure of actual fuselage with WFD
lkh d b Bulkhead Web
Frame / Tee
Within 5% of failure pressure!
MSD
Lead Crack
20
P 3 Orion test article wing failure at Lockheed
2003
Navy P-3 Orion
P-3 Orion test article wing failure at Lockheed
S t l di k Spectrum loading marks
21
WHY STRUCTURES FAIL
Negligence during design, construction or operation of
the structure.
- Challenger Space Shuttle (O-ring)
- Kansas City hotel walkway Kansas City hotel walkway
- Boeing 737 fuselage failure
- many more
Application of new design or material, which produces
an unexpected (and undesirable) result.
- World War II Liberty ships
- Composite tail rudder on Airbus 380
- and the list continues and the list continues
22
23
Structural Design Concepts
Traditional Strength of Materials
Fracture Mechanics Concept
24
Effect of Fracture Toughness on Material Failure
Mechanisms Mechanisms
25
Fracture Mechanics Family Tree
26
A sharp crack positive uses!
Fracturing diamonds
Making chopsticks
Opening pistachio nuts
Cutting glass
Pop-top Al cans
Shear pins
Explosive bolts
27
Fracture Mechanics Overview
Material Science
Theories & Models of Material
Separation at m Scales
Continuum Mechanics
Theoretical Description of o
ij
, c
ij
Relationships, Plasticity, Damage Separation at m Scales
NDE
Relationships, Plasticity, Damage
Fracture
Prevention &
Assessment
Applicable techniques?
Reliability, cost, timeliness
Fabrication
Cutting, Welding, Brazing, QA,
Assessment
Material Testing
o - c , Toughness, Loading Rate,
Temperature & Environment Effects
Cutting, Welding, Brazing, QA,
Repeatability, Cost, Engineering
vs. Workmanship Standards
Temperature & Environment Effects
Experience
What has worked in the past?
FEA/ BEA
What has worked in the past?
Understanding why it worked?
How to improve?
Solution of 2-D and 3-D Linear,
Nonlinear Boundary Value Problems
28