SGBEM modeling of fatigue crack growth in particulate composites

The symmetric-Galerkin boundary element method (SGBEM) has previously been employed to model 2-D crack growth in particulate composites under quasi-static loading conditions. In this paper, an initial attempt is made in extending the simulation technique to analyze the interaction between a growing crack and clusters of perfectly bonded particles in a brittle matrix under cyclic loading conditions. To this end, linear elastic fracture mechanics and no hysteresis are assumed. Of particular interest is the role clusters of inclusions play on the fatigue life of particulate composites. The simulations employ a fatigue crack growth prediction tool based upon the SGBEM for multiregions, a modified quarter-point crack-tip element, the displacement correlation technique for evaluating stress intensity factors, a Paris law for fatigue crack growth rates, and the maximum principal stress criterion for crack-growth direction. The numerical results suggest that this fatigue crack growth prediction tool is as robust as the quasi-static crack growth prediction tool previously developed. The simulations also show a complex interplay between a propagating crack and an inclusion cluster of different densities when it comes to predicting the fatigue life of particulate composites with various volume fractions.     

A cyclic steady-state method for fatigue crack propagation: Evaluation of plasticity-induced crack closure in 3D

The numerical study of plasticity-induced crack closure using the node-release technique presents many difficulties widely studied in literature. For instance various rules, proposed for overcoming mesh sensitivity, are challenged by more recent studies. This paper intends to propose and evaluate a numerical method for the investigation of crack propagation under fatigue loading, and particularly for the assessment of plasticity-induced crack closure in three-dimension. The method is an extension of the “steady-state method” to cyclic loadings. The steady-state method allows a direct computation (on a fixed mesh, without releasing nodes) of stress and strain fields around the crack tip and in the wake for a steady crack growth. The method is extended to simulate crack propagation under fatigue loading. Therefore it constitutes a valuable numerical tool for gaining insight into the physics of crack propagation, as it provides accurate mechanical fields around the crack tip and their relation with crack growth rate, various loading modes and parameters. The proposed method is also compared with the classical node-release technique. A very good agreement between the two methods is found. However the steady-state method needs much less mesh refinement and computational time. Following an analysis of some features of the fatigue crack, a discussion on a crack closure criterion is opened, and a reliable criterion for the determination of local crack closure is proposed.     

Effects of mixed-mode overloading on the mixed-mode I+II fatigue crack growth

In this study, the finite element modeling of the compact tension shear specimens has been used to evaluate the effects of overloading on fatigue crack growth with mixed-mode loading I+II. Element creation and modeling is done by CASCA software. FRANC2D was used for stress analysis and the determination of crack parameters. Life estimation of samples was done by using the software ETBX. To create the mixed-mode I+II, different loading angles of 0, 15, 45 and 75 degrees (with respect to normal direction to the crack surface) were used with various overloading ratios. The effects of residual stresses due to overloading with saving and restoring capabilities were considered as a separate loading. To confirm the modeling results, models were built with ABAQUS and also compared with the results of numerical and experimental data in the literature. There are good agreements in determining the path of the crack growth and life estimation. The effects of the loading direction, overloading ratio and its load ratio, combination of overloadings and their locations on the fatigue crack growth and life are investigated.     

谐振载荷作用下工程结构振动疲劳寿命预估的损伤力学-有限元法

建立了预估谐振载荷作用下结构振动疲劳寿命的损伤力学-有限元方法。首先根据损伤热力学原理,构建了损伤演化方程,建立光滑试件在恒幅应变交变载荷作用下寿命预估方法;进一步由损伤力学守恒积分原理,得到恒幅重复载荷作用下应力与寿命的关系式;然后根据标准件疲劳试验结果,拟合得到损伤演化方程中的材质参数;最后利用APDL语言编程对ANSYS软件进行了二次开发,借助ANSYS软件对谐振载荷作用下结构振动疲劳裂纹萌生寿命进行预估。作为算例,本文利用该方法预估了LC9CgS1铝合金梁谐振载荷作用下疲劳裂纹萌生寿命。     

CTS试件中复合型疲劳裂纹扩展

针对复合型循环载荷作用下的金属构件中的裂纹扩展问题进行了实验分析和理论建模. 首先 采用紧凑拉剪试件(CTS)和 Richard研制的复合型载荷加载装置，对承受复合型循环载荷的裂纹进行了实验研究. 实验选择了两种金属材料试件，分别承受3种形式的复合型循环载荷的作用，在裂纹尖端具 有相同的初始应力场强度的条件下考察复合型循环载荷对裂纹扩展规律的影响. 实验结果表明，疲劳裂纹的扩展速率与加载角度有关. 对于同样金属材料的试件，当裂尖处 初始应力场强度相等时，载荷越接近于II型，裂纹增长速率越快. 采用等效应力强度 因子(I型和II型应力强度因子的组合)、裂纹扩展速率及复合强度等参数，以实验数据为 基础，建立了一个疲劳裂纹扩展模型，用来预测裂纹在不同模式疲劳载荷作用下的扩展速率. 为验证其有效性，该模型被应用于钢制试件的数值模拟计算中. 实验结果与模拟计算曲线保 持一致，表明该模型可以用来估算带裂纹金属构件的寿命.     

A model for predicting the retardation effect following a single overload

Many engineering components are subjected to variable amplitude loading history. It is well known that retardation in fatigue crack growth occurs due to application of single overloads in a constant amplitude loading block. Many models have been proposed to capture this counter intuitive phenomenon which has resulted in improved understanding of retardation effect following tensile overloads and consequently resulting in better life prediction models. The proposed study is focused on to evaluation of retardation in fatigue life due to application of a single overload. A model for prediction of crack growth and crack growth rate following single overloads is presented. Several modifications to Wheeler’s growth idea are proposed, which incorporate a consideration for effective stress intensity factor, based on Elber’s concept of crack closure, relationship between overload ratio and the Wheeler’s exponent, and fatigue growth rate calculations. The results presented here show that plastic zone interaction following overload and the consideration of crack closure explain retardation effect following a single overload. Correlation between analysis and experimental data obtained from several sources in literature show that the scheme, is robust and provides an insight into the nonlinear aspect of crack growth results. The model has been tested for 2024-T3 aluminum alloy and 6061-T6 aluminum alloy and thorough calibrations performed, established the fidelity of the program.     

焊趾表面裂纹的形态发展曲线与疲劳寿命预测

以作者建立的焊地椭圆表面裂纹应力强度因子数据库以及复杂应力场中焊践半随圆表面裂纹前缘应力强度因子分布计算的基本模式法为基础上,给出了复杂应力场中焊践表面表纹在疲劳扩展过程中形态变化规律及寿命的工程分析方法。     

铝合金切口件在四组变幅载荷下3.5%NaCl溶液中腐蚀疲劳裂纹起始寿命试验研究与估算模型

试验研究了铝合金切口件在4组变幅块谱下、3．5％NaCl溶液中腐蚀疲劳裂纹起始寿命．结果表明，变幅载荷谱中的大超载会显著延长腐蚀疲劳裂纹起始寿命，并且加载顺序具有明显的影响．根据反映大小载荷交互作用的超载腐蚀疲劳裂纹起始寿命曲线和Miner累积损伤定则，建立了变幅载荷下切口件腐蚀疲劳裂纹起始寿命估算模型，应用该模型估算的结果与试验结果相吻合．     

海洋平台K型管节点的疲劳裂纹扩展分析Ⅰ:试验测试

对承受疲劳载荷的海洋平台K型管节点首先进行了静力测试,确定了沿着焊缝的热应力区的应力分布及热应力区最大应力点的位置,从而判断裂纹产生的位置;然后通过专用测试设备提供循环疲劳载荷,用ACPD(Alternating Current Potential Drop,即交流电流势能落差法)技术检测裂纹的产生和增长过程,得到裂纹最深点,用S-N曲线估算其疲劳寿命。对已有裂纹的K型管节点,用应力强度因子估计其剩余寿命。同时用测试的结果验证了S-N的准确性和可靠性。     

A NEW CYCLIC J-INTEGRAL FOR LOW-CYCLE FATIGUE CRACK GROWTH

The constitutive equation under the low-cycle fatigue (LCF) was discussed, and a two-dimensional (2-D) model for simulating fatigue crack extension was put forward in order to propose a new cyclic J-integral. The definition, primary characteristics, physical interpretations and numerical evaluation of the new parameter were investigated in detail. Moreover, the new cyclic J-integral for LCF behaviors was validated by the compact tension (CT) specimens. Results show that the calculated values of the new parameter can correlate well with LCF crack growth rate, during constant-amplitude loading. In addition, the phenomenon of fatigue retardation was explained through the viewpoint of energy based on the concept of the new parameter.     

Experimental Investigation and Finite Element Analysis of Fatigue Crack Growth in Pipes Containing a Circumferential Semi-elliptical Crack Subjected to Bending

In this paper, a circumferential external surface flaw in a metallic round pipe under cyclic bending loading is considered. Because of very rapid changes in the geometrical parameters around the crack front region, the mesh generation of this region must be done with great care. This may lead to an increase in the run time which makes it difficult to reach valid results and conclusions. Because of the advantages of the sub-modeling technique in problems which need very high mesh density, this method is used. Stress intensity factors in mode I condition are determined using three-dimensional finite element modeling with 20 node iso-parametric brick elements in the ANSYS 9.0 standard code and the singular form of these finite elements at the crack front. In order to estimate the analysis error, the structural parameter error in energy norm criterion was used. Because of the advantages of non-dimensional analysis, this method is employed, and the stress intensity factors are normalized. For the analysis of the fatigue crack growth, the Paris law is used. The propagation path of the surface flaw is obtained from the diagram of aspect ratio versus relative crack depth. The fatigue crack growth analysis (the relative crack depth against loading cycles diagram) of different initial crack aspect ratio under cyclic loading is also considered. Fatigue shape development of initially semi-elliptical external surface defects is illustrated. The effect of the Paris exponent (material constant) on fatigue crack propagation is shown as well. Moreover, the fatigue crack growth of several specimens is assessed experimentally using a manually-constructed experimental set up. Finally, the experimental results obtained by cyclic bending loading tests are compared with the numerical results. The experimental results show good conformity with the finite element results.     

降载勾线法在高强钢疲劳断裂试验中的应用

制作高强钢特征试件,在压、弯应力共同作用下进行疲劳断裂试验;结合疲劳辉纹产生机理,采用降载勾线法在试件断面制造出“海滩状花纹”;利用CAD软件描绘断面形貌并测量裂纹长度,用Newman-Raju理论进一步研究表面裂纹扩展的规律,并与试验值比较.结果表明降载勾线法可以解决高强度钢表面裂纹不易测量及断面难以观测到疲劳辉纹的问题;采用Newman-Raju公式模拟压弯组合应力下表面裂纹扩展形貌是合适的,但由此计算的疲劳寿命偏于保守.另外,当压弯应力比值较小时,计算扩展形貌时压应力可以忽略,而计算疲劳寿命时压应力不可忽略.     

Fatigue growth prediction of elliptical cracks in welded joint structure: Hybrid and energy density approach

A hybrid weight function approach (HWFM) is presented for the fatigue life prediction of infinite body and welded joint structure containing elliptical cracks. A self-containing computer code has been developed for this purpose. Numerical computations were first conducted on cracked infinite body showing a physical fact, that the elliptical shape of the crack becomes circular during its evolution. The prediction of the fatigue crack growth shows that the present results are in perfect concordance with those reported in the literature. Then, numerical tests were carried out on two types of specimens of welded joint structure. The present results were compared to the experimental and predicted ones of other authors, demonstrating that the hybridization method is a powerful numerical technique, and that the SEDF approach (using the Sih’s law) is more valid for the critical cases of welded joints than the SIF approach (using the Paris law). A parametric study has been conducted on the stress ratio “R” showing that the fatigue life to failure decreases with the increase of “R”.     

STUDY ON THE SURFACE CRACK GROWTH BEHAVIOR IN 14MnNbq BRIDGE STEEL

Three-dimensional crack closure correction methods are investigated in this paper.The fatigue crack growth tests of surface cracks in 14MnNbq steel for bridge plate subjected to tensile and bending loadings are systematically conducted.The experimentally measured fatigue crack growth rates of surface cracks are compared with those of through-thickness cracks in detail.It is found that the crack growth rates of surface cracks are lower than those of through-thickness cracks.In order to correct their differences in fatigue crack growth rates, a dimensionless crack closure correction model is proposed.Although this correction model is determined only by the experimental data of surface cracks under tensile loading with a constant ratio R=0.05, it can correlate the surface crack growth rates with reasonable accuracy under tensile and bending loadings with various stress ratios ranging from 0 to 0.5.Furthermore, predictions of fatigue life and crack aspect ratio for surface cracks are discussed, and the predicted results are also compared with those obtained from other prediction approaches.Comparison results show that the proposed crack closure correction model gives better prediction of fatigue life than other models.     

A two-parameter model to predict fatigue life of high-strength steels in a very high cycle fatigue regime

In this paper, ultrasonic(20 kHz) fatigue tests were performed on specimens of a high-strength steel in very high cycle fatigue(VHCF) regime. Experimental results showed that for most tested specimens failed in a VHCF regime, a fatigue crack originated from the interior of specimen with a fish-eye pattern, which contained a fine granular area(FGA) centered by an inclusion as the crack origin. Then,a two-parameter model is proposed to predict the fatigue life of high-strength steels with fish-eye mode failure in a VHCF regime, which takes into account the inclusion size and the FGA size. The model was verified by the data of present experiments and those in the literature. Furthermore, an analytic formula was obtained for estimating the equivalent crack growth rate within the FGA. The results also indicated that the stress intensity factor range at the front of the FGA varies within a small range, which is irrespective of stress amplitude and fatigue life.     

Fatigue life enhancement of structures using shape optimisation

The paper proposes a new approach for shape optimisation with fatigue life as the design objective. Conventional designs often incorporate stress optimisation that aims at reducing stress concentrations around a structural boundary by minimising the peak stress. However, this is only an effective and sufficient measure for an ‘ideal’ or ‘flaw-less’ structure. It is a well-known fact that flaws (cracks) are inevitably present in most structures. This emphasises the need to investigate the influence of cracks on optimised shapes. Numerical modelling of cracks using the Finite Element Method requires a fine mesh to model the singularity at crack tips, which makes fracture calculations computationally expensive. Furthermore, for a damage tolerance based optimisation, numerous cracks are to be considered at various arbitrary locations in a structure, and fatigue life evaluation needs to be repeated for each crack at every iteration. This makes the optimisation process extremely computationally inefficient for practical purpose. Moreover, the lack of information concerning crack size, orientation, and location makes the formulation of the optimisation problem difficult. As a result, there has been inadequate research to consider fracture parameters, such as fatigue life, in the optimisation objective. To address this, the paper presents an approach for the shape optimisation of damage tolerant structures with fatigue life as the design constraint.The damage tolerance based optimisation was performed using a number of nonlinear programming algorithms, namely the Broydon-Fletcher-Goldfarb-Shanno (BFGS) method, the Fletcher Reeves (Conjugate Direction) method, and the Sequential Unconstrained Minimisation Technique (SUMT). These methods were extended for optimising the fatigue life in the presence of numerous surface cracks. A significant enhancement in fatigue life was achieved for various crack cases consisting of different initial and final crack sizes. It is shown that the fatigue life optimised shapes can be considerably different from the corresponding stress optimised solution. This emphasises the need to explicitly consider fatigue life as a distinct design objective when optimising damage tolerant structures. A fatigue life optimisation leads to the generation of a ‘near uniform’ fatigue critical surface. The design space near the ‘optimal’ region was found to be relatively flat. This means that the precise identification of the local/global optimum solution is not critical, because a significant structural performance enhancement can be achieved in the ‘near’ optimal region. An additional benefit of fatigue life optimisation is that the resulting optimised shapes may even be lighter than the stress optimised designs. To verify the optimal solutions obtained using the nonlinear programming algorithms, the results were compared with those obtained using a heuristic optimisation method (Biological algorithm). The solutions predicted by both the methods, employing inherently different (gradient-based and gradient-less) algorithms, were found to agree very well.     

孔径尺寸对干涉配合铆接件超高周疲劳性能的影响

合理的干涉配合铆接工艺可以有效提高构件疲劳性能,本文通过试验研究与数值模拟相结合分析孔径尺寸对干涉配合铆接件超高周疲劳性能的影响。利用20kHz超声疲劳试验系统测试了三种不同孔径尺寸下干涉配合铆接件的超高周疲劳性能;基于ABAQUS模拟分析了铆接工艺过程以及孔径尺寸对干涉量和孔边残余应力的影响,通过分析高频低幅加载下孔边应力分布,结合超高周疲劳试验及断口形貌观察,分析了孔径尺寸对铆接件超高周疲劳性能的影响。结果表明:不同孔径尺寸铆接件的裂纹萌生扩展方式类似,疲劳裂纹萌生均发生在孔边距表面1.5mm最大残余拉应力处;适当减小孔径尺寸所形成的合理干涉量可以提高铆接件疲劳寿命,φ4.10mm的孔径可以形成0.66%的孔边平均干涉量,铆接件疲劳寿命最高达到3.63×108周。     

Accumulative damage near crack tip for welded bridge members: fatigue life determination

The behavior of crack growth for the fatigue damage accumulation near tip where damage is most severe is analyzed. Fatigue life is assessed for the welded members of bridges under traffic loading. Two parts are considered. They consist of the development of a fatigue damage accumulation model for welded bridge members and a method for calculating the stress intensity factor that is needed for evaluating the fatigue life of welded bridge members with cracks. Based on the concept of continuum damage accumulation and fatigue and fatigue crack growth relations, results are obtained to describe the relationship between the cracking count rate and the effective stress intensity factor. Crack growth and fatigue life are found for two types of welded members assisted by using fatigue experimental results. The stress intensity factors are modified by correcting for the geometric shape of the welded members in order to reflect the influence of the weldment and geometry. This is accomplished via the stress intensity factor. The calculated and measured fatigue lives were generally in good agreement for the initial cracking conditions of two types of welded members widely used in steel bridges.     

欧洲近海结构用钢研究计划的进展

欧洲近海结构用钢研究计划在第一阶段(1975—80年)关于海洋焊接结构在疲劳载荷下工作性能的研究基础上,于1981—87年继续进行了第二阶段的研究工作。参加国家有欧洲经济共同体6国及挪威、加拿大等。本文综合报道第二阶段研究情况与主要成果,内容包括:板厚对疲劳强度的影响,焊后改进技术与腐蚀疲劳,疲劳载荷及变幅疲劳试验,疲劳分析的断裂力学方法,某些管节点的应力分析等;并对研究计划的背景及今后研究工作的方向作了介绍。