Theoretical development and experimental validation of a thermally dissipative cohesive zone model for dynamic fracture of amorphous polymers

A thermally dissipative cohesive zone model is developed for predicting the temperature increase at the tip of a crack propagating dynamically in a nominally brittle material exhibiting a cohesive-type failure such as crazing. The model assumes that fracture energy supplied to the crack tip region that is in excess of that needed for the creation of new free surfaces during crack advance is converted to heat within the cohesive zone. Bulk dissipation mechanisms, such as plasticity, are not accounted for. Several cohesive traction laws are examined, and the model is then used to make predictions of crack tip heating at various crack propagation speeds in the nominally brittle amorphous polymer PMMA, observed to fail by a crazing-type mechanism. The heating predictions are compared to experimental data where the temperature field surrounding a high speed crack in PMMA was measured. Measurements are made in real time using a multi-point high speed HgCdTe infrared radiation detector array. At the same time as temperature, simultaneous measurement of fracture energy is made by a strain gauge technique, and crack tip speed is monitored through a resistance ladder method. Material strength can be estimated through uniaxial tension tests, thus minimizing the need for parameter fitting in the stress-opening traction law. Excellent agreement between experiments and theory is found for two of the cohesive traction law temperature predictions, but only for the case where a single craze is active during the dynamic fracture of PMMA, i.e. crack tip speed up to approximately 0.2c_R. For higher speed fracture where subsurface damage becomes prominent, the line dissipation model of a cohesive zone is inadequate, and a distributed damage model is needed.     

Cohesive zone laws for void growth — II. Numerical field projection of elasto-plastic fracture processes with vapor pressure

Modeling ductile fracture processes using Gurson-type cell elements has achieved considerable success in recent years. However, incorporating the full mechanisms of void growth and coalescence in cohesive zone laws for ductile fracture still remains an open challenge. In this work, a planar field projection method, combined with equilibrium field regularization, is used to extract crack-tip cohesive zone laws of void growth in an elastic-plastic solid. To this end, a single row of void-containing cell elements is deployed directly ahead of a crack in an elastic-plastic medium subjected to a remote K-field loading; the macroscopic behavior of each cell element is governed by the Gurson porous material relation, extended to incorporate vapor pressure effects. A thin elastic strip surrounding this fracture process zone is introduced, from which the cohesive zone variables can be extracted via the planar field projection method. We show that the material's initial porosity induces a highly convex traction-separation relationship — the cohesive traction reaches the peak almost instantaneously and decreases gradually with void growth, before succumbing to rapid softening during coalescence. The profile of this numerically extracted cohesive zone law is consistent with experimentally determined cohesive zone law in Part I for multiple micro-crazing in HIPS. In the presence of vapor pressure, both the cohesive traction and energy are dramatically lowered; the shape of the cohesive zone law, however, remains highly convex, which suggests that diffusive damage is still the governing failure mechanism.     

受载高聚物裂尖的损伤和银纹化

采用扫描电子显微镜(SEM)，对高聚物裂尖银纹损伤的引发和演化过程进行了原位观测．将固态高聚物本体材料视为线黏弹体，裂尖银纹区视为非线性损伤区，通过构造银纹区的损伤演化方程，给出了银纹区应力模型和银纹生长规律，数值结果与已有实验吻合良好。     

一种高聚物银纹损伤演化的实验研究

采用光学显微技术对高聚物蠕变条件下的银纹损伤引发和演化进行了实验观测．通过对银纹面密度的测量,定义一种损伤变量,得到了聚甲基丙烯酸甲酯不同蠕变时间和不同应力水平下的银纹损伤值,并给出了一种损伤演化模型．     

On the importance of thermo-elastic cooling in the fracture of glassy polymers at high rates

In a previous thermo-mechanical analysis [Estevez, R., Basu, S., van der Giessen, E., 2005. Analysis of temperature effects near mode I cracks in glassy polymers. Int. J. Fract. 132, 249–273] in which shear yielding of the bulk and failure by crazing were accounted for, we examined which of these two viscoplastic processes contributed to heat in mode I fracture. The present study completes this work by investigating the conditions for thermo-elastic cooling prior to crack propagation as reported experimentally by Rittel [Rittel, D., 1998. Experimental investigation of transient thermo-elastic effects in dynamic fracture. Int. J. Solids Struct. 35, 2959–2973] and Bougaut and Rittel [Bougaut, O., Rittel, D., 2001. On crack tip cooling during dynamic crack propagation. Int. J. Solids Struct. 38, 2517–2532] on high strain rate loading of PMMA. To this end, coupled thermo-mechanical finite element simulations are carried out by accounting for the thermo-elastic source, in addition to the heat sources related to shear yielding and crazing. The bulk as well as cohesive zone parameters for crazing realistically describe PMMA as they are obtained from detailed calibration experiments. Our results show that if significant thermo-elastic cooling has to be observed in the vicinity of the crack tip of a polymeric material, suppression of shear yielding as well as suppression of crazing is necessary. It seems that at these high strain rates a brittle fracture mechanism activated at very high stresses takes over from crazing, or at least that craze initiation occurs for stress levels very different to those for quasi-static conditions.     

Extraction of cohesive-zone laws from elastic far-fields of a cohesive crack tip: a field projection method

A solution method of an inverse problem is developed to extract cohesive-zone laws from elastic far-fields surrounding a crack-tip cohesive zone. The solution method is named the “field projection method (FPM).” In the process of developing the method a general form of cohesive-crack-tip fields is obtained and used for eigenfunction expansions of the plane elastic field in a complex variable representation. The closing tractions and the separation-gradients at the cohesive zone are expressed in terms of orthogonal polynomial series expansions of the general-form complex functions. The series expansion forms a set of cohesive-crack-tip eigenfunctions, which is complete and orthogonal in the sense of the interaction J-integral in the far field as well as at the cohesive-zone faces. The coefficients of the eigenfunctions in the J-orthogonal representation are extracted directly, using interaction J-integrals in the far field between the physical field of interest and auxiliary probing fields. The path-independence of the interaction J-integral enables us to identify the cohesive-zone variables, i.e. tractions and separations, and thus the cohesive-zone constitutive laws uniquely from the far-field data. A set of numerical algorithms is developed for the inversion method and the results from numerical experiments suggest that the proposed algorithms are well suited for extracting cohesive-zone laws from the far-field data. The set includes methods to find the position and size of a cohesive zone. Further included are discussions on error analysis and stability of the inversion scheme.     

Effects of lattice incompatibility-induced hardening on the fracture behavior of ductile single crystals

Plane-strain mode-I cracks in a ductile single crystal are studied under conditions of small scale yielding. The specific case of a (0 1 0) crack growing in the [1 0 1] direction for an FCC crystal is considered. Crack initiation and its subsequent growth are computed by specifying a traction-separation relation in the crack plane ahead of the crack tip. The crystal is characterized by a hardening model that incorporates physically motivated gradient effects. Significant traction elevation ahead of the crack tip is obtained by incorporating such effects, allowing a better basis for the explanation of experimentally observed cleavage in the presence of substantial plastic flow in slowly deforming ductile materials. Resistance curves based on parameters characterizing the fracture process and the continuum properties of the crystal are computed. Simulation results indicate that the length-scale of the lattice incompatibility-dominated region has to be comparable or larger than the length of the fracture process zone for gradient effects to have a significant effect on fracture resistance. Both the work of separation and the peak separation stress also play important roles in determining the fracture resistance of the crystal.     

Cohesive zone laws for fatigue crack growth: Numerical field projection of the micromechanical damage process in an elasto-plastic medium

Cohesive zone failure models are widely used to simulate fatigue crack propagation under cyclic loading, but the model parameters are phenomenological and are not closely tied to the underlying micromechanics of the problem. In this paper, we will inversely extract the cohesive zone laws for fatigue crack growth in an elasto-plastic ductile solid using a field projection method (FPM), which projects the equivalent tractions and separations at the cohesive crack-tip from field information outside the process zone. In our small-scale yielding model, a single row of discrete voids is deployed directly ahead of a crack in an elasto-plastic medium subjected to cyclic mode I K-field loading. Damage accumulation under cyclic loading is captured by the growth of voids within the micro-voiding zone ahead of the crack, while the evolution of the cohesive zone law representing the micro-voiding zone is inversely extracted via the FPM. We show that the field-projected cohesive zone law captures the essential micromechanisms of fatigue crack growth in the ductile medium: from loading and unloading hysteresis caused by void growth and plastic hardening, to the softening damage locus associated with crack propagation via a void by void growth mechanism. The results demonstrate the effectiveness of the FPM in obtaining a micromechanics-based cohesive zone law in-place of phenomenological models, which opens the way for a unified treatment of fatigue crack problems.     

Limitation on crack speed for a strip-craze model applied to PMMA

A strip-craze model is proposed to study crack propagation in polymers. A nonlinear differential equation is derived to govern the dynamic process of crack propagation. The viscous feature of the material in the craze zone is taken into account by means of an experimentally determined relationship between the craze stress and crack speed. By fitting experimental data of PMMA into the model, some parameters including the strip-craze length are deduced. A non-singular stress is introduced to control the crack propagation with a strip craze at its tip. Variations of the crack length and the crack speed with time are computed and their dependence on the non-singular stress is investigated. For PMMA, three stages of crack propagation are identified in terms of initial non-singular stress σ_ns0. When σ_ns0<60 MPa, the crack speed mm/s and the crack is basically stationary; when 60 <σ_ns0<95 MPa, then mm/s the crack is in slow propagation; when σ_ns0>95 MPa, then mm/s and the crack is in rapid propagation. The proposed model is applicable only in slow crack propagation.     

On the toughening of brittle materials by grain bridging: Promoting intergranular fracture through grain angle, strength, and toughness

The structural reliability of many brittle materials such as structural ceramics relies on the occurrence of intergranular, as opposed to transgranular, fracture in order to induce toughening by grain bridging. For a constant grain boundary strength and grain boundary toughness, the current work examines the role of grain strength, grain toughness, and grain angle in promoting intergranular fracture in order to maintain such toughening. Previous studies have illustrated that an intergranular path and the consequent grain bridging process can be partitioned into five distinct regimes, namely: propagate, kink, arrest, stall, and bridge. To determine the validity of the assumed intergranular path, the classical penetration/deflection problem of a crack impinging on an interface is re-examined within a cohesive zone framework for intergranular and transgranular fracture. Results considering both modes of propagation, i.e., a transgranular and intergranular path, reveal that crack-tip shielding is a natural outcome of the cohesive zone approach to fracture. Cohesive zone growth in one mode shields the opposing mode from the stresses required for cohesive zone initiation. Although stable propagation occurs when the required driving force is equivalent to the toughness for either transgranular or intergranular fracture, the mode of propagation depends on the normalized grain strength, normalized grain toughness, and grain angle. For each grain angle, the intersection of single path and multiple path solutions demarcates “strong” grains that increase the macroscopic toughness and “weak” grains that decrease it. The unstable transition to intergranular fracture reveals that an increasing grain toughness requires a growing region of the transgranular cohesive zone be near the cohesive strength. The inability of the body to provide the requisite stress field yields an overdriven and unstable configuration. The current results provide restrictions for the achievement of substantial toughening through intergranular fracture.     

A comparison of cohesive zone modeling and classical fracture mechanics based on near tip stress field

A mode III crack with a cohesive zone in a power-law hardening material is studied under small scale yielding conditions. The cohesive law follows a softening path with the peak traction at the start of separation process. The stress and strain fields in the plastic zone, and the cohesive traction and separation displacement in the cohesive zone are obtained. The results show that for a modest hardening material (with a hardening exponent N = 0.3), the stress distribution in a large portion of the plastic zone is significantly altered with the introduction of the cohesive zone if the peak cohesive traction is less than two times yield stress, which implies the disparity in terms of the fracture prediction between the classical approach of elastic–plastic fracture mechanics and the cohesive zone approach. The stress distributions with and without the cohesive zone converge when the peak cohesive traction becomes infinitely large. A qualitative study on the equivalency between the cohesive zone approach and the classical linear elastic fracture mechanics indicates that smaller cracks require a higher peak cohesive traction than that for longer cracks if similar fracture initiations are to be predicted by the two approaches.     

高聚物细观损伤演化的研究进展

聚合物的银纹化损伤与断裂是一个复杂和重要的研究课题。简述了银纹引发的(热)力学条件和银纹成核的微观机理。结合最新的研究进展,对银纹向前扩展的弯月面不稳定机理、银纹增厚的蠕变机理和界面转入机理作了较详细的分析与综合。考虑银纹细观结构中横系的作用,对银纹结构模型、银纹微纤断裂判据、微纤断裂行为的分子量和缠结密度相关性以及银纹与裂纹相互作用等问题进行了较详细的综述。指出银纹生长和断裂的深入研究可望建立材料宏观断裂韧性和材料细观结构以及微观参数之间的关联,为进行材料韧性的微观设计提供一条可行的途径。并对今后这一领域的研究方向和重点进行了展望。      

Analysis of crack growth and crack-tip plasticity in ductile materials using cohesive zone models

Crack initiation and crack growth resistance in elastic plastic materials, dominated by crack-tip plasticity are analyzed with the crack modeled as a cohesive zone. Two different types (exponential and bilinear) of cohesive zone models (CZMs) have been used to represent the mechanical behavior of the cohesive zones. In this work, it is suggested that different forms of CZMs (e.g., exponential, bilinear) are the manifestations of different micromechanisms-based inelastic processes that participate in dissipating energy during the fracture process and each form is specific to each material system. It is postulated that the total energy release rate comprises the plastic dissipation rate in the bounding material and the separation energy rate within the fracture process zone, the latter is determined by CZMs. The total energy release rate then becomes a function of the material properties (e.g., yield strength, strain hardening exponent) and cohesive properties of the fracture process zone (e.g., cohesive strength and cohesive energy), and the form of cohesive zone model (CZM) that determines the rate of energy dissipation in the forward and wake regions of the crack. The effects of material parameters, cohesive zone parameters as well as the form/shape of CZMs in predicting the crack growth resistance and the size of plastic zone (SPZ) surrounding the crack tip are systematically examined. It is found that in addition to the cohesive strength and cohesive energy, the form (shape) of the traction–separation law of CZM plays a very critical role in determining the crack growth resistance (R-curve) of a given material. It is further observed that the shape of the CZM corresponds to inelastic processes active in the forward and wake regions of the crack, and has a profound influence on the R-curve and SPZ.     

STOCHASTIC ELASTO-PLASTIC FRACTURE ANALYSIS OF ALUMINUM FOAMS

Model I quasi-static nonlinear fracture of aluminum foams is analyzed by considering the effect of microscopic heterogeneity. Firstly, a continuum constitutive model is adopted to account for the plastic compressibility of the metallic foams. The yield strain modeled by a two- parameter Weibull-type function is adopted in the constitutive model. Then, a modified cohesive zone model is established to characterize the fracture behavior of aluminum foams with a cohesive zone ahead of the initial crack. The tensile traction versus local crack opening displacement relation is employed to describe the softening characteristics of the material. And a Weibull statistical model for peak bridging stress within the fracture process zone is used for considering microscopic heterogeneity of aluminum foams. Lastly, the influence of stochastic parameters on the curve of stress-strain is given. Numerical examples are given to illustrate the numerical model presented in this paper and the effects of Weibull parameters and material properties on J-integral are discussed.     

内聚力模型裂纹问题分析的解析奇异单元

内聚力模型已经被广泛应用于需要考虑断裂过程区的裂纹问题当中,然而常用的数值方法应用于分析内聚力模型裂纹问题时还存在着一些不足,比如不能准确的给出断裂过程区的长度、需要网格加密等。为了克服这些缺点,论文构造了一个新型的解析奇异单元,并将之应用于基于内聚力模型的裂纹分析当中。首先将虚拟裂纹表面处的内聚力用拉格拉日插值的方法近似表示为多项式的形式,而多项式表示的内聚力所对应的特解可以被解析地给出。然后利用一个简单的迭代分析,基于内聚力模型的裂纹问题就可以被模拟出来了。最后,给出二个数值算例来证明本文方法的有效性。     

A cohesive plastic and damage zone model for dynamic crack growth in rate-dependent materials

Mode I steady-state dynamic crack growth in rate-dependent viscoplastic solids containing damage, under small scale yielding conditions, is analyzed based on a modified cohesive zone model. A multi-scale approach is used to describe the entire non-linear zone consisting of a plastic region and a damage region, each of which has its own constitutive law. Traction in the damage region is characterized by a softening power-law, in terms of the ultimate strength, a softening index and a rate sensitivity factor. In the plastic region, the cohesive law is assumed to be both strain hardening and rate dependent. The critical crack opening displacement at the physical crack-tip controls crack growth. The governing integral equations are derived and solved by a collocation method combined with associated boundary conditions. Numerical results are presented for the traction and opening profiles along the cohesive zone, the fracture energy and lengths of the damage and non-linear zones at different crack speeds and for different material parameters. The importance of factors, such as material softening, plastic deformation, crack speed and viscosity, is identified by parametric studies. In addition, the competition of plastic flow and material damage, and its effect on crack growth, are discussed.     

Analyzing the Laws of Stable Subcritical Growth of Cracks in Polymeric Materials on the Basis of Fracture Mesomechanics Models. Theory and Experiment

The laws of stable crack growth are analyzed using fracture mesomechanics models for polymeric materials under long-term subcritical tension. A review is given of experimental and theoretical studies of crack-tip process zones. The studies were conducted using physical and mechanical methods and fracture mesomechanics models, allowing for the structural and rheological features of process zones. Theoretical and experimental results on the behavior of process zones are generalized and the theory of stable crack growth in viscoelastic polymers, which assumes the autonomy of the process zone during crack development, is justified     

Adiabatic decohesion in a thermoplastic craze thickening at constant or increasing rate

When a crack in a thermally non-diffusive material is impact loaded—or propagates at high speed—a cohesive process which resists slow crack extension may itself cause decohesion by adiabatic heating. By assuming that decohesion ultimately occurs by low-energy disentanglement within a melt layer of critical thickness, the fracture resistance of craze-forming crystalline polymers can be estimated quantitatively. Previous estimates used a simple, thermomechanically linear representation of craze fibril drawing. This paper presents a more physically realistic, numerical formulation, and demonstrates it for constant craze thickening rate (as imposed by an ideal full-notch tension test) and for linearly increasing thickening rate (as at the tip of an impact-loaded or rapidly propagating crack). For a linear material, the numerical formulation gives results which asymptotically approach those from analytical solutions, as craze density approaches zero. In more realistic model polymers, the enthalpy of fusion increasingly delays decohesion as impact speed increases, although the temperature distribution of an endotherm appears to have little effect. Increasing molecular weight, heuristically associated with decreasing craze density and increasing structural dimension, increases the predicted impact fracture resistance. In every case, fracture resistance passes through a minimum as impact speed increases. The conclusions encourage the use of impact fracture tests, and discourage the use of the full-notch tension test, to assess the dynamic fracture resistance of a craze-forming polymer.