Influence of indenter geometry on half-plane with edge crack subjected to fretting condition

An edge crack is analyzed to study fretting failure. A flat punch with rounded corners and a half-plane are regarded as an indenter and a substrate, respectively. Plane strain condition is considered. Contact shear traction in the case of partial slip is evaluated numerically. It is assumed that an initial crack is extended to the point of minimum strain energy density in the half-plane from the trailing edge of contact. Dislocation density function method is used to evaluate K_I and K_II. The variations of K_I and K_II during crack growth are examined in the case of indentation by a punch with different ratio of the flat region (l) to the punch width (L). Sih's minimum strain energy density theory [1] is also applied to predict the propagation direction of the initial crack. The direction evaluated is similar to that found in the experiment. Stress intensity factor ranges (ΔK_I and ΔK_II) are examined during cyclic shear on the contact. For the design of contacting bodies, a suggestible geometry of punch for alleviating cracking failure is studied.     

Anti-plane shear of kinked interface crack in bonded dissimilar anisotropic solid

Complex potentials are derived to describe the anti-plane singular shear stress fields around a kinked crack, the main portion of which is embedded along the interface of two dissimilar anisotropic elastic media. This is accomplished by formulating the problem as singular integral equations with generalized Cauchy kernels. The shear stress singularity at the kink differs from the familiar inverse square root of the local distance; it is found to influence the magnitude of the Mode III crack tip stress intensity factor, K₃. Numerical results of K₃ are obtained and displayed in graphical forms for different degree of material anisotropy and crack dimensions.     

Failure modes of specimens containing surface flaws under cyclic torsion

Turbine-generator shafts are often subjected to a complex transient torsional loading. Such a torsional loading may initiate yielding at the outer radius of the shaft or in the fillets. The methods for predicting turbine-shaft fatigue life due to transient loading depent upon the mode of crack growth from an undetected crack. The most common location for the existence of a crack is the fillets or shoulders of the shaft. Specimens were designed from AISI 4340 steel with two diametrically opposed flat surfaces. Initial defect orientations of 0 deg, 45 deg and 90 deg with respect to the sepcimen axis on the fillet were studied. The specimens were subjected to cyclic torsion with zero mean torque and with a torque amplitude necessary to cause yielding at the outer radius of the specimen. When initial defects were aligned with a plane of maximum shear stress (0 deg and 90 deg), the cracks propagated along that plane. For 45-deg defects (aligned to a plane of maximum tensile stress) the crack still propagated along the plane of maximum shear. However, the number of cycles to initiate and to propagate the crack to failure for 45-deg defects were (two to three times) larger than those for 0-deg and 90-deg defects. Mode II and Mode III crack-growth rates were measured from specimens containing 0-deg and 90-deg defects. It was found that the crack-growth rate in Mode II was higher than in Mode III. However, all the specimens failed due to reduction of the net cross section, mostly attributed to Mode III crack growth. Similar results were obtained from specimens of turbine-shaft material (A469 steel), and 2024 aluminum with different rolling directions. Fatigue-crack-growth rates in Mode III were measured from circumferentially notched bar. They were found to be a unique function of ΔK _III alternating stress intensity in Mode III. It was found that the mechanism of crack growth is produced by the formation and linkage of elongated cavities at the crack tip.     

CTS试样I/II混合型断裂特性数值计算研究

采用CTS试样研究I/II混合型断裂特性计算裂纹前缘应力强度因子时可采用解析公式,一旦裂纹发生扩展,解析公式便不再适用。文中采用有限元法研究紧凑拉伸剪切（CTS）试样在I/II平面混合型加载下的裂纹扩展行为。采用ANSYS建立CTS试样I/II混合型测试系统有限元模型,为模拟真实受力状态,在CTS试样-销-扇型夹具以及扇型夹具-销-U型夹具之间分别建立接触对进行接触力学分析。通过与解析公式结果进行对比验证了该数值方法的可靠性。采用最大环向应力准则（MTS）,模拟了CTS试样不同加载角度下的裂纹扩展路径,获得了裂纹扩展路径中应力强度因子随裂纹长度的变化曲线,解释了裂纹扩展路径不与外载荷方向垂直的原因。结合文中计算结果,在CTS试样I/II混合型裂纹扩展速率实验测得裂纹长度与寿命的关系曲线a-N的基础上,便可得到材料I/II型混合型裂纹扩展速率曲线。     

Resolved shear stress intensity coefficient and fatigue crack growth in large crystals

Fatigue crack growth is caused primarily by shear decohesion due to dislocation motion in the crack tip region. The resolved shear stress, which drives dislocation in a crystal, is strongly orientation dependent, and therefore, the cyclic plastic deformation of the shear decohesion process is highly anisotropic.The crack planes are often inclined to the loading axis both in the inplane orientation and in the thickness direction. This inclination induces all three modes of the crack tip stress field, K_I, K_II, and K_III.Fatigue crack growth in large-grain Al 7029 aluminum alloy was studied. The crack tip stress fields of the test specimens are calculated with the finite element method. The values of K_I, K_II, and K_III are evaluated. The orientation of the crystal at a crack tip was determined with the Laue X-ray method. The crystal orientation and the calculated crack tip stress fields are used to compute the resolved shear stress intensity of each of the twelve slip systems of the crystal at the crack tip. The resolved shear stress field of a slip system is linearly proportional to the resolved shear stress intensity coefficient, RSSIC.The values of RSSIC thus evaluated are used to analyze the orientations of the crack plane and to correlate with the shear fatigue crack growth rate.     

Nonlinear interface shear fracture of end notched flexure specimens

The nonlinear analytical solutions of an end notched flexure adhesive joint or fracture test specimen with identical or dissimilar adherends are investigated. In the current study, a cohesive zone model (with arbitrary nonlinear cohesive laws) based analytical solution is obtained for the interface shear fracture of an end notched flexure (ENF) specimen with sufficiently long bond length. It is found that the scatter and inconsistency in calculating Mode II toughness may be significantly reduced by this model. The present work indicates that the Mode II toughness G_IIc under pure shear cracking condition is indeed very weakly dependent on the initial crack length. And this conclusion is well supported by the experimental results found in the literature. The parametric studies show that the interface shear strength is the most dominant parameter on the critical load. It is also interesting to note that with very short initial crack length and identical interface shear strength, higher Mode II toughness indeed cannot increase the critical load. Unlike the high insensitivity of critical load to the detailed shape of the cohesive law for Mode I peel fracture, the shape of the cohesive law becomes relatively important for the critical load of joints under pure Mode II fracture conditions, especially for joints with short initial crack length. The current study may help researchers deepen the understanding of interface shear fracture and clarify some previous concepts on this fracture mode.     

A numerical approach for a crack problem by Gauss–Chebyshev quadrature

In this paper, a problem of a crack in an orthotropic strip is studied under plane strain conditions. It is assumed that normal displacements and shear stresses do not act on neither of the boundaries of the strip. Cauchy-type singular integral equation for the crack problem is derived by using the theory of plane elasticity and the Fourier transformation technique. A quadrature collocation approach is adopted for the numerical solutions of the singular integral equation. The effect of relative thickness and mechanical properties of strip on Mode I stress intensity factors (SIFs) are examined under different loading conditions. Some sample results are given for SIFs; also, material orthotropy and geometrical effects are discussed in detail.     

A numerical analysis of flat internal cracks under mixed mode loading

A numerical/analytical approach is proposed to determine the stress intensity factors K_I, K_II, and K_III of a 3D internal crack. The main point of this approach is the meshing technique that can model very sharp crack fronts. The meshing technique is based on an elliptical coordinate transformation that starts from a circular crack. It allows the obtainment of a curved crack front with elements normal to the crack front. Remarkable accuracy can be obtained for elliptical crack fronts with axes ratio smaller that 0.01. Accuracy demonstration is provided for cylindrical element with an inclined internal crack subjected to uni-axial tension. This case corresponds to crack propagation for all three modes of loading, the solution of which can checked with references’ results.     

Mode II stress intensity factors for a crack parallel to the surface of an elastic half-space subjected to a moving point load

The direction of propagation of rolling contact fatigue cracks is observed to depend upon the direction of motion of the load. In this paper approximate calculations are described of the variation of Mode II stress intensity factors at each tip of a subsurface crack, which lies parallel to the surface of an elastic half-space, due to a load moving over the surface. In particular the effect of frictional locking of the crack faces under the load is investigated. In consequence of frictional locking the range of SIF at the trailing tip ΔK_T is found to be about 30% greater than that of the leading tip ΔK_L, which is consistent with observations that subsurface cracks propagate predominantly in the direction of motion of the load over the surface. The effects on k_t and k_lof crack length, crack face friction, traction forces at the surface and residual shear stresses are also investigated.     

Crack front curvature effect on stress intensity factor of through and part-through thickness cracks

The character of the local stresses and displacements are determined for a through crack with finite radius of curvature in a finite thickness plate. Numerical results obtained from the boundary element method show that the solutions are sufficiently accurate for /a ≤ 0.03 and 0.03 ≤ /a ≤ 0.1, where and a represent, respectively, the crack front radius of curvature and crack dimension such that a is the width of a through thickness crack and the depth of a part-through crack. For /a ≤ 0.1, the asymptotic singular stress field dominates such that the Mode I stress intensity factor K₁ can be evaluated. As the crack border radius of curvature is increased for /a ≥ 0.1, the non-singular terms become significant such that K_I would no longer dominate. Other failure criteria would have to be invoked to address fracture initiation.     

Analysis of dynamic mixed-mode isochromatics

The mixed-mode, elastodynamic state of stress in the neighborhood of a constant-velocity crack tip is used to generate numerically unsymmetric isochromatics. Unsymmetry associated with the third-order terms of a mixed-mode stress field, with and without the Mode II singular stress term, is also investigated. In extractingK _I from an unsymmetric isochromatic pattern, errors in the Mode I fracture parameters due to the assumed presence ofK _II in aK _I stress field were found to be significant when data are taken more than 4 mm from the crack tip. Paper was presented at V International Congress on Experimental Mechanics held in Montreal, Quebec, Canada on June 10–15, 1984.     

Computing lower and upper bounds on stress intensity factors in bimaterials

This paper presents a finite element approach for finding complementary bounds of stress intensity factors (SIFs) in bimaterials. The SIF is formulated as an explicit computable linear function of displacements by means of the two-point extrapolation method. An appropriate and computable form of the SIF plays a crucial role in the dual problem involved in the computing procedure of both lower and upper bounds. In our discussions, computable forms of stress intensity factors, K₀ and K_r, are derived, which are related to the energy release rate, and the ratio of the open mode and shear mode SIFs, respectively. Based on a posteriori finite element error estimation, a bounding procedure is used to compute the bounds on the two stress intensity factors. Finally, bounds on the SIFs in a bimaterial interface crack problem are provided to verify the procedure.     

Stress intensification in cracked shank of tightened bolt

Defects or cracks in the shank of bolts can degrade their load carrying capacity. The ways with which loading and residual stress intensify the crack border stress field can be reflected through the stress intensity factor quantity as defined in the linear elastic fracture mechanics theory. Use is made of the stiffness derivative method where quarter-point singular finite elements are used in the numerical calculation. Improved accuracy is achieved by considering the displacements not only of the main nodes but also of those quarter-point nodes in plane normal and adjacent to the crack.Numerical results are obtained for a semi-elliptical shaped crack in the bolt shank owing to tension, bending, residual stress and stress caused by tightening of the bolt. Maximum value of the Mode I stress intensity factor K_a due to tension or bending could prevail either at the deepest point on the crack border or at the root of the shank where the crack border terminates depending on the aspect ratio of the ellipse. In general, K₁ at the deepest point of crack penetration is larger than that at the free surface for tension and bending for a fixed crack depth with reference to the bolt diameter. Tightening of the bolt tends to increase K₁ at the free surface if the crack depth is small. The opposite is obtained for deeper cracks. Assumed residual stress effect obtained from experimental data is found to have negligible influence on the stress intensity factor when compared with that arising from tensile load.     

Observations on Mode I and III fracture of steel and PMMA

Considered in this work are the Mode I and III fractures of W18Cr4V steel, 60Si2Mn steel and PMMA specimens. The mixed mode critical stress intensity factor, denoted by K_1f, is shown to be greater than K_1c for Mode I. The ratio K_1f/K_1c depends on the ways in which K₁ and K₃ interact and is affected by the position of the load with reference to the crack position. Analytical and experimental results are presented and discussed in connection with the microfracture surface observed experimentally.     

Deflection criterion of a crack approaching a bi-material interface obliquely

Deflection criterion for oblique cracks terminating at a bi-material interface was established numerically based on a remote loading condition where the crack deflection event took place well within the K-dominant stress field. The criterion was described in terms of the ratio of the energy release rate of a deflected crack (G _d) to the maximum energy release rate of a penetrated crack (). The criterion was markedly more conservative than the existing solution based on wedge loading which did not converge with respect to limited number of a/L ratios in the literature (a is the size of the putative crack; L is the loading distance). Further, the criterion established herein for the cracks slightly oblique from the normal direction to the interface was more conservative than the crack normal to the interface.     

Analysis of cyclic crack growth in high strength roller bearings

The lives of ball and roller bearings and raceways depend on the number of rolling contacts consumed by 3 stages of the failure process: (i) the preinitiation; (ii) crack initiation, and (iii) crack growth stages. This paper employs fracture mechanics analyses to estimate the portion of the bearing life residing in the crack growth stage. Rough estimates of: (a) the Mode II, ΔK_II driving force for small cracks below the rim surface subjected to repeated 2-dimensional, pure rolling contacts, (b) the corresponding crack growth rates, and (c) the number of contacts to failure, are obtained as a function of the peak contact pressure, initial flaw size and other variables. Factors influential to the growth stage are identified. Finally, the comparisons with measured total lives provide insights into the validity of the analysis and the importance of growth relative to the preinitiation and crack initiation stages.     

Effects of surface diffusion and resolved shear stress intensity factor on environmentally assisted cracking

Hydrogen induced crack-tip plastic deformation has been known as the primary mechanism of hydrogen assisted cracking and stress corrosion cracking. It has been systematically shown that the same mechanism of environmentally assisted crack-tip dislocation emission causes hydrogen assisted cracking, stress corrosion cracking, and liquid metal embrittlement cracking.An embrittling chemical species has to reach a crack tip in order to accelerate crack growth. Very close to a sharp crack tip, surface diffusion is shown to be the dominant transport process of embrittling species for stage-II crack growth. The role of surface diffusion in stage II crack growth is analyzed. The constant cracking velocity is proportional to the surface diffusion coefficient of an embrittling species and inversely proportional to a length parameter, , which is related to the transport process upstream.Dislocation emission at a crack tip is driven by crack-tip resolved shear stress. Crack-tip resolved shear stress field is characterized by resolved shear stress intensity factor, K_RSS·K_RSS is defined, the procedure for its calculation outlined, and its applications to crack-tip dislocation emission and environmentally assisted cracking discussed.     

Non-self-similar crack growth in elastic-plastic finite thickness plate

This work is concerned with non-self-similar crack growth in medium strength metal plates while the loading step, plate thickness and material properties are altered. The three-dimensional elastic-plastic finite element stress analysis is combined with the strain energy density criterion for modeling the material damage process from crack initiation to final global instability including the intervening stage of slow crack growth. Both inelastic deformation and crack growth are accounted for each increment of loading such that the redistribution of stresses and strains are made for each new crack profile. Numerical results are obtained for the center cracked plate configuration under uniform extension with twenty-seven (27) different combinations of specimen thickness, loading step and material type. The fracture toughness S_c being related to K_1c for three different materials are predicted analytically from the corresponding uniaxial tensile test data. Effective strain energy density factor and half crack length are defined so that the results can be compared with their two-dimensional counterparts. Crack growth resistance curves (R-curves) are constructed by plotting as a function of . The condition is found to prevail during slow crack growth. Translation and/or rotation of the lines can yield results other than those calculated and serve a useful purpose for scaling component size and test time. The minimum thickness requirement for the ASTM valid K_1c test is also discussed in connection with predictions based on the strain energy density criterion. The corresponding K_1c for smaller specimens that exhibit moderate ductility and nonlinearity can also be obtained analytically. In such cases, the influence of loading step can be significant and should not be neglected. Notwithstanding the shortcomings of the theory of plasticity, the qualitative features of non-self-similar crack growth are predicted by the strain energy density criterion. Any refinements on the analytical modeling of the material damage process would only affect the results qualitatively, a subject that is left for future investigation.     

半无限横观各向同性体中共面双裂纹边界元分析

基于双横观各向同性材料基本解的对偶边界元方法,分析了半无限横观各向同性材料中两条共面裂纹的相互作用问题。裂纹面上分别作用着法向和切向两种均布荷载,材料的各向同性面及裂纹面平行于半无限域自由面。数值计算得到了该类裂纹的应力强度因子(SIF)值和两条共面裂纹相互作用的SIF值影响系数。根据数值结果分析了自由面对该类裂纹SIF值的影响,以及裂纹间距与形状、自由面对SIF值影响系数的影响。结果表明,自由面对作用法向力时的该类裂纹SIF值有明显的影响,裂纹间距与形状对SIF值影响系数影响较大,但自由面对SIF值影响系数基本无影响。     

Mixed-mode crack growth in plates under three-point bending

A combined theoretical and experimental study of the problem of crack growth in a plate subjected to unsymmetrical three-point bending was undertaken. The opening-modeK _I and sliding-modeK _II stress-intensity factors describing the local stress field around the crack tip were determined by a finite-element computer program. The crack growth was analyzed by the maximum circumferential stress and the minimum strain-energy density criteria. The critical loads for crack growth and the crack trajectories were determined both by theory and experiment. The experimental results corroborated the theoretical predictions.