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。     

Theoretical analysis of crack front instability in mode I+III

This paper focusses on the theoretical prediction of the widely observed crack front instability in mode I+III, that causes both the crack surface and crack front to deviate from planar and straight shapes, respectively. This problem is addressed within the classical framework of fracture mechanics, where the crack front evolution is governed by conditions of constant energy-release-rate (Griffith criterion) and vanishing stress intensity factor of mode II (principle of local symmetry) along the front. The formulation of the linear stability problem for the evolution of small perturbations of the crack front exploits previous results of Movchan et al. (1998) (suitably extended) and Gao and Rice (1986), which are used to derive expressions for the variations of the stress intensity factors along the front resulting from both in-plane and out-of-plane perturbations. We find exact eigenmode solutions to this problem, which correspond to perturbations of the crack front that are shaped as elliptic helices with their axis coinciding with the unperturbed straight front and an amplitude exponentially growing or decaying along the propagation direction. Exponential growth corresponding to unstable propagation occurs when the ratio of the unperturbed mode III to mode I stress intensity factors exceeds some “threshold” depending on Poisson's ratio. Moreover, the growth rate of helical perturbations is inversely proportional to their wavelength along the front. This growth rate therefore diverges when this wavelength goes to zero, which emphasizes the need for some “regularization” of crack propagation laws at very short scales. This divergence also reveals an interesting similarity between crack front instability in mode I+III and well-known growth front instabilities of interfaces governed by a Laplacian or diffusion field.     

Fatigue of fillet welded joints

The Albrecht method was used to compute stress intensity factors in non-load carrying fillet welds subjected to tension and cantilever bending for cracks growing from the tip of the weld toe through the plate thickness. The stresses were obtained using a two dimensional finite element programme with eight node isoparametric elements with two degrees of freedom in each node. A detailed study of the influence of weld and plate geometry on both the stress concentration and stress intensity factor values was carried out.The results in bending showed stress intensity values 20 to 30% lower than in tension. The weld affected the stress intensity and stress concentration results only for small crack length values less than 0.1 to 0.12 of the thickness of the main plate. The results also indicated that neither the lack of penetration nor the plate length affected the stress intensity values significantly. Weld angle and plate thickness were the main parameters influencing the stress intensity values. The results in tension were compared with similar results published in the literature and good agreement was found.     

Variation of the stress intensity factor along the front of a 3-D rectangular crack subjected to mixed-mode load

Summary  The singular integral equation method is applied to the calculation of the stress intensity factor at the front of a rectangular crack subjected to mixed-mode load. The stress field induced by a body force doublet is used as a fundamental solution. The problem is formulated as a system of integral equations with r ⁻³-singularities. In solving the integral equations, unknown functions of body-force densities are approximated by the product of polynomial and fundamental densities. The fundamental densities are chosen to express two-dimensional cracks in an infinite body for the limiting cases of the aspect ratio of the rectangle. The present method yields rapidly converging numerical results and satisfies boundary conditions all over the crack boundary. A smooth distribution of the stress intensity factor along the crack front is presented for various crack shapes and different Poisson's ratio. Received 5 March 2002; accepted for publication 2 July 2002     

Mixed-mode stress intensity factors of 3D interface crack in fully coupled electromagnetothermoelastic multiphase composites

This contribution presents an extended hypersingular intergro-differential equation (E-HIDE) method for modeling the 3D interface crack problem in fully coupled electromagnetothermoelastic anisotropic multiphase composites under extended electro-magneto-thermo-elastic coupled loads through theoretical analysis and numerical simulations. First, based on the extended boundary element method, the 3D interface crack problem is reduced to solving a set of E-HIDEs coupled with extended boundary integral equations, in which the unknown functions are the extended displacement discontinuities. Then, the behavior of the extended singular stress indices around the interface crack front terminating at the interface is analyzed by the extended main-part analysis. The extended stress intensity factors near the crack front are defined. In addition, a numerical method for a 3D interface crack problem subjected to extended loads is proposed, in which the extended displacement discontinuities are approximated by the product of basic density functions and polynomials. Finally, the radiation distribution of extended stress intensity factors at the interface crack surface are calculated, and the results are presented toward demonstrating the applicability of the proposed method.     

Investigation on 3D fatigue crack propagation in surface-cracked specimens

In the present work the fatigue crack growth in AISI304 specimens is investigated experimentally. In 3D finite element analysis the virtual crack closure technique is applied to calculate distributions and variations of the stress intensity factor along the surface crack front. It is confirmed that the stress intensity factor along the surface crack front varies non-uniformly with crack growth. Crack growth rate is proportional to the stress intensity factor distribution in the 3D cracked specimen. The fatigue crack growth in surface cracked specimens can be described by the Forman model identified in conventional compact tension specimens. For crack growth in the free specimen surface the arc length seems more suitable to quantify crack progress. Geometry and loading configuration of the surface cracked specimen seem to not affect the fatigue crack growth substantially.     

三维界面裂纹的奇性应力场和应力强度因子分析

使用有限部积分概念和极限方法得到了三维平片界面裂纹的超奇异积分－微分方程组后,进一步利用二维超奇异积分主部分析方法,对裂纹前沿的应力场作了理论分析,并获得了其奇性应力场和裂纹面位移间断表示复位应力强度因子的精确表达式,为三维平片界面裂纹的超奇异积分－微分方程组的求解建立了数值方法,并分析了界面椭圆平片裂纹问题,和现有解比较,所得数值结果令人满意。     

Experimental and numerical analysis of fretting crack formation based on 3D X-FEM frictional contact fatigue crack model

Nowadays, numerical simulation of 3D fatigue crack growth is easily handled using the eXtended Finite Element Method coupled with level set techniques. The finite element mesh does not need to conform to the crack geometry. Most difficulties associated to complex mesh generation around the crack and the re-meshing steps during the possible propagation are hence avoided. A 3D two-scale frictional contact fatigue crack model developed within the X-FEM framework is presented in this article. It allows the use of a refined discretization of the crack interface independent from the underlying finite element mesh and adapted to the frictional contact crack scale. A stabilized three-field weak formulation is also proposed to avoid possible oscillations in the local solution linked to the LBB condition when tangential slip is occurring. Two basic three-dimensional numerical examples are presented. They aim at illustrating the capacities and the high level of accuracy of the proposed X-FEM model. Stress intensity factors are computed along the crack front. Finally an experimental 3D ball/plate fretting fatigue test with running conditions inducing crack nucleation and propagation is modeled. 3D crack shapes defined from actual experimental ones and fretting loading cycle are considered. This latter numerical simulation demonstrates the model ability to deal with challenging actual complex problems and the possibility to achieve tribological fatigue prediction at a design stage based on the fatigue crack modeling.     

A study on stress intensity factors and singular stress fields of three-dimensional interface crack

By using the finite-part integral concepts and limit technique, the hypersingular integrodifferential equations of three-dimensional (3D) planar interface crack were obtained; then the dominant-part analysis of 2D hypersingular integral was further used to investigate the stress fields near the crack front theoretically, and the accurate formulae were obtained for the singular stress fields and the complex stress intensity factors. After that, a numerical method is proposed to solve the hypersingular integrodifferential equations of 3D planar interface crack, and the problem of elliptical planar crack is then considered to show the application of the method. The numerical results obtained are satisfactory. Project supported by the Foundation of Solid Mechanics Open Research Laboratory of State Education Commission at Tongji University and the National Natural Science Foundation.     

The deformation of the front of a 3D interface crack propagating quasistatically in a medium with random fracture properties

One studies the evolution in time of the deformation of the front of a semi-infinite 3D interface crack propagating quasistatically in an infinite heterogeneous elastic body. The fracture properties are assumed to be lower on the interface than in the materials so that crack propagation is channelled along the interface, and to vary randomly within the crack plane. The work is based on earlier formulae which provide the first-order change of the stress intensity factors along the front of a semi-infinite interface crack arising from some small but otherwise arbitrary in-plane perturbation of this front. The main object of study is the long-time behavior of various statistical measures of the deformation of the crack front. Special attention is paid to the influences of the mismatch of elastic properties, the type of propagation law (fatigue or brittle fracture) and the stable or unstable character of 2D crack propagation (depending on the loading) upon the development of this deformation.     

CTOD试验焊缝表面开缺口试样裂纹前沿平直度研究

对于裂纹尖端张开位移(CTOD)试验,焊缝试样中预制疲劳裂纹前沿平直度直接影响了试样制备的合格率,是试验的关键难题之一．试验中常对试样进行预处理以提高裂纹前沿平直度,但由此也使试验结果与实际情况产生一定差异．本文深入研究规范BS7448: Part2中对焊缝试样取样方向的规定,对表面开缺口试样裂纹尖端焊接残余应力进行分析,运用大型有限元软件ANSYS模拟90mm厚钢板焊接过程,求解了横向残余应力沿板厚方向及焊缝方向的分布规律,研究出横向残余应力分布是影响焊缝试样预制裂纹前沿平直度的主要原因,并通过试验进行验证．试验结果表明,表面开缺口试样可不经过局部韧带压缩等预处理而得到合格的裂纹前沿平直度,试验不改变原焊缝残余应力,可测得更加接近焊缝实际情况的CTOD韧度值,给CTOD试验中合理选取焊缝试样取样方向提供了新思路．     

Effect of cracked weld joint and yield strength dissimilarity on crack tip stress triaxiality

This paper is concerned with an elasto-plastic analysis of a weld joint containing a central crack in the weld material (WM) whose yield strength may differ from that of the base material (BM). Stress triaxiality along the path of expected crack extension is found to be influenced not only by the applied tensile load level and crack length relative to the specimen width but also by the degree of BM/WM mismatch in the yield strength.Three different cases are analyzed by application of a two-dimensional finite element analysis. They are referred to as under-match, even-match and over-match which correspond, respectively, to the WM yield strength being less than, equal to and greater than that of the BM. In general, the stress triaxiality along the crack front tends to increase for an under-matched weld and decrease for an over-matched weld using the even-matched case as a reference. As the crack length is reduced for a given specimen width, the stress triaxiality decreases accordingly and the BM/WM material dissimilarity becomes more obvious. Displayed graphically are also the crack front plastic zone size that increases with the applied tensile load level and suffers a discontinuity across the weld line.     

海洋平台K型管节点的疲劳裂纹扩展分析 II:数值分析

对于已含初始裂纹平台管节点的寿命预测很大程度上依靠应力强度因子的精确值,而复杂载荷条件下的节点应力强度因子的计算尚无参数方程直接确定。本文提出了一种含表面裂纹的K节点的有限元网格产生方法,即把整个K节点划分为几个子区域,每个子区域的网格具有不同类型的单元和不同的密度。这种方法在控制网格密度,尤其是控制沿着裂纹边缘单元的边长比方面有其独特的优越性,当所有子区域的网格自动产生后,容易得到整个结构的有限元模型。同时用J积分和位移外推插值法分别计算了一个K型节点沿着裂纹前缘的应力强度因子值,发现:试验得到的应力强度因子值和提出的模型计算结果非常吻合,证明了所提有限元模型的准确性。     

Stress intensity factors for curved and kinked cracks in plane extension

A singular integral equation containing the crack opening displacement (COD) is developed for solving plane elasticity problems. The crack may contain any number of kinks at different intervals and orientations, such as a saw-tooth shape. Cracks in the form of a sine wave can also be treated. The crack tip stress intensity factors are evaluated for a variety of crack shapes and the results are displayed graphically. The distance between the crack tips is found to be a dominant factor on the crack tip stress intensity while the angle between the tangent to the crack tip and load direction determines the proportion of Mode I and II stress intensity factors.     

各向异性双材料界面裂纹扩展裂尖场

应用界面断裂力学理论和Stroh方法,研究了广义平面变形下动态裂纹沿着各向异性双材料界面扩展时的裂尖奇异应力及动态应力强度因子.双材料界面的动态裂尖区域特性主要由两个实矩阵W和D确定,且裂尖奇异应力和动态应力强度因子可以由包含这两个矩阵的柯西奇异积分方程确定,同时给出了动态应力强度因子和能量释放率的显示表达式.算例得出当裂纹以小速度扩展时,裂尖振荡因子ε与静态时几乎相同,当界面裂纹扩展速度接近瑞利波速时,ε趋于无穷大;同时得出应力强度因子及能量释放率随裂纹扩展速度的变化关系.     

Controlling parameter of the stress intensity factors for a planar interfacial crack in three-dimensional bimaterials

Numerical solutions of singular integral equations are discussed in the analysis of a planar rectangular interfacial crack in three-dimensional bimaterials subjected to tension. The problem is formulated as a system of singular integral equations on the basis of the body force method. In the numerical analysis, unknown body force densities are approximated by the products of the fundamental density functions and power series, where the fundamental density functions are chosen to express singular behavior along the crack front of the interface crack exactly. The calculation shows that the present method gives smooth variations of stress intensity factors along the crack front for various aspect ratios. The present method gives rapidly converging numerical results and highly satisfied boundary conditions throughout the crack boundary. The stress intensity factors are given with varying the material combination and aspect ratio of the crack. It is found that the stress intensity factors K_I and K_II are determined by the bimaterial constant ε alone, independent of elastic modulus ratio and Poisson’s ratio.     

Crack paths in three-dimensional elastic solids. ii: three-term expansion of the stress intensity factors—applications and perspectives

This work continues the calculation of the stress intensity factors, as a function of position s along the front of an arbitrary (kinked and curved) infinitesimal extension of some arbitrary crack on some three-dimensional body. More precisely, ε denoting a small parameter which the crack extension length is proportional to, what is studied here is the third term, proportional to εfn2 = ε and noted K ⁽¹⁾ (s) ε, of the expansion of these stress intensity factors at the point s of the crack front in powers of ε. The novelties with respect to previous works due to Gao and Rice on the one hand and Nazarov on the other hand, are that both the original crack and its extension need not necessarily be planar, and that a kink (discontinuity of the tangent plane to the crack) can occur all along the original crack front. Two expressions of K ⁽¹⁾ (s) are obtained; the difference is that the first one is more synthetic whereas the second one makes the influence of the kink angle (which can vary along the original crack front) more explicit. Application of some criterion then allows to obtain the apriori unknown geometric parameters of the small crack extension (length, kink angle, curvature parameters). The small scale segmentation of the crack front which is observed experimentally in the presence of mode III is disregarded here because a large scale point of view is adopted; this phenomenon will be discussed in a separate paper. It is shown how these results can be used to numerically predict crack paths over arbitrary distances in three dimensions. Simple applications to problems of configurational stability and bifurcation of the crack front are finally presented.     

Measurement of the Residual Stress Tensor in a Compact Tension Weld Specimen

Neutron diffraction measurements have been performed to determine the full residual stress tensor along the expected crack path in an austenitic stainless steel (Esshete 1250) compact tension weld specimen. A destructive slitting method was then implemented on the same specimen to measure the stress intensity factor profile associated with the residual stress field as a function of crack length. Finally deformations of the cut surfaces were measured to determine a contour map of the residual stresses in the specimen prior to the cut. The distributions of transverse residual stress measured by the three techniques are in close agreement. A peak tensile stress in excess of 600 MPa was found to be associated with an electron beam weld used to attach an extension piece to the test sample, which had been extracted from a pipe manual metal arc butt weld. The neutron diffraction measurements show that exceptionally high residual stress triaxiality is present at crack depths likely to be used for creep crack growth testing and where a peak stress intensity factor of 35 MPa√m was measured (crack depth of 21 mm). The neutron diffraction measurements identified maximum values of shear stress in the order of 50 MPa and showed that the principal stress directions were aligned to within ~20° of the specimen orthogonal axes. Furthermore it was confirmed that measurement of strains by neutron diffraction in just the three specimen orthogonal directions would have been sufficient to provide a reasonably accurate characterisation of the stress state in welded CT specimens.     

Local weight functions for semi-elliptical surface cracks in finite thickness plates

Weight functions for any local point, 0 < Φ < π/2 along a semi-elliptical surface crack in finite thickness plates were derived from an assumed approximate general weight function and two reference stress intensity factors. The resulting weight functions were verified using available finite element results for two nonlinear stress fields and good agreement was achieved. When used together with weight functions for Φ = 0 and Φ = π/2 the weight functions are suitable for the calculation of stress intensity factors anywhere along the crack front for semi-elliptical surface cracks in complex stress fields with aspect ratios in the range 0 ≤ a/c ≤ 1 and relative depths 0 ≤ a/t ≤ 0.8.     

同震断层三维裂纹扩展波动时域超奇异积分法

应用波动时域超奇异积分法将P波、S波和磁电热弹多场耦合作用下同震断层任意形状三维裂纹扩展问题转化为求解以广义位移间断率为未知函数的超奇异积分方程组问题;定义了广义应力强度因子,得到裂纹前沿广义奇异应力增量解析表达式;应用波动时域有限部积分概念及体积力法,为超奇异积分方程组建立了数值求解方法,编制了FORTRAN程序,以三维矩形裂纹扩展问题为例,通过典型算例,研究了广义应力强度因子随裂纹位置变化规律;分析了同震断层裂纹扩展中力、磁、电场辐射规律.