Modeling dynamic brittle behavior of materials with circular flaws or pores

Compressive failure of brittle materials is driven primarily by crack growth from pre-existing flaws in the material. These flaws, such as grain boundaries, pores, preexisting cracks, inclusions and missing grains, are randomly spaced and have a range of possible shapes and sizes. The current work proposes a micromechanics-based model for compressive dynamic failure of brittle materials with circular pore flaws, which incorporates both the number density and the size distribution of flaws. Results show that the distribution of flaw sizes is very important, particularly at moderate strain rate, since analyses based solely on the mean flaw size overpredict strength. Therefore, in order to increase dynamic strength at low to moderate strain rates, it is most effective to control the presence of large flaws. At very high strain rates, however, crack growth is activated even in small flaws and therefore controlling the total number density rather than the size of the flaws is effective for increasing dynamic strength. Finally, the model shows that neglecting very small flaws in the pore population may not have significant effects on the results in many cases, suggesting that the model is a useful tool for identifying a minimum resolution required for experimental characterization of microstructure.     

Statistical characterization of meso-scale uniaxial compressive strength in brittle materials with randomly occurring flaws

Increasingly fine spatial resolution in numerical models of brittle materials promises to improve prediction and characterization of dynamic failure in these materials. However, as the resolution of these numerical models begins to approach the material micro-scale, the associated discretization requires a definitive connection to the microstructure. In many cases a numerical model (e.g., a finite element mesh) that explicitly resolves each flaw within the material is not feasible for macro-scale analyses. As an alternative, each element can be treated as a meso-scale continuum with constitutive properties that reflect the characteristics of the underlying microstructure. Small scale elements will exhibit random variations in the constitutive properties as a result of the random variations in the number and types of flaws and the flaw sizes contained within each element. The present paper proposes a technique for assigning probability distributions to these element properties, which can be thought of as the meso-scale constitutive properties. In particular, the strain-rate dependent compressive uniaxial strength of a ceramic is modeled using a two-dimensional analytical model developed by Paliwal and Ramesh (2008). The effect on the probability distribution of meso-scale (or element-level) strength from flaw density, flaw size distribution, flaw clustering, and strain rate are studied. Higher strain rates, more flaw clustering, and decreasing element size all contribute to greater scatter in uniaxial compressive strength. Variations in flaw size increase the scatter in the strength more for low strain rate loadings and less clustered microstructures. The results provide interesting comparisons to the classical assumption of a two-parameter Weibull-distributed strength, showing that a three-parameter Weibull distribution and even a lognormal distribution fit better with the simulated strength data.     

Computational micromechanics of dynamic compressive loading of a brittle polycrystalline material using a distribution of grain boundary properties

A two-dimensional finite element model is used to investigate compressive loading of a brittle ceramic. Intergranular cracking in the microstructure is captured explicitly by using a distribution of cohesive interfaces. The addition of confining stress increases the maximum strength and if high enough, can allow the effective material response to reach large strains before failure. Increasing the friction at the grain boundaries also increases the maximum strength until saturation of the strength is approached. Above a transitional strain rate, increasing the rate-of-deformation also increases the strength and as the strain rate increases, fragment sizes of the damaged specimen decrease. The effects of flaws within the specimen were investigated using a random distribution at various initial flaw densities. The model is able to capture an effective modulus change and degradation of strength as the initial flaw density increases. Effects of confinement, friction, and spatial distribution of flaws seem to depend on the crack coalescence and dilatation of the specimen, while strain-rate effects are result of inertial resistance to motion.     

Is Weibull distribution the correct model for predicting probability of failure initiated by non-interacting flaws?

The utility of the Weibull distribution has been traditionally justified with the belief that it is the mathematical expression of the weakest-link concept in the case of flaws locally initiating failure in a stressed volume. This paper challenges the Weibull distribution as a mathematical formulation of the weakest-link concept and its suitability for predicting probability of failure locally initiated by flaws. The paper shows that the Weibull distribution predicts correctly the probability of failure locally initiated by flaws if and only if the probability that a flaw will be critical is a power law or can be approximated by a power law of the applied stress.Contrary to the common belief, on the basis of a theoretical analysis and Monte Carlo simulations we show that in general, for non-interacting flaws randomly located in a stressed volume, the distribution of the minimum failure stress is not necessarily a Weibull distribution. For the simple cases of a single group of identical flaws or two flaw size groups each of which contains identical flaws, for example, the Weibull distribution fails to predict correctly the probability of failure. Furthermore, if in a particular load range, no new critical flaws are created by increasing the applied stress, the Weibull distribution also fails to predict correctly the probability of failure of the component. In all these cases however, the probability of failure is correctly predicted by the suggested alternative equation. This equation is the correct mathematical formulation of the weakest-link concept related to random flaws in a stressed volume. The equation does not require any assumption concerning the physical nature of the flaws and the physical mechanism of failure and can be applied in cases of locally initiated failure by non-interacting entities.     

An interacting micro-crack damage model for failure of brittle materials under compression

A model is developed for brittle failure under compressive loading with an explicit accounting of micro-crack interactions. The model incorporates a pre-existing flaw distribution in the material. The macroscopic inelastic deformation is assumed to be due to the nucleation and growth of tensile “wing” micro-cracks associated with frictional sliding on these flaws. Interactions among the cracks are modeled by means of a crack-matrix-effective-medium approach in which each crack experiences a stress field different from that acting on isolated cracks. This yields an effective stress intensity factor at the crack tips which is utilized in the formulation of the crack growth dynamics. Load-induced damage in the material is defined in terms of a scalar crack density parameter, the evolution of which is a function of the existing flaw distribution and the crack growth dynamics. This methodology is applied for the case of uniaxial compression under constant strain rate loading. The model provides a natural prediction of a peak stress (defined as the compressive strength of the material) and also of a transition strain rate, beyond which the compressive strength increases dramatically with the imposed strain rate. The influences of the crack growth dynamics, the initial flaw distribution, and the imposed strain rate on the constitutive response and the damage evolution are studied. It is shown that different characteristics of the flaw distribution are dominant at different imposed strain rates: at low rates the spread of the distribution is critical, while at high strain rates the total flaw density is critical.     

Strength and fracture toughness of heterogeneous blocks with joint lognormal modulus and failure strain

We obtain analytical approximations to the probability distribution of the fracture strengths of notched one-dimensional rods and two-dimensional plates in which the stiffness (Young’s modulus) and strength (failure strain) of the material vary as jointly lognormal random fields. The fracture strength of the specimen is measured by the elongation, load, and toughness at two critical stages: when fracture initiates at the notch tip and, in the 2D case, when fracture propagates through the entire specimen. This is an extension of a previous study on the elastic and fracture properties of systems with random Young’s modulus and deterministic material strength (Dimas et al., 2015a). For 1D rods our approach is analytical and builds upon the ANOVA decomposition technique of (Dimas et al., 2015b). In 2D we use a semi-analytical model to derive the fracture initiation strengths and regressions fitted to simulation data for the effect of crack arrest during fracture propagation. Results are validated through Monte Carlo simulation. Randomness of the material strength affects in various ways the mean and median values of the initial strengths, their log-variances, and log-correlations. Under low spatial correlation, material strength variability can significantly increase the effect of crack arrest, causing ultimate failure to be a more predictable and less brittle failure mode than fracture initiation. These insights could be used to guide design of more fracture resistant composites, and add to the design features that enhance material performance.     

Effect of flaws on the strength of Si3N4

Fracture-mechanics analysis and fractographic studies were performed to assess the effect of surface flaws on the strength of Si₃N₄. The critical surface-flaw size calculated from fracture-mechanics analysis was in agreement with the fractographically observed flaw size. A comparison of the results of fracture-mechanics calculations with fractographic observations indicates that the failure-initiating flaws grow subcritically before failure. The subcritical growth of these flaws and hence the strength is greatly influenced by the microstructure and grain-boundary phases. Paper was presented at the 1986 SEM Fall Conference on Experimental Mechanics held in Keystone, CO on November 2–5.     

An experimental and numerical study of fracture coalescence in pre-cracked specimens under uniaxial compression

This study presents crack initiation, propagation and coalescence at or near pre-existing open cracks or flaws in a specimen under uniaxial compression. The flaw geometry in the specimen was a combination of a horizontal flaw and an inclined flaw underneath. This flaw geometry is different from those reported in the previous studies, where a pair of parallel flaws was used. Three materials were used, PMMA (Poly Methyl MethAcrylate), Diastone (types of molded gypsum), and Hwangdeung granite. Crack initiation and propagation showed similar and different patterns depending on the material. In PMMA, tensile cracks initiated at the flaw tips and propagated to the tip of the other flaw in the bridge area. The cracks then coalesced at a point of the inclined flaw, which is affected by the flaw inclination angle. For Diastone and Hwangdeung granite, tensile cracks were observed followed by the initiation of shear cracks. Coalescence occurred mainly through the tensile cracks or tensile and shear cracks. Crack coalescence was classified according to the crack coalescence types of parallel flaws for overlapping flaw geometry in the past works. In addition, crack initiation and coalescence stresses in the double-flawed specimens were analyzed and compared with those in the single-flawed specimen. Numerical simulations using PFC^2D (Particle Flow Code in two dimensions) based on the DEM (Discrete Element Method) were carried out and showed a good agreement with the experimental results in the coalescence characteristics in Hwangdeung granite. These experimental and numerical results are expected to improve the understanding of the characteristics of cracking and crack coalescence and can be used to analyze the stability of rock and rock structures, such as the excavated underground openings or slopes, tunneling construction, where pre-existing cracks or fractures play a crucial role in the overall integrity of such structures.     

A 3-D ellipsoidal flaw model for brittle fracture in compression

Engineering materials are rarely free of flaws. Mode I cracking from pre-existing flaws is the major cause of the brittle fracture in compression of materials such as concrete and rock. A 3-D ellipsoidal flaw model is used to show the significant influence of flaw geometry on crack initiation in uniform uniaxial, biaxial and triaxial compression. The model shows that the governing criterion for crack initiation may change from energy to stress with increasing crack size, and that for voids of similar size a spherical void is the most critical shape for crack initiation. The model thus provides a basis for a better understanding of both the phenomenon and the mechanism of brittle fracture in compression.     

Equations and a fast algorithm for determining the probability of failure initiated by flaws

Powerful equations and an efficient algorithm are proposed for determining the probability of failure of loaded components with complex shape, containing multiple types of flaws. The equations are based on the concept ‘conditional individual probability of initiating failure’ characterising a single flaw given that it is in the stressed component. The proposed models relate in a simple fashion the conditional individual probability of failure characterising a single flaw (estimated by a Monte Carlo simulation) to the probability of failure characterising a population of flaws. The derived equations constitutes the core of a new statistical theory of failure initiated by flaws in the material, with important applications in optimising designs by decreasing their vulnerability to failure initiated by flaws during overloading or fatigue cycling.Methods have also been developed for specifying the maximum acceptable level of the flaw number density and the maximum size of the stressed volume which guarantee that the probability of failure initiated by flaws remains below a maximum acceptable level. An important parameter referred to as ‘detrimental factor’ is also introduced. Components with identical geometry and material, with the same detrimental factors are characterised by the same probability of failure. It is argued that eliminating flaws from the material should concentrate on types of flaws characterised by large detrimental factors.The equations proposed avoid conservative predictions resulting from equating the probability of failure initiated by a flaw in a stressed region with the probability of existence of the flaw in that region.     

Numerical study of failure behaviour of pre-cracked rock specimens under conventional triaxial compression

Macroscopic pre-existing flaws play an important role in evaluating the strength and the failure modes of a heterogeneous rock mass. Crack initiation, propagation and coalescence from macroscopic pre-existing flaws are considered in a 3-D numerical model (RFPA3D) to investigate their effects on the underlying failure modes of rock. A feature of the code RFPA3D is that it can numerically simulate the evolution of cracks in three-dimensional space, as well as the heterogeneity of the rock mass. Three types of flaw geometries were evaluated numerically against experimental results: Type A for intact specimen, and Types B and C for flawed cylindrical specimens with different macroscopic pre-existing flaws, respectively. The effect of confining pressure on the fracture evolution was also considered. Numerical results showed that both the ligament angle and the flaw angle of two pre-existing cracks can affect the uniaxial compressive strength of the specimen and the mechanism of fracture evolution. In addition, both the uniaxial compressive strength and the accumulated acoustic emission increase with increasing heterogeneity.     

应力波与缺陷相互作用的宏观微观数值模拟

分别利用LS-DYNA3D有限元程序以及分子动力学方法,从宏观与微观两个层次模拟在动态拉伸载荷作用下含有预置缺陷的薄板中的塑性区形成与演化过程,以及随之而来的动态失效行为。计算结果表明,动态加载下塑性区的形成是应力波与缺陷相互作用以及应力波与应力波相互作用的结果。宏观尺度的LS-DYNA模拟与微观尺度的分子动力学模拟展现出相似的物理特征,即动态载荷下裂纹将萌生在缺陷边缘的前端,然后与缺陷边界连接,最终导致整体破坏。     

The effects of micro-defects and crack on the mechanical properties of metal fiber sintered sheets

The effects of three types of defect (i.e., two micro defects—broken fibers and separation of fiber joints and one macro defect—crack) on the mechanical properties of porous metal fiber sintered sheets (MFSSs) are investigated by a combination of numerical simulation, analytical modeling, and experimental test. All simulations are based upon the previously developed micromechanics random beam model (Jin et al., 2013). Broken fibers are realized by removing cell edges (i.e., fibers between two joints) in an otherwise perfect model. Their induced decreases in the elastic moduli and strengths are found to be much lower than those of two dimensional (2D) foams and Kagome grids. For the defect in the form of separation of fiber joints, both analytical and numerical models are developed. The predicted linear decreases in the moduli and strengths (except for the compressive strength) with increasing number of separated fiber joints indicate that MFSSs be insensitive to the defect of joint separation. To explore the effect of crack, fracture toughness of MFSSs is measured and is found to be significantly higher than that of metal foams of the same relative density (i.e., volume fraction of the constituent solid material). The underlying ductile mechanism of MFSSs is further investigated by numerical simulations, showing that plastic deformation spreads all over the fibers in ligament rather than concentrates around crack tip. This study shows that MFSSs are superior in view of their resistance to the considered micro-defects and crack.     

CHARACTERISTICS OF FATIGUE SURFACE MICROCRACK GROWTH IN VICINAL INCLUSION FOR POWDER METALLURGY ALLOYS

Inclusion flaw is one of the worst flaws of powder metallurgy. The inclusion flaw plays an important role in the failure of high temperature turbine materials in aircraft components and automotive parts, especially fatigue failure. In this paper, an experimental investigation of fatigue microcrack propagation in the vicinal inclusion were carried out by the servo-hydraulic fatigue test system with scanning electron microscope (SEM). It has been found from the SEM images that the fatigue surface microcrack occurs in the matrix and inclusion. According to the SEM images, the characteristics of fatigue crack initiation and growth in vicinal inclusion for powder metallurgy alloys are analyzed in detail. The effect of the geometrical shape and material type of surface inclusions on the cracking is also discussed with the finite element method (FEM).     

基于数字图像处理的含缺陷花岗岩破裂力学分析1）

在细观尺度上,采用数字图像处理技术研究花岗岩中由石英、长石和云母等材料的形状、大小及分布对花岗岩材料造成的非均匀性,结合RFPA-DIP 程序建立了能准确反映材料真实细观结构的含缺陷花岗岩数值模型,并进行了常规单轴压缩模拟试验,研究不同矿物颗粒结构与缺陷对其细观破裂力学行为的影响,再现了外载荷作用下不同数值模型的真实破裂过程与最终破坏模式. 试验结果表明:缺陷对试样强度的影响比改变矿物颗粒的形态构造对其强度的影响更加显著,缺陷的存在削弱了颗粒形态对花岗岩强度影响的能力;缺陷及矿物颗粒的形态构造对试样裂纹的萌生、扩展以及最终破坏模式有直接影响,缺陷与矿物颗粒的空间结构关系是导致岩石形成各种复杂破坏模式的主要因素. 起裂应力水平受试样内部细观介质构造和缺陷的影响,而缺陷的存在对起裂应力的影响更加显著.     

Closure effects in delaminated graphite epoxy laminate under compression

Flaws in composite laminates may result in a severe loss of static and dynamic strength. Such flaws may be inherent or gained by misadventure. The extent of this loss can be influenced by several factors including loading, laminate stacking sequence, lamina properties, flaw size and damage type.In this study, the free-edge delamination of a laminated composite under compression loading is investigated. Computational, analytical and experimental tests are performed on a graphite/epoxy laminate AS4/3501-6 containing near surface edge defects and the crack opening behaviour is investigated.The computational analysis consists of a three dimensional finite element model where the plies can be catered for individually and interply delamination modelled. In the experimental investigations, a delamination is simulated by inserting teflon film at appropriate locations during the lay-up process.     

On flaw size and distribution in lap joints

By using adhesive as the bonding substance between metals or polymeric materials, simple structural joints can be made to bear relatively high loads. Applications have increasingly been made in substituting adhesive joints for conventional mechanical fastenings, especially in the aircraft and aerospace industries where weight is a predominant factor. In order to design a most effective adhesive-bonded joint, an understanding of the stress distribution along the joint is as important as the physical properties of the bonding agent. One of the most common and widely used adhesive joints is the single lap joint.Recent investigations using various analytical models have revealed that the cause of failure in an idealized ‘defect free’ lap joint is primarily due to the localized effect of high stress concentration at the lap ends. With the presence of flaw like defects in the adhesive layer, the load transfer from adherend to adhesive is expected to be different from the idealized joint. In addition, localized stress concentrations induced by irregular adhesive defects that may be found in practical engineering applications can further reduce fracture strength of such an imperfect joint.This paper is intended to describe an investigation into the effect of internal adhesive flaw size and distribution on the fracture behaviour of adhesive-bonded lap joints. The finite element method is used to gain a quantitative understanding of the localized shear stress distributions due to the presence of the internal flaws along the bonding layer. It is observed that the reduction in the fracture strength is relatively small when a flaw is located in the central portion of the bonding length. However, a flaw located near the lap ends of the adhesive joint can cause marked reduction in the fracture strength, due to its interaction with the high stress concentration at the lap ends.     

Porosity dependence of strength in brittle solids

The effect of pore size and pore volume fraction on strength in brittle solids is evaluated. The analysis considers that the strength degradaton of a solid containing a large number of spherical pores is due to a strong effect of porosity on Young's modulus. Each pore is assumed to possess radial or annular flaws emanating from the pore surface whose lengths are considered to be independent of pore size. The effect of stress concentration induced by the presence of the pore is included in the equation for strength through the Young's modulus dependence of porosity originally developed using the concept of crack opening displacement. It is shown that the strength of a solid containing spherical pores is controlled by the pore size, pore volume fracton and the radial (or annular) crack size to pore size ratio. Predicted variation of strength with pore volume fraction is tested against experimental data for glass and polycrystalline alumina.     

Influence of flaw inclination angle and loading condition on crack initiation and propagation

With reference to the experimental observation of crack initiation and propagation from pre-existing flaws in rock specimens under compression, the influences of pre-existing flaw inclination angle on the cracking processes were analyzed by means of finite element method (FEM) and non-linear dynamics method. FEM analysis on the stress field distribution induced by the presence of a pre-existing flaw provided better understanding for the influence of flaw inclination angle on the initiation position and initiation angle of the potential cracks. Numerical analysis based on the non-linear dynamics method was performed to simulate the cracking processes. The resultant crack types, crack initiation sequences and the overall crack pattern were different under different loading conditions. Under a relatively low loading rate or a small magnitude of maximum loading pressure, tensile cracks would tend to initiate prior to shear cracks. In contrast, under a relatively high loading rate and a large magnitude of maximum loading pressure, shear cracks would tend to initiate prior to tensile cracks instead.     

Al2O3陶瓷动静态压缩下碎片形貌与破坏机理分析

为探究Al₂O₃陶瓷的宏观力学响应与破坏机理,分别利用材料试验机和分离式霍普金森压杆对其进行准静态和动态压缩实验,同时通过原位光学成像观测试样的破坏过程,并利用同步辐射CT和扫描电镜（SEM）对回收碎片的尺寸和形状以及微观破坏模式进行表征分析。宏观强度数据表明,Al₂O₃陶瓷的抗压强度符合Weibull分布,且与加载应变率呈现指数增长关系。原位光学成像和SEM回收分析共同揭示了动静态加载下裂纹成核与扩展模式存在明显差异。准静态加载时材料微观上更易发生沿晶断裂,宏观表现为劈裂裂纹较少,且倾向于沿加载方向传播并贯穿整个试样;而动态加载时穿晶断裂占主导地位,劈裂裂纹明显增加并发生相互作用,因此在传播过程中容易分叉而形成大量次生裂纹,提高了试样内裂纹密度。这与碎片的CT表征结果一致,即碎片平均球形度和伸长、扁平指数等均随应变率对数线性增加。破坏模式的改变最终导致高应变率下陶瓷材料应变率敏感性显著增强。