A novel method for residual strength prediction for sheets with multiple site damage: Methodology and experimental validation

A unified method for solving the strip yield model for collinear cracks in finite and infinite sheet is proposed. The method is based on the weight function of a single crack. Two collinear cracks in finite and infinite sheets are used to apply and verify this method. The plastic zone size, crack opening displacement and stress distribution along the ligament between cracks obtained by using the present method are extensively compared with existing available results and finite element solutions, and very good agreements are observed. Combined with the Crack Tip Opening Angle (CTOA) criterion, the unified method is used to predict the crack growth behavior and residual strength for 2024-T3 aluminum alloy sheet with Multiple Site Damage (MSD). Thirty-two sheets with four types of MSD are designed and tested to verify this method. It is shown that the present method is able to predict various crack growth behaviors observed in experiment. The predicted residual strengths are within 9% of the corresponding test results. Compared to the elastic–plastic finite element method, the present method is much more efficient.     

On Two-Scale Model of Fracture Mesomechanics of Composites with Cracks under Compression

A two-level fracture model of composites with cracks under compression is proposed. Fiber-reinforced laminated panels with a hole are considered. The panels are compressed along the fibers so that two cracks propagate from the hole boundary at a right angle to the loading direction. The fracture mechanism is analyzed at two levels. The first level is the compression-induced stress concentration at the tip of a finite-thickness crack filled with a fractured material. At this level, the theory of elasticity of linear orthotropic body is used. The second level is compression fracture at the crack tip. The analysis performed at this level involves the three-dimensional linearized theory of stability of solids, considering microcracks in the interface between the fractured and intact materials, and the exact solution describing the compression-induced instability of the cracked interface. The second level is where results obtained by the author are used. Thus, the approach proposed employs the theory of elasticity of linear orthotropic body and the three-dimensional linearized theory of stability of solids to analyze a specific mechanism of fracture__________Published in Prikladnaya Mekhanika, Vol. 41, No. 5, pp. 141–144, May 2005Reported at ICF-11 (Turin, Italy, March 20–25, 2005). The ICF-11 proceedings have been published on CD-ROM. The author ‘s other reports presented at ICF-6 (1984) to ICF-10 (2001) are listed in Appendix.     

Strain-induced passivity breakdown in corrosion crack initiation

Corrosion crack nucleation and growth are modelled as a moving boundary problem. The model incorporates three physical processes––dissolution, passivation and straining––into a continuum mechanical framework. The dissolution triggers surface advance; the passivation restrains the access of the environment to bare metal; the deformation causes for passivity breakdown. Plane cracks nucleating from surface pits in an elastic–plastic material body under fatigue load are considered. The problem is solved using a FEM program and a moving boundary tracking procedure. The model simulates how cracks form and grow in a single continuous course. The geometry of the developed cracks is found independent of the initial pit size. Plasticity is found to influence the curvature at the tip of the nucleated corrosion cracks. The most important evolution length parameter, the width of the corrosion crack, is found to depend on the size constraints of the tracking procedure. It is concluded that the model is deficient for determining all length scales observed in reality. Physical processes to be considered in an advanced model are proposed and discussed.     

A direct complex stress function approach for modelling stiffened panels containing multiple site damage

The analysis of stiffened panel structures containing multiple site damage (MSD) is addressed through the complex variable method, in association with the requirement for displacement compatibility. The method is extended by replacing the usual single crack stress and displacement functions by those for a series of arbitrary straight collinear cracks which are used to model exactly the main and secondary crack damage in the sheet. It is shown that the problem can be reduced to a system of linear equations for the unknown forces at the attachment points between the sheet and the stiffener from which the stress intensity factor of the collinear cracks can be determined. The stress intensity factor and the attachment force distribution are determined for several configurations and compared with those from numerically based approaches.     

Numerical and experimental determination of three-dimensional multiple crack growth in fatigue

This work is concerned with the assessment of propagation of multiple fatigue cracks in three-dimensions. Computational modelling of fatigue crack propagation is made together with detection and monitoring of the crack shape development. The boundary element method (BEM) is used for automating the modelling of crack propagation in linear elastic as well as elastic–plastic regimes. Strain at several positions on the specimen surface near the crack mouth is measured to monitor crack initiation, shape development and closure levels. Examples are provided to validate the model by comparing the experimental results with those obtained by numerical predictions.     

圆盘状裂纹前缘塑性区尺寸及张开位移估计

将Ｄｕｇｄａｌｅ模型推广到三维裂纹问题计算了圆盘状裂纹前缘塑性区尺寸,并结合断裂力学中的Ｂａｒｅｎｂｌａｔｔ－Ｄｕｇｄａｌｅ裂纹模型和三维Ｊ－积分原理计算了圆盘状裂纹前缘张开位移,得到了Ｊ－积分与裂纹张开位移的关系,最后用非线性有限元方法对圆盘状裂纹的前缘塑性区尺寸作了数值分析,确定了公式中的未知常数,并对其正确性作了数值验证,本文的工作推广了Ｄｕｇｄａｌｅ模型的应用范围。     

Fatigue fracture model for thin isotropic plates with cracks in axial loading

Conclusion We have constructed a model of the growth of a fatigue crack in a thin, isotropic plate, taking the two-stage evolution of the fracture process into account. The model is based on concepts of the mechanics of a continuous defective state and on a schematic representation of the neighborhood of the tip of a fatigue crack as a plastic zone moving together with the crack. The model takes into account the influence of the cumulative defective state (damage level) along the crack propagation front on the speed of propagation.We have formulated solutions for the cases when the length of the plastic zone is constant and when it varies during the growth of fatigue cracks. We have established the fact that the plastic zone at the crack tip tends to disrupt the stability of the motion immediately at the time of inception or opening of the crack. The speed of crack propagation decreases as the plastic zone grows in size.We have shown that the problem of estimating the kinetics of fatigue cracks in thin plates can be reduced to calculating the growth rate as a function of the peak-to-peak amplitude of the stress intensity factor while preserving the structure of the governing equations of the model. We have also shown that the concept of a plastic zone of constant length induces a power-law dependence of the crack rate on K, the power exponent varying from 2 to 10–12. The Dugdale model gives a square-law dependence of the crack rate on K, which for the most part is applicable to plastic materials.S. P. Timoshenko Institute of Mechanics, National Academy of Sciences of Ukraine, Kiev. Translated from Prikladnaya Mekhanika, Vol. 30, No. 7, pp. 53–63, July, 1994.     

Surface wave diffraction at a crack in sheet ice

The time-periodic motions of a liquid layer of finite depth beneath an ice sheet with a straight infinite crack having a periodic dependence on the horizontal coordinate in the direction of the crack are considered. The ice sheet is simulated by a thin elastic plate. It is assumed that the thickness of the plate changes abruptly across the crack. The problems of plane-wave diffraction at a crack, plane-wave diffraction atN cracks in a uniform ice sheet, and plane-wave reflection from a rigid wall are solved. The effect of the pre-existing state of stress of the ice sheet on the properties of the reflected waves is investigated. The condition of nontransmission of fix-frequency waves beneath the edge of the ice is obtained.Translated from Izvestiya Rossiiskoi Akademii Nauk, Mekhanika Zhidkosti i Gaza, No.2, pp. 93–102, March–April, 1993.     

Energy approach to crack growth in a fiber-reinforced brittle material modeled by an inclusion

Brittle materials randomly reinforced with a low volume fraction of strong, stiff and ductile fibers are considered, with specific reference to fiber-reinforced cements and concrete. Visible cracks in such materials are accompanied by a surrounding damage zone – together these constitute a very complex “crack system”. Enormous effort has been put into trying to understand the micromechanics of such systems. Almost all of these efforts do not deal with the “crack system” propagation behavior as a whole. The propagation process of such a “crack system” includes propagation of the visible crack and the growth of the damage zone. Propagation may take place by lengthening of the visible crack together with the concomitant lengthening of the surrounding damage zone, or simply by broadening of the damage zone while the visible crack length remains unchanged – or simultaneously by growth of both types. A phenomenological completely theoretical model (for an ideal material) is here proposed which can serve to examine the propagation process by means of energy principles, without recourse to the microscopic details of the process. An application of this theoretical approach is presented for the case of a damage zone evolving with a rectangular shape. This shape is chosen because it is expected that it will illustrate the nature of damage evolution and because the computational procedure necessary to follow the growth is the most straightforward.     

中心小裂纹的弹塑性分析

用修正能量法得到含中心小裂纹平板在均匀载荷作用下的J积分和张开位移的全塑性解。并用弹塑性分析的工程方法得到相应的弹塑性解。结果与无限大板的解作了比校,表明当a/b≤0.05时两者的差别小于5％。而对于a/b>0.05的情况,把无限大板的解用于中心小裂纹的板条可能会产生较大的误差。     

Interaction of microcracks with a macrocrack yielded in a narrow strip

Plastic zone growth of collinear cracks has had a longstanding interest in ductile fracture. This work further considers yield zone growth in an isotropic, homogeneous elastic–perfectly plastic infinite plate containing a macrocrack with several neighboring microcracks. Normal loading is considered at distances far away from the cracks. The strip yield is adopted where the plastic zone is assumed to be confined to two narrow strips extending from the ends of a finite length crack while the microcracks are assumed to be elastic. The plastic zone length and crack opening displacement are found from asymptotic solution and compared with finite element solution.     

Numerical solution of polarization saturation/dielectric breakdown model in 2D finite piezoelectric media

The polarization saturation (PS) model [Gao, H., Barnett, D.M., 1996. An invariance property of local energy release rates in a strip saturation model of piezoelectric fracture. Int. J. Fract. 79, R25–R29; Gao, H., Zhang, T.Y., Tong, P., 1997. Local and global energy release rates for an electrically yielded crack in a piezoelectric ceramic. J. Mech. Phys. Solids 45, 491–510], and the dielectric breakdown (DB) model [Zhang, T.Y., Zhao, M.H., Cao, C.F., 2005. The strip dielectric breakdown model. Int. J. Fract. 132, 311–327] explain very well some experimental observations of fracture of piezoelectric ceramics. In this paper, the nonlinear hybrid extended displacement discontinuity-fundamental solution method (NLHEDD-FSM) is presented for numerical analysis of both the PS and DB models of two-dimensional (2D) finite piezoelectric media under impermeable and semi-permeable electric boundary conditions. In this NLHEDD-FSM, the solution is expressed approximately by a linear combination of fundamental solutions of the governing equations, which includes the extended point force fundamental solutions with sources placed at chosen points outside the domain of the problem under consideration, and the extended Crouch fundamental solutions with extended displacement discontinuities placed on the crack and the electric yielding zone. The coefficients of the fundamental solutions are determined by letting the approximated solution satisfy certain conditions on the boundary of the domain, on the crack face and the electric yielding zone. The zero electric displacement intensity factor in the PS model or the zero electric field strength intensity factor in the DB model at the outer tips of the electric yielding zone is used as a supplementary condition to determine the size of the electric yielding zone. Iteration approaches are adopted in the NLHEDD-FSM. The electric yielding zone is determined, and the extended intensity factors and the local J-integral are calculated for center cracks in piezoelectric strips. The effects of finite domain size, saturation property and different electric boundary conditions, as well as different models on the electric yielding zone and the local J-integral, are studied.     

Strain localization analysis using a large deformation anisotropic elastic–plastic model coupled with damage

Sheet metal forming processes generally involve large deformations together with complex loading sequences. In order to improve numerical simulation predictions of sheet part forming, physically-based constitutive models are often required. The main objective of this paper is to analyze the strain localization phenomenon during the plastic deformation of sheet metals in the context of such advanced constitutive models. Most often, an accurate prediction of localization requires damage to be considered in the finite element simulation. For this purpose, an advanced, anisotropic elastic–plastic model, formulated within the large strain framework and taking strain-path changes into account, has been coupled with an isotropic damage model. This coupling is carried out within the framework of continuum damage mechanics. In order to detect the strain localization during sheet metal forming, Rice’s localization criterion has been considered, thus predicting the limit strains at the occurrence of shear bands as well as their orientation. The coupled elastic–plastic-damage model has been implemented in Abaqus/implicit. The application of the model to the prediction of Forming Limit Diagrams (FLDs) provided results that are consistent with the literature and emphasized the impact of the hardening model on the strain-path dependency of the FLD. The fully three-dimensional formulation adopted in the numerical development allowed for some new results – e.g. the out-of-plane orientation of the normal to the localization band, as well as more realistic values for its in-plane orientation.     

Perfectly plastic stress field at a stationary crack tip

Under the hypothesis that all the perfectly plastic stress components at a orach tip are the functions of θ only, making use of yield conditions and equilibrium equations. we derive the generally analytical expressions of the perfectly plastic stress field at a crack tip. Applying these generally analytical expressions to the concrete cracks, the analytical expressions of perfectly plastic stress fields at the tips of Mode Ⅰ Mode Ⅱ, Mode Ⅲ and Mixed Mode Ⅰ-Ⅱ cracks are obtained.     

Study on the coalescence mechanism of splitting failure of crack-weakened rock subjected to compressive loads

It is of important significance to study the coalescence mechanism of splitting failure of crack-weakened rock masses under compressive loads. In this paper, a simplified mechanism of crack propagation, in which the crack grows along the direction of maximum principal compressive stress, is proposed. Thus, only mode I is taken into account in the formulation and solution. On the basis of the near crack line analysis method, the elastic–plastic stress field near the crack line is analyzed, and the law that the length of the plastic zone along the crack line is varied with an external loads have been established by the matching condition of the elastic- plastic fields on the boundary, the coalescence stress and the strength properties of rock masses have been determined. The solution is a function of the geometry of the crack array. The results show that the crack coalescence depends on the crack interface friction coefficient, the sliding crack spacing, orientation of the cracks, and the crack half-length. The conclusions are of important significance for rock mass engineering.     

Forming of aluminum alloys at elevated temperatures – Part 1: Material characterization

A temperature-dependent anisotropic material model for use in a coupled thermo-mechanical finite element analysis of the forming of aluminum sheets was developed. The anisotropic properties of the aluminum alloy sheet AA3003-H111 were characterized for a range of temperatures 25–260 °C (77–500 °F) and for different strain rates. Material hardening parameters (flow rule) and plastic anisotropy parameters (R₀, R₄₅ and R₉₀) were calculated using standard ASTM uniaxial tensile tests. From this experimental data, the anisotropy coefficients for the Barlat YLD96 yield function [Barlat, F., Maeda, Y., Chung, K., Yanagawa, M., Brem, J.C., Hayashida, Y., Lege, D.J., Matsui, K., Murtha, S.J., Hattori, S., Becker, R.C., Makosey, S., 1997a. Yield function development for aluminum alloy sheets. J. Mech. Phys. Solids 45 (11/12), 1727–1763] in the plane stress condition were calculated for several elevated temperatures. Curve fitting was used to calculate the anisotropy coefficients of Barlat’s YLD96 model and the hardening parameters as a function of temperature. An analytical study of the accuracy and usability of this curve fitting technique is presented through the calculation of plastic anisotropy R-parameters and yield function plots at different temperatures.     

Anisotropic plasticity for sheet metals using the concept of combined isotropic-kinematic hardening

Hill's 1948 anisotropic theory of plasticity (Hill, R., 1948. A theory of yielding and plastic flow of anisotropic metals. Proc. Roy. Soc. London A193, 281–297) is extended to include the concept of combined isotropic-kinematic hardening, and the objective of this paper is to validate the model so that it may be useful for analyses of sheet metal forming. Isotropic hardening and kinematic hardening may be experimentally observed in sheet metals, if yielding is defined by the proportional limit or by a small proof strain. In this paper, a single exponential term is used to describe isotropic hardening and Prager's linear kinematic hardening rule is applied for simplicity. It is shown that this model can satisfactorily describe both the yield stress and the plastic strain ratio, the R-ratio, observed in tension test of specimens cut at various angles measured from the rolling direction of the sheet. Kinematic hardening leads to a gradual change in the direction of the plastic strain increment, as the axial strain increases in the tension test; while in the traditional approach for sheet metal, this direction does not change due to the use of isotropic hardening.     

Modeling of ductile fracture: Significance of void coalescence

In this paper void coalescence is regarded as the result of localization of plastic flow between enlarged voids. We obtain the failure criterion for a representative material volume (RMV) in terms of the macroscopic equivalent strain (E_c) as a function of the stress triaxiality parameter (T) and the Lode angle (θ) by conducting systematic finite element analyses of the void-containing RMV subjected to different macroscopic stress states. A series of parameter studies are conducted to examine the effects of the initial shape and volume fraction of the primary void and nucleation, growth, and coalescence of secondary voids on the predicted failure surface E_c(T, θ). As an application, a numerical approach is proposed to predict ductile crack growth in thin panels of a 2024-T3 aluminum alloy, where a porous plasticity model is used to describe the void growth process and the expression for E_c is calibrated using experimental data. The calibrated computational model is applied to predict crack extension in fracture specimens having various initial crack configurations and the numerical predictions agree very well with experimental measurements.     

裂纹体分析的权函数理论与应用: 回顾和展望

断裂力学是工程材料和结构的疲劳与断裂分析、损伤容限设计和结构完整性评定的理论基础. 应力强度因子作为线弹性裂纹尖端奇异场的单一表征参量和裂纹扩展驱动力, 在裂纹体的断裂力学分析中发挥着关键作用. 权函数法为复杂受载裂纹体的应力强度因子求解计算提供了强有力的解析工具, 不但具有远高于各类数值解法的计算效率, 而且精度可靠, 使用方便. 本文结合笔者团队在权函数法方面的长期研究工作, 对该方法自20世纪70年代初提出至今半个世纪以来, 国际断裂界在二维和三维权函数理论与应用方面的主要研究进展作了回顾和评述, 并对其未来发展提出了展望. 主要内容涵盖: 当前国际断裂界广泛应用的3种二维裂纹解析权函数法简介和以格林函数为基准的验证评价; 三维裂纹问题的片条合成权函数法和点载荷权函数法; 权函数法在复杂受载裂纹体的应力强度因子和裂纹张开位移等关键力学参量计算、内聚力/桥连等裂纹模型分析、共线多裂纹权函数理论及其在剩余强度预测等方面的应用, 以及复杂裂纹几何的工程化权函数分析和权函数法的反向应用问题.      

A centrally cracked thin circular disk, Part I: 3D Elastic–plastic finite element analysis

A full field solution, based on small deformation, three-dimensional elastic–plastic finite element analysis of the centrally cracked thin disk under mode I loading has been performed. The solution for the stresses under small-scale yielding and lo!cally fully plastic state has been compared with the HRR plane stress solution. At the outside of the 3D zone, within a distance of rσ_o/J=18, HRR dominance is maintained in the presence of a significant amount of compressive stress along the crack flanks. Ahead of this region, the HRR field overestimate the stresses. These results demonstrate a completely reversed state of stress in the near crack front compared to that in the plane strain case. The combined effect of geometry and finite thickness of the specimen on elastic–plastic crack tip stress field has been explored. To the best of our knowledge, such an attempt in the published literature has not been made yet. For the qualitative assessment of the results some of the field parameters have been compared to the available experimental results of K, gives a fair estimate of the crack opening stress near the crack front at a distance of order 10⁻² in. On the basis of this analysis, the Linear Elastic Fracture Mechanics approach has been adopted in analyzing the fatigue crack extension experiments performed in the disk (Part II).