An improved atomistic simulation based mixed-mode cohesive zone law considering non-planar crack growth

A novel and improved atomistic simulation based cohesive zone law characterizing interfacial debonding is developed which explicitly accounts for the non-planarity of the crack propagation. Group of atoms in the simulation constituting cohesive zones which are used to obtain local stress and crack opening displacement data are determined dynamically during the non-planar crack growth as they cannot be determined apriori. The methodology is used to study the debonding of Σ5 (2 1 0)/[0 0 1] symmetric tilt grain boundary interface in a Cu bicrystal under several mixed mode loading conditions. Simulations show that such bicrystalline specimen exhibits three types of energy dissipative mechanisms – shear coupled GB migration (SCM) away from the crack-tips, change in spacial orientation of GB structural units rendering highly disordered grain boundary near the crack tips and brittle intergranular fracture. Which combination of these three deformation mechanism will be active influencing the degree of non-planarity of the crack propagation at various stages of loading depends on the loading mode-mixity. As the ratio of shear component of the loading parallel to the GB plane and normal to the tilt axis with respect to the normal loading increases (thereby increasing the mode-mixity), overall strain-to-failure also increases and SCM tends to become the dominant deformation mechanism. Through this framework, analytical functional forms and parameters describing cohesive laws for both normal and shear traction as a function of the mode-mixity of the loading and crack opening displacement are predicted.     

A cohesive zone model for fatigue crack growth allowing for crack retardation

A damage-based cohesive model is developed for simulating crack growth due to fatigue loading. The cohesive model follows a linear damage-dependent traction–separation relation coupled with a damage evolution equation. The rate of damage evolution is characterized by three material parameters corresponding to common features of fatigue behavior captured by the model, namely, damage accumulation, crack retardation and stress threshold. Good agreement is obtained between finite element solutions using the model and fatigue test results for an aluminum alloy under different load ratios and for the overload effect on ductile 316 L steel.     

Asymptotic crack-tip fields for dynamic crack growth in compressive power-law hardening materials

The effect of material compressibility on the stress and strain fields for a mode-I crack propagating steadily in a power-law hardening material is investigated under plane strain conditions. The plastic deformation of materials is characterized by the J₂ flow theory within the framework of isotropic hardening and infinitesimal displacement gradient. The asymptotic solutions developed by the present authors [Zhu, X.K., Hwang K.C., 2002. Dynamic crack-tip field for tensile cracks propagating in power-law hardening materials. International Journal of Fracture 115, 323–342] for incompressible hardening materials are extended in this work to the compressible hardening materials. The results show that all stresses, strains, and particle velocities in the asymptotic fields are fully continuous and bounded without elastic unloading near the dynamic crack tip. The stress field contains two free parameters σ_eq0 and s₃₃₀ that cannot be determined in the asymptotic analysis, and can be determined from the full-field solutions. For the given values of σ_eq0 and s₃₃₀, all field quantities around the crack tip are determined through numerical integration, and then the effects of the hardening exponent n, the Poisson ratio ν, and the crack growth speed M on the asymptotic fields are studied. The approximate behaviors of the proposed solutions are discussed in the limit of ν → 0.5 or n → ∞.     

A unified definition for stress intensity factors of interface corners and cracks

Based upon linear fracture mechanics, it is well known that the singular order of stresses near the crack tip in homogeneous materials is a constant value −1/2, which is nothing to do with the material properties. For the interface cracks between two dissimilar materials, the near tip stresses are oscillatory due to the order of singularity being −1/2 ± iε and −1/2. The oscillation index ε is a constant related to the elastic properties of both materials. While for the general interface corners, their singular orders depend on the corner angle as well as the elastic properties of the materials. Owing to the difference of the singular orders of homogeneous cracks, interface cracks and interface corners, their associated stress intensity factors are usually defined separately and even not compatibly. Since homogenous cracks and interface cracks are just special cases of interface corners, in order to build a direct connection among them a unified definition for their stress intensity factors is proposed in this paper. Based upon the analytical solutions obtained previously for the multibonded anisotropic wedges, the near tip solutions for the general interface corners have been divided into five different categories depending on whether the singular order is distinct or repeated, real or complex. To provide a stable and efficient computing approach for the general mixed-mode stress intensity factors, the path-independent H-integral based on reciprocal theorem of Betti and Rayleigh is established in this paper. The complementary solutions needed for calculation of H-integral are also provided in this paper. To illustrate our results, several different kinds of examples are shown such as cracks in homogenous isotropic or anisotropic materials, central or edge notches in isotropic materials, interface cracks and interface corners between two dissimilar materials.     

Asymptotic fields around an interfacial crack with a cohesive zone ahead of the crack tip

This paper considers an interfacial crack with a cohesive zone ahead of the crack tip in a linearly elastic isotropic bi-material and derives the mixed-mode asymptotic stress and displacement fields around the crack and cohesive zone under plane deformation conditions (plane stress or plane strain). The field solution is obtained using elliptic coordinates and complex functions and can be represented in terms of a complete set of complex eigenfunction terms. The imaginary portion of the eigenvalues is characterized by a bi-material mismatch parameter ε = arctanh(β)/π, where β is a Dundurs parameter, and the resulting fields do not contain stress singularity. The behaviors of “Mode I” type and “Mode II” type fields based on dominant eigenfunction terms are discussed in detail. For completeness, the counterpart for the Mode III solution is included in an appendix.     

An experimental and numerical study of the localization behavior of tantalum and stainless steel

In general, the shear localization process involves initiation and growth. Initiation is expected to be a stochastic process in material space where anisotropy in the elastic–plastic behavior of single crystals and inter-crystalline interactions serve to form natural perturbations to the material’s local stability. A hat-shaped sample geometry was used to study shear localization growth. It is an axi-symmetric sample with an upper “hat” portion and a lower “brim” portion with the shear zone located between the hat and brim. The shear zone length is 870–890 μm with deformation imposed through a split-Hopkinson pressure bar system at maximum top-to-bottom velocity in the range of 8–25 m/s. We present experimental results of the deformation response of tantalum and 316L stainless steel samples. The tantalum samples did not form shear bands but the stainless steel sample formed a late stage shear band. We have also modeled these experiments using both conductive and adiabatic continuum models. An anisotropic elasto-viscoplastic constitutive model with damage evolution was used within the finite element code EPIC. A Mie-Gruneisen equation of state and the rate and temperature sensitive MTS flow stress model together with a Gurson flow surface were employed. The models performed well in predicting the experimental data. The numerical results for tantalum suggested a maximum equivalent strain rate on the order of 7 × 10⁴ s⁻¹ in the gage section for an imposed top surface displacement rate of 17.5 m/s. The models also suggested that for an initial temperature of 298 K a temperature in the neighborhood of 900 K was reached within the shear section. The numerical results for stainless steel suggest that melting temperature was reached throughout the shear band shortly after peak load. Due to sample geometry, the stress state in the shear zone was not pure shear; a significant normal stress relative to the shear zone basis line was developed.     

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.     

Phenomenological study of parabolic and spherical indentation of elastic-ideally plastic material

A phenomenological study of parabolic and spherical indentation of elastic ideally plastic materials was carried out by using precise results of finite elements calculations. The study shows that no “pseudo-Hertzian” regime occurs during spherical indentation. As soon as the yield stress of the indented material is exceeded, a deviation from the, purely elastic Hertzian contact behaviour is found. Two elastic–plastic regimes and two plastic regimes are observed for materials of very large Young modulus to Yield stress ratio, E/σ_y. The first elastic–plastic regime corresponds to a strong evolution of the indented plastic zone. The first plastic regime corresponds to the commonly called “fully plastic regime”, in which the average indentation pressure is constant and equal to about three times the yield stress of the indented material. In this regime, the contact depth to penetration depth ratio tends toward a constant value, i.e. h_c/h = 1.47. h_c/h is only constant for very low values of yield strain (σ_y/E lower than 5 × 10^?6) when aE¹/Rσ_y is higher than 10,000. The second plastic regime corresponds to a decrease in the average indentation pressure and to a steeper increase in the pile-up. For materials with very large E/σ_y ratio, the second plastic regime appears when the value of the non-dimensional contact radius a/R is lower than 0.01. In the case of spherical and parabolic indentation, results show that the first plastic regime exists only for elastic-ideally plastic materials having an E/σ_y ratio higher than approximately 2.000.     

Finite element micromechanics model of impact compression of closed-cell polymer foams

Finite element analysis, of regular Kelvin foam models with all the material in uniform-thickness faces, was used to predict the compressive impact response of low-density closed-cell polyethylene and polystyrene foams. Cell air compression was analysed, treating cells as surface-based fluid cavities. For a typical 1 mm cell size and 50 s^?1 impact strain rate, the elastic buckling of cell faces, and pop-in shape inversion of some buckled square faces, caused a non-linear stress strain response before yield. Pairs of plastic hinges formed across hexagonal faces, then yield occurred when trios of faces concertinaed. The predicted compressive yield stresses were close to experimental data, for a range of foam densities. Air compression was the hardening mechanism for engineering strains <0.6, with face-to-face contact also contributing for strains >0.7. Predictions of lateral expansion and residual strains after impact were reasonable. There were no significant changes in the predicted behavior at a compressive strain rate of 500 s^?1.     

Pressure-sensitive ductile layers – I. Modeling the growth of extensive damage

Polymeric adhesives sandwiched between two elastic substrates are commonly found in multi-layers and IC packages. The non-elastic deformation and flow stress of such adhesive joints are highly pressure-sensitive. In this work, we study the effects of pressure-sensitivity, α, and plastic dilatancy, β, on void growth and coalescence ahead of a crack in ductile adhesive joints. To this end, a single layer of discrete voids is placed ahead of the crack in a pressure-sensitive dilatant adhesive sandwiched between two elastic substrates. The adhesive joint is subjected to small-scale yielding conditions. Using an associated flow rule (α = β), we show that pressure-sensitivity not only intensifies damage levels but also increases its spatial extent several fold. The damage level as well as its spatial extent is found to be even greater when a non-associated flow rule (β < α) is deployed. A reduction in the damage process zone’s thickness further increases the voiding activity in the adhesive, thereby resulting in brittle-like failure. This work also examines the fracture toughness trends using a material failure criterion for crack growth.     

A reexamination of plasticity-induced crack closure in fatigue crack propagation

The crack closure concept is often used to consider the R-ratio and overload effects on fatigue crack growth. The presumption is that when the crack is closed, the external load produces negligible fatigue damage in the cracked component. The current investigation provides a reassessment of the frequently used concept with an emphasis on the plasticity-induced crack closure. A center cracked specimen made of 1070 steel was investigated. The specimen was subjected to plane-stress mode I loading. An elastic–plastic stress analysis was conducted for the cracked specimens using the finite element method. By applying the commonly used one-node-per-cycle debonding scheme for the crack closure simulations, it was shown that the predicted crack opening load did not stabilize when the extended crack was less than four times of the plastic zone size. The predicted opening load was strongly influenced by the plasticity model used. When the elastic–perfectly plastic (EPP) stress–strain relationship was used together with the kinematic hardening plasticity theory, the predicted crack opening load was found to be critically dependent on the element size of the finite element mesh model. For R = 0, the predicted crack opening load was greatly reduced when the finite element size became very fine. The kinematic hardening rule with the bilinear (BL) stress–strain relationship predicted crack closure with less dependence on the element size. When a recently developed cyclic plasticity model was used, the element size effect on the predicted crack opening level was insignificant. While crack closure may occur, it was demonstrated that cyclic plasticity persisted in the material near the crack tip. The cyclic plasticity was reduced but not negligible when the crack was closed. The traditional approaches may have overestimated the effect of crack closure in fatigue crack growth predictions.     

Analytical and numerical techniques to predict carbon nanotubes properties

In this paper, two different approaches for modeling the behaviour of carbon nanotubes are presented. The first method models carbon nanotubes as an inhomogeneous cylindrical network shell using the asymptotic homogenization method. Explicit formulae are derived representing Young’s and shear moduli of single-walled nanotubes in terms of pertinent material and geometric parameters. As an example, assuming certain values for these parameters, the Young’s modulus was found to be 1.71 TPa, while the shear modulus was 0.32 TPa. The second method is based on finite element models. The inter-atomic interactions due to covalent and non-covalent bonds are replaced by beam and spring elements, respectively, in the structural model. Correlations between classical molecular mechanics and structural mechanics are used to effectively model the physics governing the nanotubes. Finite element models are developed for single-, double- and multi-walled carbon nanotubes. The deformations from the finite element simulations are subsequently used to predict the elastic and shear moduli of the nanotubes. The variation of mechanical properties with tube diameter is investigated for both zig-zag and armchair configurations. Furthermore, the dependence of mechanical properties on the number of nanotubules in multi-walled structures is also examined. Based on the finite element model, the value for the elastic modulus varied from 0.9 to 1.05 TPa for single and 1.32 to 1.58 TPa for double/multi-walled nanotubes. The shear modulus was found to vary from 0.14 to 0.47 TPa for single-walled nanotubes and 0.37 to 0.62 for double/multi-walled nanotubes.     

The high strain mechanical response of the wet Kelvin model for open-cell foams

Surface Evolver software was used to create the three-dimensional geometry of a Kelvin open-cell foam, to simulate that of polyurethane flexible foams. Finite Element Analysis (FEA) with 3D elements was used to model large compressive deformation in the [0 0 1] and [1 1 1] directions, using cyclic boundary conditions when necessary, treating the polyurethane as an elastic or elastic–plastic material. The predicted foam Young’s moduli in the [0 0 1] direction are double those of foams with uniform Plateau border cross-section edges, for the same foam density and material properties. For compression in the [1 1 1] direction, the normalized Young’s modulus increases from 0.9 to 1.1 with foam relative density, and the predicted stress–strain relationship can have a plateau, even for a linearly-elastic polymer. As the foam density increases, the predicted effects of material plasticity become larger. For foam of relative density 0.028, edge-to-edge contact is predicted to occur at a 66% strain for [1 1 1] direction compression. The foam is predicted to contract laterally when the [1 1 1] direction compressive strain exceeds 25%.     

Modelling of the plastic flow of trip-aided multiphase steel based on an incremental mean-field approach

An incremental mean-field model is developed for the prediction of transformation induced plasticity (TRIP) in multiphase steel. The partitioning of strain between softer and harder constituents is computed based on an elastic-plastic Mori–Tanaka approach that accounts for the progressive transformation of austenite into martensite. The latter transformation is predicted using an energy-balance criterion that is formulated at the level of individual austenite grains. The model has been tested against experimental data. Macroscopic stress-strain curves and rate of martensite formation have been measured on sheet samples subjected to various loading modes: uniaxial tension, simple shear, and (in-plane) uniaxial compression. These experiments were performed at 20 °C and the uniaxial tensile test was repeated at ?30 °C. The mean-field model produces fair predictions of the macroscopic hardening resulting from TRIP on the condition that a sufficient proportion of the load is carried by the very hard martensite inclusions. Such prediction implies that one accounts for the stress heterogeneity across the ferrite-based matrix. At the same time, the model reproduces the elastic lattice strains and the plastic elongation which are measured within the phases by neutron diffraction and by image correlation in a scanning electron microscope, respectively. The model can be used in finite element simulations of forming processes which is illustrated in a study of necking of a cylindrical bar under uniaxial tension.     

Periodic group crack problems in an infinite plate

This paper investigates periodic group crack problems in an infinite plate. The periodic group crack is composed of infinite groups with numbering from j = −∞, …, −2, −1, 0, 1, 2, …, to j = ∞, and the groups are placed periodically. The same loading condition and the same geometry are assumed for cracks in all groups. A singular integral equation is used to solve the problems. The singular integral equation is formulated on cracks of the 0th group (or the central group) with the collection of influences from the infinite groups. The influences of many neighboring groups to the central group are evaluated exactly. Meantime, the influences of many remote groups to the central group can be summed up into one term approximately. The stress intensity factors at crack tips can be evaluated from the solution of the singular integral equation. It is found from some sample problems that the obtained results are very accurate. Finally, several numerical examples are presented and interaction among the group cracks is addressed.     

An analytical and computational study of crack initiation under transient creep conditions

An analytical method has been developed to predict creep crack initiation (CCI), based on the accumulation of a critical level of damage at a critical distance. The method accounts for the re-distribution of stress from the elastic or elastic–plastic field, experienced on initial loading, to a steady state creep stress distribution, via a transient creep region. The method has been applied to predict CCI times in a fracture specimen of type 316H stainless steel at 550 °C. The failure model has been also been implemented into a finite element (FE) framework. Reasonable and conservative predictions of CCI time can be obtained from the analytical solution relative to FE solutions. Conservative predictions of experimental CCI times are obtained when stress redistribution is taking into account. However, CCI times predicted from a steady state creep model are found to be non-conservative.     

Coplanar propagation paths of 3D cracks in infinite bodies loaded in shear

Bower and Ortiz, recently followed by Lazarus, developed a powerful method, based on a theoretical work of Rice, for numerical simulation of planar propagation paths of mode 1 cracks in infinite isotropic elastic bodies. The efficiency of this method arose from the need for the sole 1D meshing of the crack front. This paper presents an extension of Rice’s theoretical work and the associated numerical scheme to mixed-mode (2 + 3) shear loadings. Propagation is supposed to be channeled along some weak planar layer and to remain therefore coplanar, as in the case of a geological fault for instance. The capabilities of the method are illustrated by computing the propagation paths of cracks with various initial contours (circular, elliptic, rectangular, heart-shaped) in both fatigue and brittle fracture. The crack quickly reaches a stable, almost elliptic shape in all cases. An approximate but accurate analytic formula for the ratio of the axes of this stable shape is derived.     

Cracked infinite cylinder with two rigid inclusions under axisymmetric tension

This paper considers the problem of an axisymmetric infinite cylinder with a ring shaped crack at z = 0 and two ring-shaped rigid inclusions with negligible thickness at z = ±L. The cylinder is under the action of uniformly distributed axial tension applied at infinity and its lateral surface is free of traction. It is assumed that the material of the cylinder is linearly elastic and isotropic. Crack surfaces are free and the constant displacements are continuous along the rigid inclusions while the stresses have jumps. Formulation of the mixed boundary value problem under consideration is reduced to three singular integral equations in terms of the derivative of the crack surface displacement and the stress jumps on the rigid inclusions. These equations, together with the single-valuedness condition for the displacements around the crack and the equilibrium equations along the inclusions, are converted to a system of linear algebraic equations, which is solved numerically. Stress intensity factors are calculated and presented in graphical form.     

Simple constitutive modelling of nonlinear viscoelasticity under general extension

We study the behaviour of a single integral constitutive equation, capable of providing analytic expressions for the viscoelastic stress in extensional flows of a variety of deformation histories and geometries, ranging from uniaxial to equibiaxial. It is based on the use of a stress damping function, with a power-law dependence on the elongation, λ: h(λ) = 1/λⁿ. The parameter n (0 ≤ n ≤ 2) signifies the nonlinear viscoelastic character of the material and, therefore, is an inverse measure of network connectivity strength of the underlying microstructure. This renders the constitutive approach applicable to incompressible polymers of a variable degree of branching, strain hardening and stress thinning behavior. Methods of connecting n with the macromolecular architecture and the alignment strength of the flow are also explored.