3/28/2017

FRANC3D Training Workshop:

Part VI
April - 2017

Drs. Bruce Carter, Paul Wash

Wawrzynek, Tony Ingraffea, and
Omar Ibrahim

Fracture Analysis
Consultants, Inc.

Workshop Agenda

Part I: Introduction to Fracture Mechanics Analysis

Part II: Introduction to FRANC3D
Part III: Finite Element (FE) Model Import
Part IV: Crack Insertion
Part V: Static Crack Analysis & SIF Computation
Part VI: Crack Growth
Part VII: Multiple/Variable DOF Approach to Fatigue Life
Part VIII: SIF History & Fatigue Life
Part IX: Session Log, Command Line and Python Interface
Part X: Miscellaneous

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Part I

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Crack Growth Prediction

Computing crack growth is a three-step process:
Kink angle for each node (direction)
Based on the crack-front stresses in polar coordinates
Several options for computing kink angle
Relative amount of local crack extension for each FE node
Computed using either a quasi-static or a fatigue growth model
such as Paris model
Smooth the crack front
Polynomial curves used to smooth and extrapolate crack front

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Part V

Crack Growth Prediction

predicted front (blue)

local kink angle

local extension
smoothed front (red)

original front

SIFs used to predict the direction and relative

extent of crack growth along the front.

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Part V

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Crack Propagation Kink Angle

s max theory:

Crack kinks in direction normal to the maximum

circumferential (hoop) stress; ignoring higher order terms:

y
1 3
s cos K I cos2 K II sin
2r 2 2 2

s max
2
or c 2 tan 1 1 1 8( K II K I )
s max 4( K II K I )

c

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Part V

Crack Propagation Relative Extension

Simple quasi-static growth:
n
SIF at i
Extension at mid-side node-i = user-input-extension (or cycles) x
median SIF

predicted
new crack
front

point i ai computed
max KI
point with the extension
median K
median KI value am specified
current extension
min KI crack
front

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Part V

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Crack Propagation Smoothing

polynomial fit
Curve is
extrapolated no smoothing
outside the
model surface.

Set crack front

Specify median fitting options
crack extension

Specifying extension
Use simplest
is more stable than
specifying cycles.
fit that works.

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Part V

Geometry of Crack Growth

Cracks extended by reinserting extended geometry into original uncracked model:
1. simplifies the code
2. reduces amount of information stored between steps, and
3. allows the local sub-volume to be changed between crack growth steps

initial crack

non-planar crack growth

crack extension

meshed extended crack

Partial crack front growth
is under development. 8
Part VI

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Crack Turning or Kinking

Part V 9

Maximum Hoop Stress Crack Turning Demonstration

SEN(B) polymethylmethacrylate (PMMA) beams

Initial crack location and length varied among specimens.

Note: all dimensions

in inches
2.0 0.5 dia. thickness: 0.5
typ.
8.0
2.0

2.75
b 4.0

a
9.0 9.0
10.0 10.0
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Part V

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Comparisons between observations and predictions

- two initial crack configurations

analysis

experiment
Analysis crack-
increment lengths:
a = 0.3 inch
a = 0.2 inch
a = 0.05 inch

pre-cut slot pre-cut slot

2.5 inches
1.0 inch 6.0 inches 6.0 inches
(from bottom
(from centerline) (from centerline)
of plate)

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Part V

Kink Angle: Max Stress Criterion (isotropy)

The max stress criterion says that the crack will kink in the
direction of a maximum value of a stress component.
Some materials show a transition from Mode I
to Mode II crack growth for stable tearing.
y
s r
LEFM Max stress
Amstutz (1995) 2024-T3, L-T
Amstutz (1995) 2024-T3, T-L
Hallback & Nilsson (1994) 7075-T6
Maccagno & Knott (1989), PMMA
Maccagno & Knott (1991), HY130 @ -196C

s
80
70

60 Mode I x
50
40

c 30 Transition Mode I only:

20 Transition 2024-T3
10 7075-T6
kink for maxs
0
-10
-20
Mode II Mode I or Mode II:
-30
0 10 20 30 40 50 60 70 80 90
kink for maxmaxs , max s r
Mode mixity , tan 1K II K I
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Part V

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Many Materials Exhibit More Complicated Behavior

Material orientation toughness anisotropy

Load level higher order stress terms (T-stress)
FRANC3D computes T-stress, but does not use it.
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Part V

Kink Angle: Max Stress Criterion (orthotropy)

The orthotropic max stress criterion says that the crack will kink in the direction
where the ratio of the hoop stress to the effective toughness is maximum.
n12
K12a22 K13a32 1 n2a2 K23a32 K21a12 1 n3a2 K31a12 K32a22
2 2
K eff
1 a12 2 3

Where Keff is a function of six principal toughnesses and crack s

orientation relative to the material kink for max
K eff a, n

predicted direction of
n y
crack propagation

s
x

Keff a, n

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Part V

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Kink Angle: Max Stress Criterion (orthotropy)

s
c such that
k p
max

k p (90 )
n=
n=2

n=1

n = .5
n = .3

k p ( )

k p (0 )

1 2l
2 l 2 l 2 l
n n n
k p k p n, a 12 22 32
k1 k2 k3

1 2 n
2 n n
a 2
ki a 1 ai2 2 k2
j a
K K
ij ik 15
Part V

Quasi-Static Crack Growth

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Part VI

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FRANC3D Quasi-Static Crack Growth Procedure

Quasi-static growth can be used if

fatigue data/model is not available.
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Part VI

FRANC3D Quasi-Static Crack Growth Model

predicted new
crack front

point i ai computed
point with the extension
median K value
am specified
current extension
crack front

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Part VI

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Plasticity Analogy for Quasi-Static Crack Growth

P s K
P
sy Kc



u a

s sc yield function K Kc

0 0
u 0
Kuhn-Tucker a 0
relations
u 0 a 0

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Part VI

2D Quasi-Static Crack Growth

K
Taylor expansion
P
K K Kc
K (a a, P P) K (a, p) a P
a P

from the Kuhn-Tucker relations
a
K (a a, P P) K (a, p) Kc
stable crack growth

K K
so a P 0 K
a P configuration: 0
a
K K

and a P
P a

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Part VI

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3D Quasi-Static Crack Growth

Ki K K
Ki (a a, P P) Ki (a, P) a i an i P
i a1 1 an P

j K K
i a P
a
j P

K 1K
a P
a P

Unfortunately, we do not yet know of an
accurate and efficient technique for
computing this matrix.
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Part VI

Example (from Brett Davis)

Part V 22

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Example (from Brett Davis)

Part V 23

Approximate 3D Quasi-Static Crack Growth

If we ignore interactions among nodes:

Ki Kc s i ai f (ai ) (s i s i ) (ai ai ) f (ai ai )

s i ai f (ai ) i
(ai ai )
(s i s i ) f (ai ai )
j
2
1 s i ai f (ai )
ai ai
(s i s i ) f (ai ai )

1 Ki 2
ai ai
(s i s i ) f (ai ai ) K 2
ai a j i
Kj
ai ~ Ki2

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Part VI

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Fatigue Crack Growth:

A Brief Summary of Options
to Grow a Crack in Fatigue

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Part VI

FRANC3D Fatigue Crack Growth Procedure

Constant Amplitude:
- Given R
- Computed R

If your model has multiple

load steps that correspond to
maximum and minimum
SIFs (loads) FRANC3D
can compute the R value.

Fatigue crack growth rate is

typically dependent on R.

Part V 26

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FRANC3D Fatigue Crack Growth Procedure

Constant Amplitude Fatigue

Select the
New Model
button to set
fatigue model
parameters.

Several different
models available:
- temperature
dependent as well
as R dependent.

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Part VI

Variable Amplitude Loads

Variable amplitude:
Spectrum Variable load spectrum
Sequence
Transient

Load Sequence
Load changes
Load

cruise with time

takeoff land

Time
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Part VI

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Demo: Crack Growth

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Part VI

FRANC3D Tutorial 1 Manual Crack Growth

Step 1: From FRANC3D menu,
select Cracks - Grow Crack

Choose Quasi-Static
growth for simplicity
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Part VI

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FRANC3D Tutorial 1 Manual Crack Growth

Step 2: Specify Growth Rate Step 3: Specify median extension and
fitting parameters

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Part VI

FRANC3D Tutorial 1 Manual Crack Growth

Step 4: Specify Template Mesh

Resulting remeshed model is

ready for analysis.

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Part VI

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Demo: Automated Crack Growth

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Part VI

FRANC3D Tutorial 1 Automatic Crack Growth

Step 1: From FRANC3D menu, select
Analysis - Crack Growth Analysis

Choose method
to compute SIFs

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Part VI

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FRANC3D Tutorial 1 Automatic Crack Growth

Step 2: Specify crack growth model and parameters

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Part VI

FRANC3D Tutorial 1 Automatic Crack Growth

Step 3: Specify crack front fitting and extension options

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Part VI

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FRANC3D Tutorial 1 Automatic Crack Growth

Step 4: Specify analysis code options

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Part VI

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