Enginedng Fmcwe Mechanics Vol. 44, No. 6, pp.

895-912, 1993

Printed in Great Britain.

0013-7944/93 s6.00 + 0.00 0 1993 Pergamon Fkss Ltd.

STRESS STRUCTURE AND DEFORMATION BEHAVIOR OF MODE I THREE-DIMENSIONAL CRACK IN ELASTIC-PLASTIC STATE
X. M. CHEN and H. G. HAHN
L.ehrstuhl fi% Teehnische Mechanik, Universitat

Kaiserslautern, Postfach 3049, Geb. 44, 6750 Kaiserslautern, Germany

Ahatraet-The effects of load and geometry on the stress structure of a Mode I three-dimensional crack are investigated by means of finite element method. The functions of plastic deformation and stress triaxiality constraint, during the failure process, are then analyzed. It is found that three regions, namely the plane strain similar zone ZI, the plane stress similar zone ZIII and the transition layer between them ZII, exist in front of the crack tip; three-dimensional deformation behavior is different from that in two-dimensional states even in the ZI and ZIII zones. It is also revealed that the failure form and position of a Mode I three-dimensional crack will be determined by both plastic strain and stress triaxiaiity.

INTRODUCTION
known that the stress and strain fields of a Mode I crack are three-dimensional in nature, especially when plastic deformation is notable. However, they are different from those in general three-dimensional cases because of the particularities of specimen geometry and applied load. Some investigations on this subject show that Mode I cracked bodies can be treated as plane strain or plane stress problems using Hutchinson-Rice+Rosengren (HRR) solutions [l, 21 so long as the sizes of specimens are in agreement with certain requirements [3,4]. Generally speaking, the stress and strain fields of a Mode I crack are constituted of three parts, the one similar to the plane strain solution, the one similar to the plane stress solution and the one with thr~-dimensional behavior. The work done by Narasi~a~ and Rosakis [S] indicates that the plane strain field prevails in the interior of a lo-mm-thick three-point bend specimen very near the crack tip, and plane stress conditions are approached for distances from the crack tip exceeding about half of the specimen thickness. A further study by Narasimhan et al. 161, which considers a damage accumulation model accounting for void nucleation, growth and coalescence, gives support to the conclusion mentioned above. In [7], it is proved that for a Mode I thin plate, the plane strain condition, a,/(~, + o,,~) = 0.5, is restricted to r/t G 0.01 ahead of the crack tip; a nearly plane stress condition exists everywhere except in the region near the crack tip. A similar result is obtained by Horn and McMeeking [8] using large deformation three-dimensional finite element analysis for a blunting Mode I crack in a thin elastic-plastic sheet. A three-dimensional fiuite element analysis done by Kikuchi and Yano [9] is aimed at both compact tension {CT) and center cracked tension (ET) specimens. It points out that for CT specimens, the stress and ~spla~ent fields agree very well with HRR solutions while the thicknesses are larger than those recommended by the standard of fracture toughness testing; the HRR field exists only in the region near the mid-section of the specimens when the thicknesses are little smaller than the recommended value. There is no HRR field in the CCT specimen in their investigation. However, a study by Malik and Fu [lo] of a CCT specimen by means of MOL (method of line) shows that an approximate plane strain condition occurs immediately ahead of the crack tip on the mid-plane. It has been recognized that the variation of stress structure and the loss of HRR singularity of a Mode I crack are due to different stress constraints, and they may be described by a stress triaxiality parameter. A plane strain state exists where stress triaxiality is large. On the contrary, a plane stress state corresponds to low triaxiality. Stress triaxialities for three-dimensional fields are between the two limits. ODowd and Shih [l 11suggest characterizing a family of crack-tip fields by a triaxiality parameter, called the Q-family. A Q-value is used to order the ~nst~int of crack geometry. Then, a two-p~ameter fracture criterion is in~odu~d~ It is shown by Sun et al. f12] that the critical value of J-integral to predict crack initiation is concerned with stress triaxiality. IT IS well

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X. M. CHEN and H. G. HAHN

There are two purposes in the present work. One is to describe load and geometry effects on a three-dimensional stress structure; the other is to analyze the functions of plastic deformation and stress triaxiality constraint during the failure process. The three-dimensional stress and strain fields of CT specimens with different thicknesses are obtained using finite element method and the stress structure is presented graphically. It is verified that three regions, with plane strain similar behavior, plane stress similar behavior and a transition layer between them, exist in front of the crack tip. Two essential factors, plastic strain and stress triaxiality, are investigated based on the three-dimensional stress and strain fields. It is found that three-dimensional deformation has its own characteristics, differing from corresponding twodimensional ones even in the plane strain and plane stress similar regions. Failure prediction here depends on a void growth ratio criterion, which takes account of plastic deformation and stress triaxiality simultaneously. It is revealed that the failure form and position will be determined by both of these two important factors. STRESS STRUCTURE IN FRONT OF THE CRACK TIP

It has been known by inferences from numerous studies that plane stress (for relatively thin specimens) or plane strain (for relatively thick specimens) prevails simply in the area far away from the crack tip. However, the near tip stress field is complicated. The solution of a Mode I three-dimensional crack (Fig. 1) in an elastic-plastic state is summed up as a boundary value problem of a differential equation of fourth order. There is obviously no direct way to solve it. A previous investigation of the authors [13] was made combining analytical method with finite element simulation and the stress structure of a Mode I three-dimensional crack was obtained qualitatively, It is pointed out in this work that three regions can be divided in the thickness direction, namely, a plane strain similar zone ZI, a transition layer ZII and a plane stress similar zone ZIII. Such a stress structure is described graphically in Fig. 2, which implies that the fringe lines connecting the three regions are curves instead of straights. The shapes and sizes of the regions are concerned with applied load, specimen geometry, material characteristics and other service conditions as well. The three regions, ZI, ZII and ZIII, usually exist simultaneously. ZI might be, in some cases, very small compared with the other two. Further analysis will be done in the following. NUMERICAL PROCEDURE

CT specimens with three different thicknesses, B = 4 mm, B = 8 mm and B = 24 mm are modeled for numerical simulation. The three-dimensional stress and strain fields are calculated by means of finite element method using the ADINA [14] program. The material chosen is 2024-T351 aluminum. It behaves with a power-law hardening characteristic with n = 11, a = 0.8. The relationship between stress and strain is described by a multi-linear approximation during the computational procedure.

Fig. 1. Mode I threedimensional crack and the coordinates.

Fig. 2. Region division of Mode I three-dimensional crack (thin specimen).

Stress structure of Mode I 3-D crack

897

Fig. 3. Finite element mesh of CT specimen.

Only one quarter of a specimen is taken into consideration due to symmetry. There are four element layers through the half-thickness for the specimen with B = 4 mm; six layers for that with B = 8 mm and eight layers for that with B = 24 mm. Element layers become thinner as the free surface is approached.The meshes are shown in Figs 3 and 4. Twenty-noded isoparametric elements with 2 x 2 x 2 Gauss integration for the stiffness are adopted. Degeneration elements are employed for those directly in front of the crack tip. The Broyden-Fletcher-GoldfarbShanno (BFGS) method is used to solve the equilibrium equations during the performance, which brings credible precision and saves computer running time. Stress and strain distributions under two-dimensional plane stress and plane strain conditions are also analyxed in order to compare them with the corresponding three-dimensional results.

Fig. 4. Mesh in front of crack tip.

898

X.

M. CHEN and H. G. HAHN

STRESS STRUCTURE CHARACTERISTICS

It has been mentioned above that three regions can be defined in front of the crack tip, which are named the plane strain similar zone ZI; the transition layer ZII; and the plane stress similar zone ZIII. Detailed results obtained from finite element simulation are shown in Figs 5-7, which describe the effect of applied load and specimen geometry on stress structure. The stresses and strains obtained by FEM are output by Gauss integration points. The points with plane strain similar behavior satisfy 0.45 < a,/(o,* f cyv) < 0.5, and those with plane stress similar behavior satisfy: I%r/(cxx + q,,)l < 0.05, cxr, CYZ + 1. c,,, 8, < 1;

Further analyses show that the plane strain similar region ZI exists directly in front of the crack tip. It forms in the vicinity of 8 = x/2, mid-section z/@/2) = 0, and expands as applied load and specimen thickness increase. In a plane where z/@/2) = const, the shape of ZI appears to be a fan. It always has its maximum area in the plane z/@/2) = 0. For a given thickness B = const, region ZI grows with loading. The maximum radial size of ZI, for the CT specimen with B = 8 mm, is 0.1 when P/P, = 0.6 and 0.25 when P/P, = 1.0 (P, is the maximum P during loading). Similar conclusions are obtained by investigating other specimens. Under a given load P/Pr = const, the thicker the specimen is, the larger its plane strain similar region will be. As P/P, = 1.O, the maximum radial size is 0.1 for the specimen with B = 4 mm, 0.25 for B = 8 mm and 0.4 for B = 24mm.

. with pstress behavior

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Stress structure of Mode I 3-D crack

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Z/W2)4.02 P/Pr=O.8 behavior

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Fig. 5(b) Fig. S(a) and (b). Stress structure of B = 4 mm CT specimen.

X. M. CHEN

and H. G. HAHN

behavior

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behavior

100
z/W2)=0.6 ?,o PiP,=O.6

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902

X. M. CHEN and H. G. HAHN

behavior

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X/t Jo/coo)

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behavior

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904

X. M. CHEN and H. G. HAHN

The plane stress similar region ZIII prevails in a much larger area than does region ZI. It reduces as applied load and specimen thickness increase and vanishes, first of all, near 9 = n mid-section. However, the stress structure is plane stress similar while the free surface z/(B/2) = 1.O is approached no matter how load and thickness change. It can be predicted that there is a certain thickness, B,, related to material character, within which only one plane stress similar state exists. It is suggested here that B, should be the thickness of the shear lip.

PLASTIC ZONE AND PLASTIC DEFORMATION The plastic zone and the plastic deformation of a three-dimensional CT specimen, even in its ZI and ZIII regions, are not the same as those under corresponding two-dimensional conditions. Details are shown in Figs 8 and 9, which show the plastic zones of CT specimens with different thicknesses. For a given thickness, the plastic zone expands with the increase of applied load. There are only a few distinctions, under low load, among the zones in planes where z/(8/2) = const. This is because the stress structure, from mid-section to free surface, has not yet changed much. The distinctions become notable as the formation of regions ZI, ZII and ZIII at a higher load level. Specimen thickness is an essential factor, which affects the shape and size of the plastic zone. Under a given load, the plastic zone of a thin specimen is larger than that of a thick one. On the other hand, the plastic zone of a thin specimen does not change so much, from mid-section to free surface, as that of a thick one does because of the relative uniformity of its stress structure. Comparisons between three- and two-dimensional results are shown in Figs 10 and 11. It can be seen here that the plastic zone of the plane strain condition is smaller than that of the

I-

100

0.025 Z/(8/2)=0.6 0.99 P/Pr=0.6 ---------

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0.025 Z/(9/2)=0.6 ._--0.99 ----P/P,=l.O

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-50

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1oc

Fig. 8. Plastic zone of CT specimen with B = 4 mm.

Stress t&ructurcof Mode i 3-D crack

905

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0.025 Z/(8/2)=0.6 0.99 P/Pr=O .6

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-100

-50

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-50

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101

Fig. 9. Plastic zone of Cl specimen with B = 24 mm.

three-dimensional mid-section. This behavior is more notable for larger applied loads and thinner specimens. The plastic zone of the plane stress condition is usually larger than that of three-dimensional free surface, especially for specimens with greater thicknesses. Figures 12 and 13 show the distributions of effective plastic strain along 9 = const, which help to analyze the deformation characteristics of CT specimens. Plastic deformation, in the plane stress condition, starts and has its maximum at 9 = 0, which leads to the formation and growth of a plastic zone nearby. In the plane strain condition, plastic deformation is always significant in the vicinity of 8 = a/2, so that its plastic zone grows here, The plastic mm ofa ~~ension~ CT specimen forms near 9 = z f2, as does that of the plane strain state. It grows more cluickly in the area of 0 6 9 < nf2 than in s/2 6 9 < 71,similar to the plane stress state, especially in planes near the free surface.

904 100 2 2 Y t

X. hf. CHEN and H. G. HAHN 3-D mid-section plane strain P/Pr=O.6 -

loo 2 3 :

3-D mid-section plane strain P&+=0.6 ---___

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X/l JO/SO)

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plane strain P/Pr=l.O

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-100

-50

0 XA Jo/oo)

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lO(

-100

-50

50

100

Fig. 10. Comparison with two-dimensional results (B = 4 mm).

Fig. 11. Comparison with _. two-dimensional results (B = 24 mm).

Stress structureof Mode I 3-D crack

mid-section ~ _ __ plane strain ------1.0

0.02 .

0.00

a/4

r/2

3~12

Fig. 12. Distribution of effective plastic strain for B = 4 mm.

It should be noticed, in the three-dimensional condition, that the magnitude of effective plastic strain ep at the free surface is not always greater than that at mid-section. An example is given for the CT specimen with B = 24 mm. The value of IZ,, at the free surface is greater than the L,, at mid-section only if 9 < 9, (8, < n/2). This means that in the vicinity where plastic deformation reaches its peak value, c+,is more notable at mid-section because of the higher level of stresses. However, the plastic zone grows more slowly at mid-section for a stronger constraint. Such a phenomenon can be seen more obviously for thicker specimens, which are generally under three-dimensional conditions. It is not very typical for thinner specimens. DISTRIBUTION OF STRESS TRIAXIALITY PARAMETER

The failure feature of a cracked body is substantially related to its stress constraint status, which can be described by the stress triaxiality parameter R,.

where a,,, is the average stress and a, is the equivalent stress. It has been known that plane strain deformation is accompanied by higher stress triaxiality than is plane stress deformation. Moreover, the R, of the three-dimensional stress field varies within the range provided by two-dimensional states. Figures 14 and 15 show the curves of R,, versus 9. In a plane where z = const, the stress triaxiality constraint is larger as the ligament (8 = 0) is adjoined for both three- and two-dimensional conditions. In the thickness direction, R, decreases from mid-section to the free surface.

908 0.04

X. M. CHEN and H. G. HAHN

mid-section plans strain .-----. 0.03 1*0 i-- P/Pr=O.8

0.02

0.01

0.00

n/4

n/2 3 +---

3a/2

0.04
--fr.e.ywrface

o,03 r

1.0 p/q=o.a
0.6

Fig. 13. Distribution of effective plastic strah for /3 = 24 mm.

mid-section plane strain _-----. 1.0 r- P&=0.8

(3

a
4x
free surface plane strsss -------

3.0 a? 2.0 (b)

1.0

0.0

x/4

n/2

3x/2

Fig. 14. Distribution of stress triaxidty parameter for B = 4mm.

0.0

n/4

lr/2 3

3~12

II

T.

3.0

free surface plane stress -------

0.0

lt.f4

r/2 a

3n/2

Fig. 15. ~st~b~tion of stress triaxidity parameter for B = 24mm.

The stress triaxiality parameter is not very sensitive to applied load, especially when plastic deformation is notable. This feature can be seen in Fig. 14b, from the three-dimensional curves in Fig. 14a, as well as from the three-dimensional curves near 9 = n/2 in Fig. 15a. The three-dimensional R,-$ curves at mid-section coincide well with those in the plane strain state only if the specimen is thick enough (here with B = 24 mm), However, the agreement among the curves at the free surface and in the plane stress state is not restricted by a similar rule. FAILURE PRED~~~N

The void growth ratio parameter Vgis employed in the present work to predict the failure of Mode I t~imensional cracked bodies, The ~r~s~nding criterion is written as:

vg= v,,.
VWis the critical void growth ratio, which has been tested as being a material constant independent of stress triaxiality [1Sj, and V, is expressed as:

V, = tpexp(3&/2).

(1)

Both plastic deformation and stress triaxiality effects are taken into consideration in this expression. It seams, from eq. (1), that R,, plays a more important role than c,, does because V, is the ex~~cn~~ function of it. However, this is not absolutely true because of the in~siti~ty of stress triaxiality to applied load. An inference can be drawn, from the features of % and c,,, that for a given thickness B, the increment of void growth ratio is caused mainly by plastic defo~ation but the position where maximum IJd takes place will be determined by both of these factors.

910

X. M. CHEN and H. G. HAHN

plane strain ----_.. 0.3 9 0.2

free surface plane stress ----..r

n/4

lc/2

3~12

Fig. 16. Distribution of void growth ratio for B = 4 mm.

mid-sectian 0.3 9 0.2 piane strain ._---_. 1.0

Fig. 17. Distribution of void growth ratio for B = 24 mm.

Stress structure of Mode I 3-D crack

911

In the thickness direction, the R, of the actual three-dimensional state is a monotone decreasing function in the range 0 G z/@/2) < 1. Furthermore, V,, itself, also decreases monotoneously from mid-section to free surface. In a plane where z = const, as well as in two-dimensional conditions, the stress triaxiality parameter shown in Figs 14 and 15 increases as the ligament is approached; and the R,,--?Jcurves are relatively stable in the range 0 $9 < n/4. The effective plastic strain tP in the plane stress state has its maximum near 9 = 0 as does &. There is no doubt that the highest V, will take place here. The ~~-8 curves in th~dimens~on~ and plane strain conditions have their peak values near 9 = nJ2. The highest Vg, in such eases, take place in the range of 7t/4 d 9 6 n/2. Details are shown in Figs 16 and 17. By comparing the three-dimensional V8-9 curves with the two-dimensional ones, the following conclusions can be obtained. (1) For a given CT specimen with B = const, the highest value of void growth ratio will appear at a mid-section of the three-dimensional state. (2) Under a given nominal applied load, the V, of a thinner specimen is greater than the V, of a thicker one. Furthermore, failure will start in the range of n/4 < 9 f x/2, the mid-section of a three-dimensional CT specimen; the thinner the specimen is, the more serious the failure will be. CONCLUSIONS The stress and strain fields of a Mode I cracked body are actually thr~-dimensional but differ from general thr~-dimensional ones because of the particular load and geometry conditions. Three regions, namely the plane strain similar zone 21, the transition layer ZII, and the plane stress similar zone ZIII, can be defined according to the stress characteristrcs, A plane strain similar zone ZI exists directly in front of the crack tip. It starts in the vicinity of 9 = n/2, mid-section, and expands with increments of applied load and specimen thickness, The plane stress similar zone ZIII prevails in a much larger area than does ZI. It reduces with increments of load and thickness. However, there is a layer with thickness B,near the free surface for CT specimens. The stress field within it is always plane stress similar, no matter how the load and thickness change. This layer is suggested as being the shear lip of the specimen. The plastic zone of a CT specimen varies in the thickness direction and the variation is si~i~cant for thicker specimens. It is larger, at mid-s~tion~ than that in the plane strain state, but smaller, at the free surface, than that in the plane stress state. In a plane where z = const, the shape of the plastic zone looks like that under the plane strain condition because of the similarity of their fp-8 curves. The stress triaxiality constraint decreases, in the thickness direction, from mid-section to free surface. It has higher magnitude near the specimen ligament and is relatively stable in the range 0 6 9 G n/4. The stress triaxiality parameter R,is not very sensitive to applied load but is sensitive to specimen thickness. The void growth ratio criterion may be used to predict the failure of Mode I three-dimensional cracked bodies. For a CT specimen with thickness B, the increment of void growth ratio Vg is caused mainly by plastic deformation, but the position where highest V, takes place will be determined by both plastic defo~ation and stress triaxiality constraints. Actually, the three-dimensional situation is more dangerous than corresponding two-dimensional ones, especially for thinner specimens. It is pointed out that failure will start in the range of 7~/4G 9 6 x/2, mod-s~tion, where V, reaches its highest value.
Acknowledgement-This work was supported by the Alexander von Humboldt Foundation.

REFERENCES
J. W. Rutchinson,J. &C/I. Phys. Solids 16, 13-31 (1968). 3. R. Rim and G. F. Rosengren, J. Mech. P&L So& 16, 1-12 (1968). C. F. Shih and M. D. German. Int. J. Fracture Me& 17. 2743 (1981). Sun Jlan, Deng Zengjie and Tu Mmgjing, Erzgttg FracttueMech. $7, 6%680 (B90). R. N~~rnh~ and A. J. Rosakis, J, appt. Mech. 57, 607-617 (1990) R. Nation, A. 1. Rosakis and B. Moran, SM 89-5, ~tifo~a Institute of Technology, CA (1989). T. Nakamura and D. M. Parks, J. ;cdech. Phys. So/& 38,787-8 13 (1990). C. L. Horn and R. M. McMeeking, in& J. Fracture 45, 103-122 (1990).
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X. M. CHEN and H. G. HAHN

[9] M. Kikuchi and K. Yano, In Collected Works of Japanese Society of Mechanical Engineering, Volume 55, No. 516 (1989-g), Paper No. 88-1428 (1989). [lo] S. N. Malik and L. S. Fu, ht. J. Fracture 18, 45563 (1982). [I I] N. P. GDowd and C. F. Shih, Family of crack-tip fields characterized by a triaxiality parameter: part I--structure of fields. J. Mech. Phys. Soliak 39, 989-1015 (1991). [12] Sun Jun, Deng Zengjie, Li Zhonghua and Tu Mingjing, Engng Fracture Mech. 36, 321-326 (1990). [13] X. M. Chen, N. S. Yang and Z. X. Guan, Acta Mech. Solida Sinica 3, 263-287 (1990). [14] ADINA Engineering, Inc., Automatic dynamic incremental nonlinear analysis, Report AE 83-5 (1983). [15] C. Q. Zheng, L. Zhou and J. M. Lui, The criterion of critical void growth rate and its application. Proceedings of ZCMS, Beijing, pp. 213-218 (1987).
(Received 8 July 1992)