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Influence of The Interaction On Stress Intensity Factor of Semielliptical Surface Cracks
Influence of The Interaction On Stress Intensity Factor of Semielliptical Surface Cracks
Introduction ing cracks for various conditions, such as relative position, rela-
tive size, aspect ratio, and loading condition. The average of the
The stress intensity factor 共SIF兲 of interacting surface cracks
SIF along the crack front is used as a parameter representing the
has been investigated by numerical analyses, such as the finite intensity of the interaction. Based on the analysis results, the re-
element method 共FEM兲 关1–4兴 and the body force method 关5,6兴, lationship between the magnitude of the interaction and the area
and it was revealed that the SIF is magnified when the cracks size of the interacting cracks is evaluated, and the validity of the
approach each other. Since the enhanced SIF causes the crack current combination rule is discussed together with the proposed
growth to accelerate, it is important to know the change in the SIF one.
due to the interaction. The influence of the interaction on the SIF
is dependent not only on the distance between cracks and on crack
geometry such as the aspect ratio and loading condition, but also Calculation Procedure
on relative size. Furthermore, the magnitude of the change in the Two types of interacting crack models were used for the analy-
SIF is different at each crack tip position along the crack front. At ses, as shown in Fig. 1. The first one consisted of two interacting
interacting surface cracks of the same plane, the increase in the semielliptical cracks in the same plane. The distance between the
SIF due to interaction is larger at the surface point of the neigh- cracks was represented by a parameter S. If the cracks approach
boring side than at the other side and middle position. Therefore, each other, S decreases and finally becomes zero. The other model
it is not easy to evaluate the influence of the interaction on the corresponded to coalesced cracks of which S is zero. These mod-
crack growth behavior. els are referred to as the separated crack model and the combined
In the in-service plants, multiple cracks are often found to be in crack model, respectively. The ratio of crack depth, a1, and half
close proximity to one another 关7兴, so the influences of the inter- crack length at the surface, c1, was set to a1 / c1 = 0.5 and 0.8. The
action on the SIF must be taken into account when evaluating the size of the other crack, a2 and c2, was set to a2 / a1 = 0.3– 1.0, while
crack growth and fracture. In the current fitness-for-service codes, the ratio was kept at a2 / c2 = a1 / c1.
such as the American Society of Mechanical Engineers 共ASME兲 As shown in Fig. 2, the cracks were located on a plate, of which
Boiler and Pressure Vessel Code Section XI 关8兴 or the Japan So- thickness t, half-length B, and half-width of the plate W were
ciety of Mechanical Engineers 共JSME兲 Fitness-for-Service Code t / a1 = 5, B / a1 = 20, and W / a1 = 16. Poisson’s ratio of the material
关9兴, multiple discrete cracks are combined and treated as a single was taken to be 0.3. The plate was subjected to a tensile and
crack if the distance between two cracks satisfies a simple crite- bending stress of magnitude 0.
rion. However, due to the complexity of the interacting phenom- The FEAM was employed for the SIF evaluation of the sepa-
enon, the combination rules were pointed out to be excessively rated crack model, while the conventional FEM was used for the
conservative and so were revised based on evaluations of the SIF combined crack model. The FEAM is an alternating technique in
关10兴. conjunction with the FEM analysis and the analytical solution for
In this study, to investigate the influence of the interaction on an elliptical crack in an infinite solid subject to arbitrary crack-
the growth behavior due to fatigue and stress corrosion cracking, face traction 关11,22兴, and allows us to evaluate precisely the SIF
the SIFs of interacting semielliptical surface cracks were evalu- of interacting surface cracks without a finite element mesh for a
ated by the FEM and finite element alternating method 共FEAM兲 cracked body 关11–21兴. Namely, the SIFs under different S and
关11–21兴. These methods enable us to evaluate the SIF of interact- a2 / a1 conditions can be evaluated using the same finite element
mesh, which is shown in Fig. 3. Fine elements were adopted
around the crack portion for an accurate analysis, although a
Contributed by the Pressure Vessel and Piping Division of ASME for publication cracked mesh was not included. The mesh consists of 171,606
in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received January 4,
2006; final manuscript received October 11, 2006; published online January 30,
eight-noded solid elements. The validity and accuracy of the
2008. Review conducted by Douglas Scarth. Paper presented at the 2005 ASME FEAM for interacting surface cracks were confirmed in a previous
Pressure Vessels and Piping Conference 共PVP2005兲, Denver, CO, July 17–21, 2005. study 关20兴. Figure 4 shows the finite element mesh used for the
Journal of Pressure Vessel Technology Copyright © 2008 by ASME FEBRUARY 2008, Vol. 130 / 011406-1
Calculation Results
Stress Intensity Factor Along the Crack Front. Figures 5 and
6 show the SIF along the crack front of crack 1 for a tensile and
bending stress, respectively. The SIFs are normalized by the fol-
lowing equation:
KI
F共x兲 = 共1兲
0冑x
where KI denotes the SIF of mode I and x corresponds to a crack
size, which is a1 in these cases. The crack tip position is repre-
sented by p, as defined in Fig. 1. The SIF changes depending on
Fig. 2 Geometry of a plate for interacting cracks the distance S, and the magnitude of the variation is different at
the crack tip position. The SIF of the inner crack tip 共p = 0 deg兲
gets larger as the distance S decreases, while only a slight change
appeared at the outer crack tip 共p = 180 deg兲 and around the deep-
est point 共p = 90 deg兲. The change in the SIF was brought about by
the interaction between two cracks, and the interaction becomes
maximum in the case of S = 0. Although the geometrical profile of
the combined crack model is different from that of the separated
crack model, the distribution of the SIF of the combined crack
seems to be a continuation of the separated cracks. It was pointed
out that the SIF of interacting cracks is almost equivalent to that
of coalesced single cracks when the cracks are close to each other
关24,25兴. This implies that the change in the SIF is dependent on
the distance S rather than on the geometrical condition that the
cracks are coalesced or separated. The intensity of the interaction
is larger in the case of a1 / c1 = 0.8 than in a1 / c1 = 0.5, although the
results obtained under the tensile and bending stress conditions
exhibit a similar tendency.
Fig. 3 Finite element mesh for FEAM analyses „for the sepa- Influence of Relative Position. To evaluate the influence of the
rated crack model…. „a… Whole view. „b… Magnified view. „c… interaction on the SIF, which takes various values along the crack
Sight A. front, the averaged SIF, Fm, was defined as
T= 冕⌫
dw 共3兲
cs = 冑 2A0
共5兲
冕 冊
Discussion
Stress Intensity Factor of Coalesced Crack. In the previous + F共冑A1 + A2兲dw 共6兲
⌫2
study 关26兴, it was suggested that the averaged SIF of surface
cracks that have complex front shapes is almost the same when where Ai, ⌫i, and Ti denote the area size, path, and length of the
the area of the crack face is the same. Figure 9 shows the averaged crack front of crack i, respectively. Therefore, Fm共1+2兲 is identical
to Fm共cs兲 defined by Eq. 共2兲 if the two cracks coalesce. Figures 10
and 11 show the relationship between the distance S and Fm共1+2兲
normalized by Fm共cs兲 of coalesced cracks, which is evaluated us-
ing the combined model and is indicated as Fm共cs兲S=0, for tensile
and bending stresses, respectively. The normalized Fm共1+2兲 in-
creases to 1 as the distance S decreases. The change in Fm共1+2兲
under the condition of a2 / a1 = 0.5 is also shown in the figure,
although the values are normalized by Fm共cs兲S=0 evaluated under
the condition of a2 / a1 = 1. From these results, we can say that
although the magnitude of the interaction is dependent on the
distance between the cracks and is different at each crack tip
position, it can be represented by the scalar value Fm共1+2兲. The
maximum interaction is equivalent to the value of coalesced
cracks, the SIF of which can be evaluated based on the simple
addition of the area size, regardless of the loading condition, as-
pect ratio, and relative crack size.
Change in Area Size Due to Coalescence. In accordance with
the ASME Boiler and Pressure Vessel Code Section 关XI兴 关8兴, the
Fitness-for-Service Code of JSME 关9兴, the American Petroleum
Institute 共API兲 关27兴, and the British Standard 共BS兲 关28兴, for crack
growth evaluation, multiple discrete cracks are combined and
Fig. 9 Averaged SIFs of surface cracks having various crack treated as a single crack if the distance between two cracks satis-
front shapes fies the following criteria:
S 艋 c1 + c2 共API兲 共8兲
The depth of the combined crack, ac, is the same as that of the
deeper crack, which is a1 in the case of Fig. 1. The surface length
2cc is the sum of the surface lengths of two cracks, and the dis-
tance S is cc = c1 + c2 + S / 2. Figure 12 shows the areas of the com-
bined single crack, which is denoted as Ac共=ccac / 2.0兲, against the
distance S normalized by c1 + c2. Ac is normalized by a simple sum
of the areas of two cracks, A共1+2兲共=c1a1 / 2.0+ c2a2 / 2.0兲. Based on
the previous discussion, replacement of the interacting cracks with
a semielliptical crack that has the same area of the coalesced
cracks leads to a conservative result in an amount of crack growth.
From the mechanical point of view, the current rule provides a
conservative evaluation since the value of Ac is larger than A共1+2兲
in all cases, especially for the case of different crack sizes. Gains
in area size obtained by the combination rule of the API code are
Ac / A共1+2兲 = 1.5 and 1.8 in the cases of a2 / a1 = 1 and a2 / a1 = 0.5,
respectively. On the other hand, there is no gain in area size in the
case of similar crack sizes according to the codes of ASME,
JSME, and BS. As shown in previous figures, the interaction ex-
ists in the condition of S ⬎ 0. To take into account the acceleration
in crack growth due to the interaction before the coalescence of
neighboring cracks, some margin should be included. Namely, the Fig. 12 Relationship between area of combined crack and dis-
current criterion for ASME, JSME, and BS might bring unconser- tance between the cracks „a1 / c1 = a2 / c2 = 0.8…
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