FRACTURE MECHANICS IN ANSYS R16

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Fracture Mechanics in Ansys R16

Session-01
Introduction to Fracture
Mechanics

Ozen Engineering Inc.

1210 E. Arques Ave, Suite 207
Sunnyvale, CA 94085
info@ozeninc.com
Design Philosophies
• It is critical to decide on a design philosophy
– Safe-Life
– Fail-Safe
– Damage-Tolerant

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What is Fracture Mechanics?
• It is the study of flaws and cracks in materials
• Can be seen as a special case among different
design philosophies
• Mostly deals with crack growth and life-time
estimation

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2
Why is Fracture Mechanics important?
• Strength of Material approach does not anticipate the
presence of a crack or does via concentration factors
• Presence of cracks can significantly decrease the
structural strength and reliability

𝐹 𝐹
𝜎= 𝜎≫
𝐴 𝐴

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 Why is Fracture Mechanics important?
• Flaw Size (a) is an important parameter in
fracture mechanics approach
• Fracture Toughness replaces strength of material
– For Linear-Elastic Fracture
Mechanics (LEFM), fracture
𝑲𝑰𝑪 toughness of a material is
determined from “Stress 𝐹
Intensity Factor” 𝜎≫
𝐴
– For Elastic-Plastic Fracture
𝑱𝑰𝑪 Mechanics(EPFM), fracture
toughness is determined via
energy required to grow a crack a
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Industries
• Probably encountered in any industry dealing
with structures
– Automotive
– Electronics
– Healthcare
– Aviation
– Civil
– Nuclear
– Defense
– Maritime
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 Historical Background
• Comet Airplanes

[1] “The DeHavilland Comet Crash | Aerospace Engineering Blog.” [Online]. Available:
http://aerospaceengineeringblog.com/dehavilland-comet-crash/. [Accessed: 17-Mar-2015].
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Historical Background
• Liberty Ships
• ~1,500 instances of
brittle fracture during
WWII
• Studies revealed ships in
North Atlantic were
exposed to cold
temperatures were
subject to brittle fracture

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Effect of Temperature on Fracture Toughness
• Fracture Toughness of materials are affected
by temperature
• Ships experiencing cold weather conditions
may be prone to fracture type failures

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Historical Background
• Aloha Flight #243 in 1988:

• German Train ICE Accident in 1998:

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Crack Initiation & Propagation
• Life span definition:

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Crack Initiation & Propagation
• Life span definition for fatigue analysis:

Simulation context

The initiation stage During the stable propagation stage the The crack grows
can represent a large crack speed grows exponentially with the unstably until the
part of the life span crack size ductile fracture

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CRACK INITIATION
• Physically, cracks initiate from;
– An imperfection
– An already existing crack
– A damaged (locally weakened) area

• A failure analysis must include;

– Stress analysis
– Failure criterion

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Theoretical Developments
• A. Griffith (1893-1963)
published the results of his
studies on brittle fracture
• He found the strength of glass
depended on the size of
microscopic cracks

S a  CONSTANT

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Three Modes of Fracture
• Mode I denotes a symmetric opening (opening or tension mode)
• Mode II denotes an antisymmetric separation (In-plane shear mode)
• Mode III denotes an antisymmetric separation (out-of-plane shear or
tearing mode)
• Crack growth usually takes place in mode I or close to it.
• The crack “adjusts” itself such that the load is perpendicular to the crack
faces.

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Fracture Mechanics Parameters
• J-Integral
• Energy-Release Rate
• Stress-Intensity Factor
• T-Stress
• Material Force
• C*-Integral
– UMM Method (Unstructured Mesh)

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Energy Release Rate and J-Integral

 Energy release rate can be calculated from stress intensity

factors

 The J-integral can be defined as a path-independent line

integral that measures the strength of the singular stresses
and strains near a crack tip.

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Stress Intensity Factor
• The magnitude of stress field in the immediate vicinity of the crack tip is measured
by the “Stress Intensity Factor”
• Stress Intensity Factor is a quantity determined analytically and varies as a function
of the crack configuration and the external loads are applied
• Critical stress intensity factor is independent of the crack geometry and loading
and may be regarded as a material constant.
• Typical critical stress intensity factor values are;
Ultimate Critical Stress
Strength Intensity Factor
• AL 7075-T651 83 ksi 26 ksi in1/2
• AISI 4340 280 ksi 40 ksi in1/2

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T-Stress
• Is the stress acting parallel to the crack faces
• Unlike J-integral, it can have both negative and
positive values
• Positive T-stress values promotes fracture,
where negative T-stress values results in larger
plastic zones)

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Material Force
• “Material Force” method provides parameters for
global material and dissipation forces that yield
near-tip crack-driving force
• Can be applied to all kind of material models
(elastic, visco-elastic, plastic…)

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C*-Integral
• Creep crack growth becomes a concern when
structural components are operated at high
temperatures (ie Nuclear Industry)
• C*-Integral can be used to evaluate the crack
tip fields under creep deformation
• C*-Integral is a path-independent integral,
which is the steady-state creep analogue of J
integral.

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UMM Method
• The unstructured mesh method (UMM) is a
numerical tool used for evaluating fracture
mechanics parameters on unstructured hex or
tet element meshes.
• Unstructured mesh method supports:
– J-integral
– Stress-intensity factor

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Fracture Mechanics Table
• Which parameters is applicable for which assumptions:
Method Material Behavior
J-Integral Linear isotropic elasticity
Isotropic plasticity
Energy-Release Rate Linear isotropic elasticity
(VCCT Method) Orthotropic elasticity
Anisotropic elasticity
Stress-Intensity Factor Linear isotropic elasticity
T-Stress Linear isotropic elasticity
Isotropic plasticity
Material Force Various (including plasticity,
viscoelasticity)
C*-Integral Creep
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Crack-Growth Simulation
• VCCT-Based Interface Element Method
• Cohesive Zone Method
• XFEM-Based Method

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Fracture Mechanics Meshing & Element Support
 KSCON command is used to skew
mid-side nodes around the crack tip.
 This way the crack tip 1/(r
1/2)

singularity is captured.

PLANE183

PLANE183
SKEWED NODES
SOLID186
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Fracture Mechanics Meshing & Element Support

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2-D Edge Crack Propagation

 2 D Edge cracked plate

analysis
 can be solved both using
fracture mechanics tools
and cohesive zone
elements in ANSYS.

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2-D Edge Crack Propagation

Crack Propagation Animation, β =15° (a) Crack Propagation Path, (b) SIF, FI; β =15°

• Fracture parameters can be calculated directly using KCALC and CINT command in ANSYS.
• Crack initiation angle and energy release rate can be calculated from stress intensity factors.
• Cracks propagate straight (parallel to loading direction) to attain pure mode-I conditions.

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Interface modeling

Problem Geometry Finite Element Model

 Edge crack propagation in a thin film-substrate(SiO2/Si) is studied.

 Effect of interface layer on crack propagation path is examined using cohesive zone elements.

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3-D Edge Crack Analysis
In Thin Film-Substrate Systems

(a) Propagation Animation; Cut (b) Propagation Path; Cut Length=150

Length=150
 Crack propagation is performed quasi-statically. Fracture parameters are calculated
at each propagation step and the geometry is updated for the next propagation step.
 Cohesive zone elements are placed between thin film and substrate to model

interface.
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 Industrial Example: Pump Housing Fracture
• Pump housing subjected to internal pressure with a through
crack
Crack

0.16
Inner surface
Path 1
J Integral 0.12 Path 2
Calculations Path 3
0.08 Path 4
Path 5
0.04

0
33 0 1 2 3 4
Outer surface
Industrial example: Cracked helicopter flanged plate
• Automatic crack growth simulation under variable loading

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Following Week Schedule
• March 26th: 10AM-10:45AM PT How to Perform
Fracture Mechanics Analysis in Workbench
• April 2nd: 10AM-10:45AM PT XFEM Method –
Meshless Fracture Mechanics
• April 9th: 10AM-10:45AM PT Fracture
Mechanics with Cohesive Zone and Delamination
• April 16th: 10AM-10:45AM PTFatigue Crack
Propagation

www.ozeninc.com

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 END
Thanks for your attention !!!
Questions ?

CONTACT:
Attention: Can Ozcan
OZEN ENGINEERING, INC.
1210 E. ARQUES AVE. SUITE: 207
SUNNYVALE, CA 94085
(408) 732-4665
info@ozeninc.com
www.ozeninc.com