Solid Mechanics EMM331

Ir. Dr. Feizal Yusof

Fracture Mechanics 3
Week 11-12 (6 hrs)

1
 Round hole with cracks
1. The presence of a circular hole in a 4. Obviously the SIF or K for such a crack
plate like structural member is a emanating from a hole cannot be just
common occurrence and the influenced by the length of the crack
conventional stress concentration but must also be influenced by the
factor is well known. hole.
2. However when the hole is filled 5. Fig 18 shows a correction factor
with a bolt or pin, with some 𝑓(𝑎/𝑟) for crack from a hole from
interference fitting, small cracks Barsom and Rolfe (1987).
may develop around the hole.
3. The classical case of a hole-crack
combination is the symmetric
cracks at a hole in a semi-infinite
geometry (Fig 17)

Fig 17

2
Fig 18
 Round hole with cracks
6. Fig 18 has x-axis represented by 𝑎/𝑟
and the y-axis represented by
𝑓(𝑎/𝑟). 𝑟 is the radius of the hole
and 𝑎 is the crack length emanating
from the surface of the hole (see Fig
18)
7. From the y-axis, the curve ranges
from 1 to slightly greater than 3.
when the hole is vanishingly small, so
r à 0 so a/r à ∞ and f(a/r)à 1.
8. when the crack size 𝑎 is vanishingly
small compared to the hole radius, r,
then a/r à 0 and 𝑓(𝑎⁄𝑟) à 3 which
is a typical stress concentration
factor, 𝑘! for a hole. 3.36
Fig 18
9. The general stress intensity solution
from lecture 2,
𝐾 = 𝜎 𝜋𝑎 --- (19)
10. And for crack around a hole can be
given as
𝐾 = 𝜎 𝜋𝑎 𝑓(𝑎/𝑟) --- (27)
11. From Fig 18, we find that the
maximum value of 𝑓(𝑎/𝑟) for a
vanishingly small crack at a hole is
From Fig 18: 𝑓 𝑎⁄𝑟 = 3.36
But it is also correct that (for a/r << 0.1)
𝑘! × 𝑌
the multiplication of a 𝑌 for a crack in a
semi-infinite geometry ≅ 1.12 and a 𝑘𝑡 of
a hole in a geometry ≅ 3
𝑘! ×𝑌 = 3×1.12 = 3.36
3
 Example 1
Assume you have a 10mm-thick metallic plate with a circular hole in it, where a crack
has initiated as shown in the fig below. The diameter of the circular hole is 12 mm and
the length of the crack (a) is 6 mm. If the plate has a fracture toughness of 24.2
MPa.m1/2 and a yield strength of 495 MPa, will the plate fail when the applied stress is
450 MPa?
Thickness of plate, 𝑡 = 10 𝑚𝑚
Dia of hole, 𝐷 = 12 𝑚𝑚
Radius if hole, 𝑟 = 𝐷⁄2 = 6 𝑚𝑚
Length of crack, 𝑎 = 6 𝑚𝑚
Yield strength, 𝜎! = 495 𝑀𝑃𝑎
Fracture toughness, 𝐾" = 24.2 𝑀𝑃𝑎 𝑚
will plate fail at 𝜎#$$ = 450 𝑀𝑃𝑎?
Solution:
𝐾 = 𝜎 𝜋𝑎 𝑓(𝑎⁄𝑟)
𝑎⁄𝑟 = 6⁄6 = 1
So from Fig 18 𝑓(𝑎/𝑟) à 1.4
𝐾" = 𝜎% 𝜋𝑎 𝑓(𝑎⁄𝑟)
𝐾"
𝜎% =
𝜋𝑎 𝑓(𝑎⁄𝑟)
24.2×10&
𝜎% = = 246.7 M𝑃𝑎
𝜋 6×10'( ×1.4
So plate failed at 246.7 MPa and cannot sustain an applied
stress of 450 MPa.

4
 Superposition of stress intensity
1. The general technique of elastic
factors
4. So
superposition* can be stated as 𝐾" 𝐹 = 𝐾" 𝐴 + 𝐾" 𝐵 + 𝐾" 𝐶 + ⋯
follows: where the final loading F is the sum of
– ‘The stress pattern due to different individual loadings A, B, C …
loadings on the same body can be
superposed (added algebraically at each 5. This principle of superposition allows
point) provided that the materials stress- us to solve complex design problems
strain relation is linear.’
by using known simple expression for
2. Thus, for example the stresses due to stress intensity factors.
tension on a bar and the stresses due 6. An example is a crack in a riveted
to bending on the same bar can be plate as shown below where a load 𝑃
added to find the total stress at each and a stress, 𝜎 is acting on a crack of
point (as long as the yield strength is 2𝑎
not exceeded).
3. This principle means that stress
intensity factors for different loadings
on the same body can be added
Fig 19
algebraically.

5
*Elastic superposition – read Timoshenko and Goodier (1951) “Theory of elasticity” McGraw-Hill
 K in combined loadings
cL Ka

where:
Kb

Fig 20

7. Another example here, consider a

finite-width bar with a single edge- 8. As the fij(q) is identical for both cases
notch (Fig 20), subject simultaneously (given that the Mode of loading is
to a tensile load and a bending the same) the total stress intensity
moment, the crack tip stresses due to factor is shown to be algebraically the
each of these loadings will be given sum of the individual factors
by: (eqn.31).
)! "#$%&'$
𝜎#$ = f-. (𝜃) --- (29)
!%&'#(& *+,
)! (#$)
𝜎#$ /%&0 = *+,
f-. (𝜃) --- (30)
So
)! "#$%&'$ 3)! (#$)
𝜎#$ !(!12 = *+,
f-. (𝜃)---(31)
6
 Example 2
A riveted plate (12 in. wide and 1 in. thick) or (304.8 mm and 25.4 mm thick) in a large
structure has developed a crack as shown in Fig 19. If the plate is fabricated from
maraging steel with a plane strain fracture toughness of 100 ksi (in.)1/2 or (109.0
MPa(m)1/2, what is the maximum stress at failure?

Solution Fig 19

Apply superposition à

Since the loadings (a) and (d) are identical:

𝐾" 1 = 𝐾" / + 𝐾" 4 − 𝐾" 1
2𝐾" 1 = 𝐾" / + 𝐾" 4
𝐾" 1 = 100 𝑘𝑠𝑖 𝑖𝑛 and 𝐾" / = 𝜎 𝜋𝑎 and 𝐾" 4 = 𝑃/ 𝜋𝑎 (when 𝑃 are centrally
placed on the crack). From equilibrium of forces, 𝑃 = 𝜎 12×1 = 12𝜎. Because this is
a plane strain problem, thickness of plate, t = 1 in and therefore crack is also 1 in.
length and 𝑎 = 0.5 in, hence:
2×100 = 𝜎 0.5×𝜋 + 12/ 0.5𝜋
𝜎 = 18.5 𝑘𝑠𝑖 or (127 MPa)
For converting fracture mechanics parameters from US unit to SI units you may refer to : http://www.zentech.co.uk/zencrack_support_unitconversion.htm 7
 Residual stresses
1. From the Stress intensity factor
formula, 𝐾 = 𝜎 𝜋𝑎, the parameter
that affects K are the stress/load and
the crack length.
2. However the state of the stresses at a
crack tip can be affected not only by
the directly applied loads but can
also be influenced by other
conditions that are not visible as we
now will see.
3. Residual stress is “a stress which are
resident inside a component or
structure after all applied forces have
been removed”
4. What causes Residual stresses?
Residual stresses are generated upon
equilibrium of material, after plastic
deformation that is caused by applied
mechanical loads, thermal loads or
phase changes of the material.
5. Mechanical and thermal processes
applied to a component during
service may also alter its residual
stress state.
6. What is the total stress in a
component? à The total stress
experienced by the material at a
given location within a component is
equal to the residual stress plus the
applied stress
∑𝜎 = 𝜎,' + 𝜎155 --- (32)
5. If a material with a 𝜎,' = -400 Mpa (a -
ve sign indicate compressive stress) is
subjected to an applied stress 𝜎155 =
+500 MPa. Then from Eq. (32), ∑𝜎 =
+100 MPa. But if the 𝜎,' is a +ve sign
that indicate a tensile stress, then
from the problem given, the ∑𝜎=
+600 MPa. 8
 Residual stresses
6. If we put the problem described in
point 5 from pg 8 in a crack, we have
a situation as shown in Fig 21.

Fig 21

9
 Example 3
The welding process in a plate in a bridge structure has developed residual stresses as
shown in Fig 22. Subsequent inspection detects a through crack of length 0.5 in. the
plate is made of 4130 steel with critical plane strain fracture toughness of 100 ksi 𝑖𝑛
and yield strength of 160 ksi. What is the maximum applied tensile stress the plate can
withstand and what is the failure stress if the residual stress can be relieved?

1. Using the principle of superposition

𝐾! 𝑓𝑖𝑛𝑎𝑙 = 𝐾! 𝑟𝑒𝑠𝑖𝑑𝑢𝑎𝑙 + 𝐾! (𝑎𝑝𝑝𝑙𝑖𝑒𝑑)

2. At failure,
𝐾! 𝑓𝑖𝑛𝑎𝑙 = 𝐾!" Fig 22
𝐾! 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 = 𝜎#$$ 𝜋𝑎
𝜎% 3. If the plate was stress relieved before
𝐾! 𝑟𝑒𝑠𝑖𝑑𝑢𝑎𝑙 = 𝜋𝑎 the application of remote load, the failure
2
&
So stress, 𝜎#$$ will improve to
𝜎% 𝐾!" = 𝜎 𝜋𝑎
𝐾!" = 𝜋𝑎 + 𝜎 𝜋𝑎
2 100 = 𝜎 0.25𝜋
100 = 80 0.25𝜋 + 𝜎#$$ 0.25𝜋 &
𝜎#$$ = 112.9 ksi (778 MPa)
𝜎#$$ = 32.9 𝑘𝑠𝑖 (227 𝑀𝑃𝑎)
10
 What we learned?
1. There are many ways the SIF/K can be 5. Residual stress in structures are usually
influenced by geometrical complexities caused by plastic deformation
– Cracks emanating from geometrical stress experienced by the structures due to
raisers.
manufacturing e.g. welding; mechanical
– Multiple loads applied to a crack.
induced stresses e.g. shot peened;
– Plastic deformation near a crack tip due to
manufacturing or in-service loads. mechanical strengthening e.g. steel
2. The K formula can be modified to reinforced concrete.
consider these complex effects to stress 𝐾<=<>? = 𝐾@ EFGHIJ>? G<EFGG + 𝐾@(>KK)
field at the crack tip But residual stress are vector dependent
3. For cracks emanating from stress raisers and must be carefully identified in the
i.e. hole, fillets, corner, chamfers calculations.
𝐾 = 𝜎 𝜋𝑎 𝑓(𝑎⁄𝑟)
𝐾 = 𝜎 𝜋𝑎 (𝑘< ×𝑌) for a/r<<0.1
where f(a/r) are suitable calibration factors
4. For cracks under multiple loads, a linear
elastic superposition techniques states
that loads applied can be added
algebraically
𝐾<=<>? = 𝐾@(>) + 𝐾@(A) + ⋯ + 𝐾@(BCD)

11