Franc3D V6 Reference

Reference
Manual
Version 6
Fracture Analysis Consultants, Inc

www.fracanalysis.com
Revised: November 2011

Table of Contents:
Table of Contents: ............................................................................................................... 1
1. Introduction .................................................................................................................... 5
2. General and 3D View Manipulation .............................................................................. 5
2.1 View Controls .......................................................................................................... 8
3. Menus............................................................................................................................. 9
3.1 Help .......................................................................................................................... 9
3.1.1 About Dialog ................................................................................................... 10
3.2 File ......................................................................................................................... 11
3.3 Edit ......................................................................................................................... 12
3.4 Cracks .................................................................................................................... 12
3.5 Materials ................................................................................................................ 13
3.6 Loads ...................................................................................................................... 14
3.7 Analysis.................................................................................................................. 14
3.8 Fatigue.................................................................................................................... 15
3.9 Fretting ................................................................................................................... 15
3.10 Advanced ............................................................................................................. 16
4. File Menu Wizards and Dialog Boxes ......................................................................... 17
4.1 Open…Ctrl-O ........................................................................................................ 17
4.1.1 FRANC3D Restart Files ................................................................................. 18
4.1.2 FEM Input Wizard .......................................................................................... 20
4.1.3 Retain Model Panel ......................................................................................... 21
4.1.4 Select Items to Retain Panel ........................................................................... 22
4.1.5 Materials to Retain Panel ................................................................................ 23
4.1.6 Coordinate Systems to Retain Panel ............................................................... 24
4.1.7 Boundary Conditions to Retain Panel ............................................................. 24
4.1.8 Components/Nsets to Retain as Mesh Facets Panel ....................................... 25
4.1.9 Surfaces to Retain for Contact/Constraint Panel ............................................ 26
4.1.10 Components/Nsets for Residual Stress Panel ............................................... 26
4.2 Close ...................................................................................................................... 27
4.3 Save As… .............................................................................................................. 27
4.4 Read Results........................................................................................................... 29
4.5 Playback…. ............................................................................................................ 30
4.6 Quit - Ctrl-Q........................................................................................................... 31
5. Edit Menu Wizards and Dialog Boxes......................................................................... 31
5.1 Undo - Ctrl-Z ......................................................................................................... 31
5.2 Redo ....................................................................................................................... 32
5.3 Preferences… ......................................................................................................... 32
5.3.1 Folders Tab ..................................................................................................... 32
5.3.2 Window Tab.................................................................................................... 33
5.3.3 3D View Tab ................................................................................................... 34
5.3.4 Display Tab ..................................................................................................... 34
5.3.5 ANSYS Tab .................................................................................................... 35
5.3.6 ABAQUS Tab ................................................................................................. 36
5.3.7 NASTRAN Tab .............................................................................................. 37
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5.3.8 FEAWD Tab ................................................................................................... 37
5.3.9 Meshing Tab ................................................................................................... 38
6. Cracks Menu Wizards and Dialog Boxes .................................................................... 39
6.1 New Flaw Wizard .................................................................................................. 39
6.1.1 Flaw type panel ............................................................................................... 40
6.1.2 Crack type panel ............................................................................................. 41
6.1.3 Elliptical crack panel....................................................................................... 41
6.1.4 Single-front Through-the-thickness crack panel ............................................. 42
6.1.5 Two-front Through-the-thickness crack panel................................................ 43
6.1.6 Long shallow surface crack panel ................................................................... 43
6.1.7 Two-front Elliptical crack panel ..................................................................... 44
6.1.8 User-defined crack panel ................................................................................ 45
6.1.9 Advanced Geometry button ............................................................................ 46
6.1.9.1 Refine ....................................................................................................... 47
6.1.9.2 Reset ......................................................................................................... 47
6.1.9.3 Edit ........................................................................................................... 48
6.1.10 Ellipsoidal void panel ................................................................................... 49
6.1.11 Flaw translation and rotation panel ............................................................... 50
6.1.11.1 Orient with Vectors ................................................................................ 50
6.1.12 Crack Front Mesh Template Panel ............................................................... 51
6.1.12.1 Meshing Parameters Dialog ................................................................... 52
6.1.12.2 Advanced Template Options Dialog ...................................................... 53
6.1.13 Flaw Insertion ................................................................................................ 55
6.2 Flaw from Files ..................................................................................................... 55
6.3 Multiple Flaw Insert ............................................................................................... 56
6.4 Stress-Intensity Factor ........................................................................................... 58
6.4.1 M-integral or Displacement Correlation Panel ............................................... 58
6.4.2 SIF Plot Panel ................................................................................................. 60
6.5 Grow Crack ............................................................................................................ 61
6.5.1 Crack Growth Parameters Wizard ................................................................... 62
6.5.1.1 First Growth Parameters Panel ................................................................. 62
6.5.1.2 Fatigue Growth Rate Model...................................................................... 66
6.5.1.3 Quasi-Static Growth Model ...................................................................... 74
6.5.1.4 Constant Amplitude Panel ........................................................................ 74
6.5.1.5 Variable Amplitude Panel ......................................................................... 77
6.5.2 Advanced Crack Growth Parameters Wizard .................................................. 82
6.5.2.1 First Advanced Growth Parameters Panel ................................................ 82
6.5.2.2 Second Advanced Growth Parameters Panel ............................................ 87
6.5.2.3 Third Advanced Growth Parameters Panel............................................... 89
6.5.2.4 Fourth Advanced Growth Parameters Panel ............................................. 91
6.5.3 Crack Growth Wizard ...................................................................................... 94
6.5.3.1 First Crack Growth Panel.......................................................................... 94
6.5.3.2 Second Crack Growth Panel ................................................................... 100
6.6 Read Crack Growth Wizard ................................................................................. 101
6.7 Grow/Merge Cracks Wizard ................................................................................ 102
7. Materials Menu Wizards and Dialog Boxes .............................................................. 104
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7.1 Material Properties ............................................................................................... 104
7.1.1 View Material ............................................................................................... 104
7.1.2 New Material ................................................................................................ 105
7.2 Apply Material ..................................................................................................... 106
7.3 Apply Coordinate System .................................................................................... 106
8. Wizards and Dialog Boxes for Loads Menu .............................................................. 107
8.1 Map Current State ................................................................................................ 107
8.2 Crack Face Pressure/Traction .............................................................................. 107
8.2.1 Constant Crack Face Pressure Panel ............................................................. 108
8.2.2 1-D Radial Residual Stress Distribution Panel ............................................. 109
8.2.3 2-D Radial Residual Stress Distribution Panel ............................................. 111
8.2.4 Surface Treatment Residual Stress Distribution Panel ................................. 112
8.2.5 Mesh-Based Stress Distribution Panel .......................................................... 114
9. Wizards and Dialog Boxes for Analysis Menu.......................................................... 115
9.1 Static Crack Analysis ........................................................................................... 115
9.1.1 Fdb File Name Panel ..................................................................................... 115
9.1.2 Analysis Code Panel ..................................................................................... 116
9.1.3 ANSYS Options Panel .................................................................................. 116
9.1.4 ANSYS local/global model connection Panel .............................................. 118
9.1.5 ANSYS Script Panel ..................................................................................... 120
9.1.6 ANSYS Command Line Panel...................................................................... 120
9.1.7 ABAQUS Options Panel............................................................................... 121
9.1.8 ABAQUS local/global model connection Panel ........................................... 122
9.1.9 ABAQUS Script Panel .................................................................................. 123
9.1.10 ABAQUS Command Line Panel ................................................................ 124
9.1.11 NASTRAN Options Panel .......................................................................... 124
9.1.12 NASTRAN local/global model connection Panel ...................................... 126
9.1.13 NASTRAN Script Panel ............................................................................. 128
9.1.14 NASTRAN Command Line Panel .............................................................. 128
9.2 Crack Growth Analysis ........................................................................................ 128
9.2.1 Crack Front Smoothing Panel ....................................................................... 128
9.2.2 Crack Growth Increments Panel ................................................................... 129
9.2.3 Analysis Code Panel ..................................................................................... 130
9.2.4 ANSYS Analysis .......................................................................................... 131
9.2.5 ABAQUS Analysis ....................................................................................... 131
9.2.6 NASTRAN Analysis..................................................................................... 131
10. Fatigue Menu Wizards and Dialog Boxes ............................................................... 131
10.1 SIF History ......................................................................................................... 131
10.2 Discrete Crack Life ............................................................................................ 138
11. Fretting Menu Wizards and Dialog Boxes............................................................... 145
11.1 Read Model and Results ................................................................................. 145
11.2 Import Nucleation Data................................................................................... 148
11.3 Fretting Crack Nucleation ............................................................................... 152
11.4 Extract Subvolume .......................................................................................... 159
11.5 Turn Off Region Color.................................................................................... 161
12. Advanced Menu Wizards and Dialog Boxes ........................................................... 162
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12.1 Edges Wizard ..................................................................................................... 162
12.2 No Crack Regions .............................................................................................. 163
12.3 Write Crack Front Data ...................................................................................... 165
12.4 Write COD Data ................................................................................................ 166
12.5 Write Template Data .......................................................................................... 167
12.6 View Response................................................................................................... 168
12.7 Create Growth History ....................................................................................... 170
12.8 Crack Growth Sequence .................................................................................... 172
13. FRANC3D Command Language and Session Files ................................................ 173
14. FRANC3D Python Extensions ................................................................................ 173
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1. Introduction
FRANC3D Version 6 is a program that inserts and extends cracks and/or voids in pre-
existing finite element meshes. This manual describes the components of the graphical
user interface of the program. It also includes underlying theory and concepts where
appropriate.
There are three separate tutorial documents that describe the program usage when
combined with the three supported commercial FE codes: ANSYS, ABAQUS and
NASTRAN. In addition, there is a Benchmark document that describes a number of
crack configurations for which there are analytical or handbook solutions for stress
intensity factors (SIFs) where the FRANC3D SIFs are compared to the existing SIFs.
To get started using FRANC3D, one can choose one of the tutorials and follow the steps.
One can consult this reference document for more details at any of the FRANC3D
modeling steps in the tutorials. One should also try to reproduce some of the Benchmark
examples or choose your own model for validation.
In this document, menu buttons, dialog or wizard panel titles, and buttons on these panels
are indicated by bold text. Fields, labels and selectable options inside the dialog or
wizard panels are indicated by underlined text. Tab labels and pane labels inside the
dialog and wizard panels are indicated by italicized-underlined text. This formatting is
intended to be consistent with the tutorials.
2. General and 3D View Manipulation

An image of the main FRANC3D window is shown in Figure 2.0.1. Most of the screen is
used by a 3D graphics window that displays the current model.
When a model is first displayed, the 3D view is set such that the viewer is looking toward
the center of the model from a position in the positive z direction. The distance from the
viewer to the model is set so that the full model is visible.
For most operations, one will likely want to change the view to see a different side of the
model and/or to view details more closely. As with many other programs, the view is
changed by moving the mouse in the 3D graphics window with the appropriate
combination of mouse buttons and keyboard keys depressed. There are eight functions
for view manipulation and selection. A unique combination of mouse buttons and
keyboard keys is defined for each of the functions. The button and key assignments can
be changed using the 3D View tab in the Preferences dialog box (described in Section
4.4).
5
Figure 2.0.1 FRANC3D main window.
The view functions are (using the default mouse and keyboard key assignments):
Rotate (left mouse button, no keyboard keys): Mouse motion rotates the model on the
screen. The mouse can be moved in any direction. The axis of rotation is defined to be
perpendicular to the mouse motion and passes through the current center of rotation. The
center of rotation is defined as the horizontal and vertical center of the graphics window
at a location midway between the front and back clipping planes (described below).
Pan (center mouse button or wheel, no keyboard keys): Mouse motion pans or drags the
model around the screen. The mouse can be moved in any direction, and the model
moves in such a way as if it were following the mouse.
Zoom/Spin (right mouse button, no keyboard keys): These are actually two different
types of updates activated by the same mouse key. If the mouse is moved up or down it
will appear as if the viewer is getting closer or farther, respectively, from the model. If
the mouse is moved left or right, the model rotates about an axis that is perpendicular to
the plane of the screen and passes through the horizontal and vertical centers of the
window.
6
Front Clip (center mouse button or wheel plus shift key): A cutting or clipping plane can
be moved parallel to the screen from the viewer toward the model. This can be used, for
example, to clip away the front of a model to see internal features such as cracks.
Moving the mouse upward "pushes" the clipping plane away from the viewer toward the
model, cutting away the portion of the model closest to the viewer. Moving the mouse
downward "pulls" the plane away from the model and toward the viewer.
Back Clip (right mouse button or wheel plus shift key): A cutting or clipping plane can
be moved parallel the screen from behind the model toward the viewer. This can be used,
for example, to clip away parts of the model that may be making the view confusing (this
is especially useful when the model is displayed in "wireframe" mode without polygons).
Moving the mouse upward "pushes" the clipping plane away from the viewer. Moving
the mouse downward "pulls" the clipping plane toward the viewer, which will cut away
the back portion of the model.
Recenter (left mouse button plus shift, ctrl, and alt keys): Sometimes it is convenient to
change the center of rotation. The horizontal and vertical position of the center of
rotation is always the center of the screen and can effectively be changed by panning the
model. The location of the center in the direction perpendicular to the screen is set by the
current location of the front and back clipping planes. However, it is difficult and
somewhat non-intuitive to set its location using the front and back clip functions. The
Recenter function presents a graphical tool for setting the center of location. This is a
multi-step process. In the first step, while depressing the shift, ctrl and alt keys, one
should depress and release the left mouse button while the cursor is at the horizontal and
vertical location that one wants as the new center of rotation. A dialog box then will pop
up, Figure 2.0.2 – left panel, which contains a 3D view of the model shown as though one
had walked 90 degrees around the model to the left. It also shows a green line that is a
projection of the point one picked in the previous step along the depth direction in the
model. In this step, one should select a point horizontally (using left mouse button plus
the shift key only) along the projection to set the depth location of the new center of
rotation. A small box will be displayed at the new center location, Figure 2.0.2 – right
panel. Select Accept to complete the re-centering process; the model view will be
updated in the FRANC3D model view window to reflect the new center.
7
Figure 2.0.2 Recenter View dialog.
2.1 View Controls

The View Controls box along the right hand side of the FRANC3D main window
provides additional options for manipulating the view of the model, Figure 2.1.1.
Figure 2.1.1 View control panel.
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Graphical Element Toggles: Graphics in 3D display windows consist of a combination
of markers, vectors, polygons, and text. The toggles in this box will turn these items on
or off independently.
Update Gain Controls: These dials adjust the gain between mouse motion and model
motion for rotations and translations. Rotating to the right increases the gain, rotating to
the left decreases it.
Axes Toggle: This turns the axes display on or off.
F/B Colors Toggle: This turns the front/back coloring on or off. By default, the front and
back side of a surface are shaded differently. This toggle is useful when looking at the
crack surface where there are two coincident surfaces.
Named camera positions: The list of named camera positions is displayed in the list box.
There should always be a reset view provided as the default (d) view. The icons below
allow one to save additional camera positions to the list as well as saving them to a file.
Camera positions can be read from a file, renamed, or deleted.
Preset Controls: These icons provide quick access to preset views that place the viewer
along one of the Cartesian axes. The two icons on the right switch the view from
perspective (the default) to orthotropic.
Mesh Toggle: This toggles the surface mesh on and off.
3. Menus
A brief summary of the menus from the menu bar shown in Figure 2.0.1, is provided
here. In general, selecting a menu item leads to a wizard or dialog and these are
described in more detail in Sections 4-12.
3.1 Help
The Help menu, Figure 3.1.1, is on the far-right side of the menu bar and has options for
accessing the FRANC3D documentation either locally, if installed, or on-line from
FAC’s www server (www.fracanalysis.com). If the user selects the Reference, Tutorial
for…, or Benchmark menu options, the appropriate documentation will be displayed in
a web browser window if the files have been installed locally and the file paths set. If the
file paths have not been set, the user is presented with the dialog box shown in Figure
3.1.2, and can select the appropriate index.html file. Alternatively, if the Online
Documentation menu option is selected, the list of FRANC3D documents that are
available from FAC’s web server are displayed in a web browser.
9
Figure 3.1.1 Help Menu.
Figure 3.1.2 FRANC3D documentation file location dialog.
3.1.1 About Dialog
The last menu item displays the About dialog, which contains the version number, the
build number and date, acknowledgements, and a list of supporting agencies, Figure
3.1.3. We also wish to acknowledge the help and support of all of our users for their
contributions.
10
Figure 3.1.3 About dialog box.
3.2 File
The File menu is shown in Figure 3.2.1. Each of the menu items is listed below.
Figure 3.2.1 File Menu.
Open ... - Displays an Open File dialog box that allows one to read a model, which is
described in Section 4.1. A number of different types of files can be read, including:
.fdb, .cdb, .inp, .bdf, and .model. The .fdb files are FRANC3D database (restart) files.
The .cdb files are ANSYS database files in ASCII format. The .inp files are ABAQUS
input files. The .bdf are NASTRAN database files. The .model files are mesh files in
FAC's internal format.
If an ANSYS .cdb file is selected, the ANSYS version of the FEM Input wizard is
invoked; this wizard is described in Section 4.1 and is similar for all the other file types
(except for the .fdb restart files).
11
Close - Closes the current model so that a new model can be read.
SaveAs ... - Displays a Save File As dialog box, which is described in Section 4.3. This
option allows one to save the current model to a file. Models can be saved in .fdb, .cdb,
.inp, or .model formats. (See Open for file extension descriptions.)
Hint: By using Open and SaveAs, FRANC3D can be used as a file format translator.
However, all features of a model might not be translated.
Read Results ... - Invokes the Read Results File dialog, which is described in Section
4.4.
Playback ... - Invokes the Playback Session File dialog, which is described in Section
4.5, allowing the user to read in a session log file and reproduce the saved commands.
Quit - Closes the model and exits the program.
3.3 Edit
The Edit menu is shown in Figure 3.3.1. Each of the menu items is listed below.
Figure 3.3.1 Edit Menu.
Undo - Undo the last executed command. This feature is not completed yet.
Redo - Redo the last command that was undone. This feature is not completed yet.
Implementation note: the mechanism is in place to support Undo and Redo, but the
details have not yet been implemented.
Preferences... - Invokes the Preferences dialog box, which is described in Section 5.3.
3.4 Cracks
The Cracks menu is shown in Figure 3.4.1. Each of the menu items is listed below.
12
Figure 3.4.1 Cracks Menu.
New Flaw Wizard ... - Invokes the New Flaw wizard, which is described in Section 6.1.
Flaw From Files ... - Invokes the Locate Flaw File dialog, described in Section 6.2,
followed by a subset of the New Flaw wizard, described in Section 6.1.10 - 11. This
option allows one to select a flaw description from a file, or from multiple files, and
insert it into the current model.
Multiple Flaw Insert ... Invokes the Multiple Flaw wizard, which is described in Section
6.3.
Compute SIF's ... - Invokes the Compute SIF's wizard, which is described in Section
6.4. Note that displacements from a completed analysis must be available for this option
to be enabled.
Grow Crack ... - Invokes the Crack Growth wizard, which is described in Section 6.5.
Note that displacements from a completed analysis must be available for this option to be
enabled.
Read Crack Growth ... - Invokes the Read Crack Growth wizard, which is described in
Section 6.6.
Grow/Merge Cracks ... - Invokes the Crack Growth/Merge wizard, which is described
in Section 6.7. This feature is not completed yet.
3.5 Materials
The Materials menu is shown in Figure 3.5.1. Each of the menu items is listed below.
Figure 3.5.1 Materials Menu.
13
Material Properties ... - Invokes the Material Properties wizard, which is described in
Section 7.1.
Apply Material ... - Invokes the Apply Material to Elements dialog, which is described
in Section 7.2.
Apply Coordinates ... - Invokes the Apply Coordinate System to Elements dialog,
which is described in Section 7.3.
3.6 Loads
The Loads menu is shown in Figure 3.6.1. Each of the menu items is listed below.
Figure 3.6.1 Loads Menu.
Map Current State ... - Invokes the Map Current State dialog, which is described in
Section 8.1. Note that a previous model and previous results must be available for this
option to be enabled. This option is not completed yet and the menu option is inactive.
Crack Face Pressure/Traction ... - Invokes the Crack-Face Tractions dialog, which is
described in Section 8.2.
3.7 Analysis
The Analysis menu is shown in Figure 3.7.1. Each of the menu items is listed below.
Figure 3.7.1 Analysis Menu.
Static Crack Analysis ... - Invokes the Static Crack Analysis wizard, which is described
in Section 9.1.
Crack Growth Analysis ... – Invokes the Crack Growth Analysis wizard, which is
14
3.8 Fatigue
The Fatigue menu is shown in Figure 3.8.1. Each of the menu items is listed below.
Figure 3.8.1 Fatigue Menu.
SIF History ... - Invokes the SIF History wizard, which is described in Section 10.1.
Discrete Crack Life ... - Invokes the Discrete Crack Life wizard, which is described in
Section 10.2.
3.9 Fretting
The Fretting menu is shown in Figure 3.9.1. Each of the menu items is listed below.
Figure 3.9.1 Fretting Menu.
Read Model and Results ... - Invokes the Fretting Model Import wizard, which is
Import Nucleation Data ... - Invokes the Fretting Data Import/Analysis wizard, which
is described in Section 11.2.
Fretting Crack Nucleation ... - Invokes the Fretting Crack Nucleation wizard, which is
Extract Subvolume ... - Invokes the Extract Subvolume wizard, which is described in
Section 11.4.
Turn Off Region Color ... - Invokes the Region Color dialog, which is described in
Section 11.5.
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3.10 Advanced
The Advanced menu is shown in Figure 3.10.1. Each of the menu items is listed below.
Figure 3.10.1 Advanced Menu.
Edges Wizard ... - Invokes the Edge Extraction wizard, which is described in Section
12.1.
No Crack Regions ... - Invokes the No Crack Regions dialog, which is described in
Section 12.2.
Write Crack Front Data ... - Invokes the Write Crack Front Data dialog, which is
described Section 12.3.
Write COD Data ... - Invokes the Write COD Data wizard, which is described Section
12.4.
Write Template Data ... - Invokes the Write Template Data dialog, which is described
Section 12.5.
View Response ... - Invokes the View Response dialog, which is described Section 12.6.
Create Growth History ... - Invokes the Create Growth History dialog, which is
Crack Growth Sequence ... - Invokes the Crack Growth Sequence dialog, which is
16
4. File Menu Wizards and Dialog Boxes
The wizards and dialog boxes for the File menu options are described in this section.
4.1 Open…Ctrl-O
The File Open menu option allows the user to read either a FRANC3D restart file, with
.fdb extension, or an uncracked finite element model file. The supported file types
include: ANSYS .cdb, ABAQUS .inp, NASTRAN .bdf and FAC’s .model format.
These files are all ASCII format. The .model format will not be discussed here.
The Model File dialog is displayed, Figure 4.1.1, which allows the user to specify the
desired file type using the File Filter. This dialog allows the user to change directories.
The file name can be selected with the left-mouse button or typed into the field. The user
should select Accept once the file name has been entered.
This dialog contains one extra check box at the bottom that is only activated if the file
filter is set to Ansys Files. The Read extra ANSYS load step files check box allows the
user to read ANSYS specific .s## files that contain boundary conditions for load steps (or
cases). If this box is checked, once the ANSYS .cdb file is accepted, a second dialog is
presented, Figure 4.1.2, which allows the user to select one or more of the .s## files. The
boundary condition data is imported from each selected file and stored in separate load
cases.
Figure 4.1.1 Model File dialog box.
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Figure 4.1.2 ANSYS load step file dialog box.
4.1.1 FRANC3D Restart Files
The user can choose a .fdb file from the Model File dialog, Figure 4.1.1. FRANC3D
reads the contents of this file and any files that are referenced inside the .fdb file. The
.fdb file is organized in blocks with each block having a title and a version number. The
blocks and their content are summarized here.
F3DMETA (
Uncracked finite element file name, type, and retained data.
)
HISTORY_SUMMARY (
Summary of the crack step file names.
)
STATICMETA (
Analysis type, input and results file names.
)
FLAWSURF (
Description of crack geometry: surface patches, crack front vertices, and template
parameters.
)
CRACKFRONTIDS (
List of crack front identifiers.
)
TEMPLATENODES {
List of crack front mesh template node ids.
}
TEMPLATENODECOORDS {
List of crack front mesh template node coordinates.
}
SIF_COMP_PARAMS (
18
Stress intensity factor computation parameters.
)
GROWTH_PARAMS (
Crack growth computation parameters.
)
TEMPLATE_PARAMS (
Crack front mesh template parameters.
)
MATERIAL_DATA (
Material properties.
)
CRACKFACENODES {
List of crack face nodes with the local normal to the crack surface.
}
EDGE_EXTRACT_PARAMS (
Edge extraction parameters.
)
MESH_PARAMS (
Meshing parameters.
)
CRACK_GROWTH_DATA (
Crack growth history data.
)
SAVED_VIEWS {
List of saved camera positions.
}
If one selects a .fdb file, FRANC3D attempts to read all the relevant files. If a file
referenced by the .fdb file is missing, the user is prompted to locate that file, Figure
4.1.1.1. Note that you need the original uncracked finite element model file to perform
crack growth simulations. FRANC3D will also ask the user if the model path will be the
current working directory, Figure 4.1.1.2. Note that the working (default) directory can
be set in the Preferences dialog (see Section 5).
Figure 4.1.1.1 Locate File dialog box for finding missing files.
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Figure 4.1.1.2 Model File Path dialog box to set working directory.
4.1.2 FEM Input Wizard
The user can switch the File Filter in the Model File dialog, Figure 4.1, from Franc3D
Database Files (.fdb) to Ansys Files (.cdb), Abaqus Files (.inp) or Nastran Files (.bdf).
The process for reading an ANSYS .cdb file is essentially the same as the process for
reading .inp or .bdf files. Reading ANSYS files has one extra option, however, as
described in the previous section. Thus, the description below refers to ANSYS, but can
be applied to the other file types as well.
The FE Mesh File Input wizard is invoked from the File: Open… menu item if the user
selects an ANSYS, ABAQUS or NASTRAN mesh file. The File Open dialog is
presented, Figure 4.1.2.1, and depending on the File Filter, the list of files that are
presented will vary. In Figure 4.1.2.1, the File Filter is set to ANSYS, and the Read extra
ANSYS files check box is activated. With this box checked, the next dialog prompts the
user to select one or more .s## files, Figure 4.1.2.2, which contain the load step boundary
condition data.
Figure 4.1.2.1 Model File Open dialog with File Filter set to ANSYS cdb files and the
Read additional files check box activated.
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Figure 4.1.2.2 Locate .s## files dialog for reading ANSYS load steps.
The rest of the wizard panels that follow the File Open dialog are basically the same for
all the supported finite element input file types. The ANSYS specific panels are
described next.
4.1.3 Retain Model Panel
The FEM Input wizard allows the user to specify what is retained from the finite
element file (in this example an ANSYS cdb file). The first panel allows the user to
retain everything or to retain selected items, Figure 4.1.3.1. Note that the nodes and
elements will be retained by default even if nothing else is retained. The View .cdb
button invokes a text box with the ANSYS .cdb information displayed, Figure 4.1.3.2.
Note that similar View buttons will be available for ABAQUS and NASTRAN. If the
user chooses to retain everything, then there is nothing more to do except click Finish
and wait for the model to load.
In general, the only time one would retain everything is when using FRANC3D as a file
format translator.
21
Figure 4.1.3.1 Retain everything or selected items.
Figure 4.1.3.2 View ANSYS cdb file dialog.
4.1.4 Select Items to Retain Panel
If the user chose to select the items to be retained, the next panel, Figure 4.1.4.1, lists all
of the supported data that is present in the file. Materials, coordinate systems, boundary
conditions, contact and constraint information, and node components are supported. The
user can choose to select none, all, or some of the items presented. If an item, such as a
coordinate system, does not exist in the input file, then that item is not presented in the
dialog box.
22
Figure 4.1.4.1 Select items to retain panel.
4.1.5 Materials to Retain Panel
If the user chooses to select individual materials to retain, the next panel, Figure 4.1.5.1,
lists all of the materials that are present in the file. The basic material properties required
to compute stress intensity factors are retained regardless of this selection. If the model is
self-contained and will not be merged with a global model, then the materials should be
retained.
If there are multiple materials, the regions will be separated by default based on the
material ids. The boundaries between material regions can be ignored so that a single
volume is created and the selected or first material id will be assigned to all elements.
This is accomplished by checking the Ignore material id boundary option in Figure
4.1.5.1.
23
Figure 4.1.5.1 Materials to retain panel.
4.1.6 Coordinate Systems to Retain Panel
If the user chooses to select individual coordinate systems to retain, the next panel, Figure
4.1.6.1, lists all of the coordinate systems that are present in the file. If the model is self-
contained and will not be merged with a global model, then the coordinate systems
should be retained.
Figure 4.1.6.1 Coordinate systems to retain panel (portion of full panel shown).
4.1.7 Boundary Conditions to Retain Panel
If the user chooses to select individual boundary conditions to retain, the next panel,
Figure 4.1.7.1, lists all of the boundary condition types that are present in the file. The
boundary condition types can be retained either with or without retaining the mesh facets
and nodes where the boundary conditions are applied; this is true for all but the
temperature boundary conditions because only surface mesh facets can be retained and
temperatures are generally applied throughout the volume. If the boundary conditions are
retained without retaining the mesh facets, the boundary conditions will be mapped to the
remeshed surfaces.
Note that the mesh should not be retained on a surface where a crack will be inserted.
24
Figure 4.1.7.1 Boundary conditions to retain panel.
4.1.8 Components/Nsets to Retain as Mesh Facets Panel
If the user chooses to select individual mesh facet groups to retain, the next panel, Figure
4.1.8.1, lists all of the node components that are present in the file. If a component is
selected, then all the nodes and the mesh facets on the surface of the mesh will be
retained. Be careful not to retain facets where the crack will be inserted as this will cause
errors later. Single nodes will not be retained at this time, only complete facets are
retained.
The Inverse retain mesh option allows the user to retain all but the selected component.
Figure 4.1.8.1 Components/Nsets to retain as mesh facets panel.
25
4.1.9 Surfaces to Retain for Contact/Constraint Panel
If the user chooses to select individual surfaces for contact/constraint, the next panel
Figure 4.1.9.1, lists all of the surfaces (components, nsets, or other) that are present in the
file. The mesh facets can be retained with the selected surfaces. If the mesh facets are
not retained, the contact/constraint conditions will be mapped to the remeshed surfaces.
Note that the mesh should not be retained on a surface where a crack will be inserted.
Figure 4.1.9.1 Surfaces to retain for contact/constraint panel.
4.1.10 Components/Nsets for Residual Stress Panel
If the user chooses to select surfaces for residual stress, the next panel, Figure 4.1.10.1,
lists all of the surfaces (components, nsets, or other) that are present in the file. The mesh
facets are not retained with these surfaces.
These surfaces are used in conjunction with the crack face traction option where a
residual stress normal to the selected surface is defined. This feature is described in more
detail in Section 8.2.4.
26
Figure 4.1.10.1 Components/Nsets for residual stress panel.
4.2 Close
The File Close menu item closes the current model without quitting FRANC3D. If a
model is open and has not been saved, the Save Model Warning dialog, Figure 4.2.1, is
displayed. If the user wishes to save the model, the Cancel button can be selected.
Selecting the OK button will close the model without saving.
Figure 4.2.1 Save Model Warning dialog.
4.3 Save As…

The File Save As menu item can be used to save the initial uncracked input file in any of
the supported formats; FRANC3D will act as a translator. The File Save As option can
also be used to save a FRANC3D restart (fdb) file of a cracked model if the user does not
want to perform an analysis of the model. The dialog shown in Figure 4.3.1 allows one
to switch the File Filter to save in the desired format.
The default is to save a FRANC3D restart (fdb) file. If the user enters a .fdb file name
and selects OK, the File Output Options dialog is presented, Figure 4.3.2, and the user
can choose to save the finite element data in ANSYS, ABAQUS or NASTRAN format.
27
Figure 4.3.1 Save File As dialog.
Figure 4.3.2 Fdb Output Options dialog for choosing analysis code file format.
The next panel, Figure 4.3.3, allows the user to specify output options: elements can be
defined as linear or quadratic, nodes and elements can be renumbered, and boundary
condition (bcs) data and solution information can be output or suppressed. If the user
switches the File Filter in Figure 4.3.1, then the dialog shown in Figure 4.3.2 is skipped.
When the user selects Finish in Figure 4.3.3, the files are written in the appropriate
format.
28
Figure 4.3.3 Fdb Output Options dialog for defining output parameters.
4.4 Read Results

Results for one or multiple load cases can be read into the FRANC3D database. The load
case results can be used in conjunction with the crack growth wizard (see Section 6.5).
The File Read Results menu item invokes the dialog shown in Figure 4.4.1, which
allows the user to choose the analysis results file to be read. The user can switch the File
Filter if it is not correct. The user can either replace or add load case results, using the
radio buttons (Replace current set of results or Add these results) at the top of the dialog.
For ANSYS, the results file will either be a .dtp file that is created using the FRANC3D
generated macros or a simple nodal listing of displacements saved to a .dsp file. The .dtp
file will contain displacements, temperatures if not equal to the reference temperature,
and contact pressures on crack surfaces if such exist. For ABAQUS, all results will be
contained in the .fil file. FRANC3D includes commands in the .inp file that instructs
ABAQUS to write results in ASCII format to the .fil file, including displacements,
temperatures and crack surface contact pressures. For NASTRAN, all results will be
contained in a .pch file, which will include displacements, temperatures and crack surface
contact pressures. The .dtp, .fil and .pch file can include results for multiple load cases.
If the results file contains data for multiple load steps, all of the data is read and stored in
the FRANC3D database. Thus, one should be careful when entering the frequency for
output in the analysis codes; for instance, in ABAQUS, the output frequency is usually
set to 99999. Only the results for load cases (or steps) where SIFs are to be computed are
needed by FRANC3D. In fact, only the results for the crack front template mesh are
needed to compute SIFs.
29
Figure 4.4.1 Read results file dialog.
4.5 Playback….
The File Playback menu item allows playback of recorded session (log) files. Each time
the FRANC3D program is executed, a session##.log file is saved. This file records the
commands that the user executes through the menus and dialogs. A sample .log file
might look like this:
OpenMeshModel(
model_type=ANSYS,
file_name='C:\cube\cube.cdb',
retained_mats=[ALL],
retained_bcs=[ALL])
InsertFileFlaw(
file_name='C:\cube\cube_05.crk')
RunAnsysAnalysis(
file_name='C:\cube\cracked_cube',
flags=[QUADRATIC],
executable='C:\ANSYS Inc\v121\ansys\bin\WINX64\ANSYS121.exe',
command='"C:\ANSYS Inc\v121\ansys\bin\WINX64\ANSYS121.exe" -b -p
struct -i "C:\cube\cracked_cube.macro" -o "C:\cube\cracked_cube.out"',
license=struct)
ComputeSif(
load_case_factors=[[1,1,1]])
30
A complete description of the FRANC3D command language is provided in Section 12.
Selecting the Playback menu item invokes the Playback Session File selection dialog,
Figure 4.5.1. The user selects the desired session file and then selects OK. FRANC3D
will read and execute the commands from the session file.
Figure 4.5.1 Playback session file selection dialog.
4.6 Quit - Ctrl-Q

The File Quit menu item exits FRANC3D. As for the File Close menu item (see Section
4.2), the Save Model Warning dialog (see Figure 4.2.1) will be displayed if the model
has not been saved.
5. Edit Menu Wizards and Dialog Boxes

The wizards and dialog boxes for the Edit menu options are described in this section.
Note that the first two menu items, Undo and Redo, are inactive in Version 6.
5.1 Undo - Ctrl-Z

The Edit Undo menu item is intended to undo user actions. It is not active in Version 6.
31
5.2 Redo
The Edit Redo menu item is intended to redo actions that have been undone. It is not
active in Version 6.
5.3 Preferences…
Selecting the Edit Preferences menu item invokes the Preferences dialog, which allows
one to set program-wide configurations. These preferences are stored in a database that
is read when FRANC3D is started. Some settings might not take effect until the program
is restarted. The Preferences dialog has nine tabs, and each of these will be described
next.
5.3.1 Folders Tab
In the Folders tab, one can set the default working directory and the help file directory,
Figure 5.3.1.1. The working directory is the folder where the model files will be read
from and written to by default. The user can override the default directory when reading
the FRANC3D restart file as described in Section 4.1.1.
The Help File directory is the top level directory for the web-help files described in
Section 3.1. Help files are accessed from the Help menu. The web-help files can be
accessed over the internet, and they can be installed locally by the user. These will
consist of folders labeled as: FRANC3D_V6_Reference.web or similar for the various
FRANC3D documents.
Figure 5.3.1.1 Folders tab of Preferences dialog.
32
5.3.2 Window Tab
In the Window tab, one can set the font and colors used in the graphical user interface
windows, Figure 5.3.2.1. The GUI font Select button will pop up a dialog box that will
allow one to select from the available fonts, Figure 5.3.2.2. Clicking any of the color
swatches (colored rectangles) will pop up a dialog box, Figure 5.3.2.3, which allows one
to select a new color.
The Defaults button restores all values to default settings.
Figure 5.3.2.1 Window tab of Preferences dialog.
Figure 5.3.2.2 Font selection dialog.
33
Figure 5.3.2.3 Color selection dialog.
5.3.3 3D View Tab
The 3D View tab is used to set the combinations of mouse buttons and keyboard keys that
are used to invoke the view and select functions, Figure 5.3.3.1. One should ensure that
each function has a unique set of buttons and keys. The view manipulations were
described in Section 2.
Figure 5.3.1.1 3D View tab of Preferences dialog.
5.3.4 Display Tab
The Display tab allows the user to set the colors used for the 3D model view, Figure
5.3.4.1. Clicking any of the color swatches will pop up a dialog box (see Figure 5.3.2.3),
34
which allows one to select a new color. The line width can be set also; the default is 1,
but this value can be increased for thicker lines. The program can be restarted or the
model reread for this setting to take effect.
Figure 5.3.4.1 Display tab of Preferences dialog.
5.3.5 ANSYS Tab
The ANSYS tab allows the user to set default ANSYS analysis parameters, Figure 5.3.5.1.
Configuration details that do not change frequently, such as the path to the ANSYS
executable and the license type can be set here. These values will then appear as default
values for every ANSYS analysis.
Ansys Executable stores the path to the ANSYS executable program. The Browse button
will pop up a file browser that can be used to locate the program.
License Type stores the ANSYS license type.
Solver allows one to specify the ANSYS equation solver.
Total and Database Memory options allow one to set the amount of memory that will be
requested on the ANSYS command line (see ANSYS documentation for details).
Number of Processors is self-explanatory.
35
Figure 5.3.5.1 ANSYS tab of Preferences dialog.
5.3.6 ABAQUS Tab
The ABAQUS tab allows the user to set default ABAQUS analysis parameters, Figure
5.3.6.1. Currently, only the location of the ABAQUS executable (or batch) file location
can be set in the preferences. The Browse button will pop up a file browser that can be
used to locate the program. For MSWindows, one should choose the abaqus.bat file from
the ABAQUS Commands folder.
Figure 5.8 ABAQUS tab of Preferences dialog.
36
5.3.7 NASTRAN Tab
The NASTRAN tab allows the user to set default NASTRAN analysis parameters, Figure
5.3.7.1. The location of the NASTRAN executable file location can be set in the
preferences. The Browse button will pop up a file browser that can be used to locate the
program. The user can also choose the default setting for pyramid elements, depending
on their version of NASTRAN. MSC NASTRAN does not support pyramid elements, so
all pyramid elements in FRANC3D must be split into two tetrahedral elements. NX
NASTRAN supports pyramid elements, and these are preferred.
Figure 5.3.7.1 NASTRAN tab of Preferences dialog.
5.3.8 FEAWD Tab
The FEAWD tab allows the user to set default FEAWD analysis parameters, Figure
5.3.8.1. The location of the FEAWD executable file location can be set in the
preferences. The Browse button will pop up a file browser that can be used to locate the
program. Note that FEAWD is one of FAC’s in-house analysis codes.
37
Figure 5.3.8.1 FEAWD tab of Preferences dialog.
5.3.9 Meshing Tab
The Meshing tab allows the user to set default meshing parameters, Figure 5.3.9.1. The
options are listed here.
Max volume elements sets a limit on the number of volume elements FRANC3D can
generate.
Max backtrack restarts sets a limit on the number of FRANC3D volume meshing
attempts. If the volume meshing gets stuck, the program will backtrack and restarts.
Coarsen crack mouth turns on/off the mesh coarsening along the crack mouth.
Local surface refinement turns on/off the local surface mesh refinement.
Condense mesh turns on/off condensing of the mesh node and element numbering.
Start node id sets the starting node number if condensing is turned on.
Start element sets the starting element number if condensing is turned on.
Volume mesh using allows the user to choose between FRANC3D, ANSYS and
ABAQUS volume meshing.
For ANSYS/ABAQUS write files only allows the user to write the surface mesh and the
commands to generate the volume mesh from the surface mesh to files without actually
running ANSYS or ABAQUS. This gives the user the option of sending the files to a
38
different computer or modifying the commands. During the meshing phase of crack
insertion, FRANC3D will prompt the user to save the surface mesh files, and then will
wait for the volume mesh file to be selected.
Figure 5.3.9.1 Meshing tab of Preferences dialog.
6. Cracks Menu Wizards and Dialog Boxes

The wizards and dialog boxes for the Cracks menu options are described in this section.
6.1 New Flaw Wizard

The New Flaw wizard leads the user through the process of creating and orienting a
parametrically defined flaw. This wizard contains a number of different panels; however,
normally one will not see all panels. Choices in some of the panels determine which
panels are shown next. The overall flow is illustrated in Figure 6.1.1. Note that the
elliptical and through crack boxes house a couple of crack shapes.
The individual wizard panels are described below.
39
Figure 6.1.1 New Flaw wizard flow diagram.
6.1.1 Flaw type panel
The first panel determines the flaw type, Figure 6.1.1.1. This panel allows one to specify
that either a crack (zero volume flaw) or a void (finite volume flaw) should be inserted.
It also allows one to save the flaw description to a file. The default is to add the flaw to
the model without saving to a (.crk) file. The second radio button (Save to file and add
flaw) allows the user to save the flaw to a file and add it to the model. The third option
(Save to file only) saves the flaw to a file without adding it to the model.
Figure 6.1.1.1 New Flaw wizard first panel selects flaw type.
40
6.1.2 Crack type panel
The current crack types include: 1) an elliptical crack with one crack front – top left icon
in Figure 6.1.2.1, 2) a through-the-thickness crack with one front – bottom left icon, 3) a
through-the-thickness crack with two fronts – top middle icon, 4) a long-shallow surface
crack shape to be used instead of long thin ellipses – bottom middle icon, 5) an elliptical
crack shape with two fronts – top right icon, or 6) a user-defined crack – bottom right
icon). The crack fronts are indicated by the thicker lines. Selecting the crack shape icon
specifies the crack type that will be shown in the next panel.
Figure 6.1.2.1 New Flaw Wizard crack (zero volume flaw) types.
6.1.3 Elliptical crack panel
Single front elliptical cracks are defined by entering the semi-axes lengths (a and b).
Once values have been specified the length of the axes, the ellipse is displayed in the 3D
view window, Figure 6.1.3.1. The ellipse is displayed in its local orientation, which is in
the x-y plane and centered at the global Cartesian origin.
The Advanced Geometry button is common to all predefined crack shapes and will be
described in Section 6.1.9.
41
Figure 6.1.3.1 New Flaw Wizard elliptical crack parameters panel.
6.1.4 Single-front Through-the-thickness crack panel
Single-front through-the-thickness cracks are specified using three lengths (a – c) and the
width (d), Figure 6.1.4.1. If set appropriately, the three lengths can be used to define a
straight or a quadratic shape crack front. The crack is displayed in its local orientation,
which is in the x-y plane with one corner at the global Cartesian origin.
Figure 6.1.4.1 New Flaw Wizard single-front through-crack parameters panel.
42
6.1.5 Two-front Through-the-thickness crack panel
Two-front through-the-thickness center cracks are specified using six crack lengths (a – f)
and the crack width (g), Figure 6.1.5.1. If set appropriately, the six lengths can be used to
define either straight or a quadratic shape crack fronts. The crack is displayed in its local
orientation, which is in the x-y plane with one mid-side at the global Cartesian origin.
Figure 6.1.5.1 New Flaw Wizard two-front through-crack parameters panel.
6.1.6 Long shallow surface crack panel
Long-shallow-surface cracks are specified using the crack length (a), the crack width (b),
and a corner radius (c), Figure 6.1.6.1. This crack shape can be used in place of high-
aspect ratio elliptical surface cracks. The crack is displayed in its local orientation, which
is in the x-y plane with the global Cartesian origin as shown in Figure 6.1.6.1.
43
Figure 6.1.6.1 New Flaw Wizard long shallow surface crack parameters panel.
6.1.7 Two-front Elliptical crack panel
Two-front elliptical cracks are defined by entering the outer semi-axes lengths (a and b)
and the inner semi-axes lengths (c and d). The user also has the option of turning off the
crack front for either the outer or inner front; this allows one to define a circumferential
crack in the outer or inner wall of a pipe.
Once values have been specified for the length of the axes, the ellipse is displayed in the
3D view window, Figure 6.1.7.1. The ellipses are displayed in the local orientation,
which is in the x-y plane and centered at the Cartesian origin. Both outer axes must be
larger than the inner axes to create a valid crack.
44
Figure 6.1.7.1 New Flaw Wizard two-front elliptical crack parameters panel.
6.1.8 User-defined crack panel
The user-defined crack requires a set of points that completely defines the crack
boundary geometry, including the crack front. Click on Define Points, Figure 6.1.8.1, to
display a dialog that allows one to enter the geometry points, Figure 6.1.8.2. The front
pts field in Figure 6.1.8.2 allows one to define points as crack front points using a value
of 1; non-front points should have this field set to 0. Note that unless one is defining an
embedded crack, there typically should be at least one point on the crack boundary that is
not a crack front point. The front points are displayed in blue (Figure 6.1.8.1) and
numbered corresponding to the listing shown in Figure 6.1.8.2. Points must be
consecutive around the boundary.
One can read the points from a file using the File Open menu in the dialog shown in
Figure 6.1.8.2. The file should be a simple ASCII .txt file with the format:
x y z flag
x y z flag
x y z flag
…
The Smooth Front Points option in Figure 6.1.8.1 allows the user to smooth and re-
parameterize the crack front points. This allows for more uniform crack surface
geometry as the boundary points are used with a surface triangulation routine to produce
the interior crack surface geometry.
45
Figure 6.1.8.1 User-defined crack panel.
Figure 6.1.8.2 User-defined crack points dialog.
6.1.9 Advanced Geometry button
Selecting the Advanced Geometry button on any of the predefined crack shapes leads to
the dialog shown in Figure 6.1.9.1. The crack shape shown here corresponds to the
single front ellipse with major and minor axes equal. Note that the triangular facets
represent the geometry, not a finite element surface mesh.
There are three buttons on the top menu bar: Refine, Reset and Edit. The crack
geometry is shown in the window. The menu options are described below.
46
Figure 6.1.9.1 Crack Advanced Geometry dialog.
6.1.9.1 Refine
The Refine button alters the discretization of the crack surface geometry. Although
cracks notionally have an analytical geometry (e.g. elliptical or quadratic), they are
actually defined geometrically by triangular cubic-Bezier patches. These patches only
approximate the analytical form. As the number of geometry patches is increased, the
approximation improves, but at the cost of additional processing time required to insert
the crack. The Refine button performs a uniform refinement of the patches, where each
patch is divided into four smaller patches. This is illustrated in the images in Figure
6.1.9.2. The Refine process can be repeated any number of times.
Refinement might be required for higher-aspect ratio elliptical cracks, specifically for the
ends of the major axis.
6.1.9.2 Reset
The Reset button sets the crack geometry back to the original default configuration.
47
Figure 6.1.9.2 Example of a Refined crack geometry. The left panel shows one level of
refinement from Figure 6.1.9.1, and the right panel shows a second level of refinement.
6.1.9.3 Edit
The Edit button invokes the Flaw Editor, Figure 6.1.9.3. This dialog allows the user to
redefine the default shape of the flaw. The vertices (black circles in Figure 6.1.9.3) can
be selected by holding down the Shift key and selecting the black circle with the left-
mouse button. The vertices turn red when they are selected (see right panel of Figure
6.1.9.3). The red circle can be moved by holding down the Shift key and dragging the
item to the new location using the left mouse button. The x and y coordinates of the
vertex are shown in the fields near the top of the dialog.
Unselect the vertex by holding the Shift key down and picking a point that is not close to
any vertex. The undo and redo icons (to the left of the coordinate fields) allow the user to
undo (or redo) any movement of the vertices that is not desired.
Select Accept and the revised flaw shape will be shown in the initial Advanced Geometry
window (see Figure 6.1.9.1).
Select Accept in the Advanced Geometry window (see Figure 6.1.9.1) to return to the
regular flaw insertion wizard panel. The user can then proceed to locate and orient the
edited flaw in the model.
Note that the flaw editor must be used before rotating and translating the flaw.
48
Figure 6.1.9.3 Flaw Editor dialog. Left panel shows the initial geometry and right panel
shows edited geometry.
6.1.10 Ellipsoidal void panel
Ellipsoidal voids are the only void shapes currently available. They are defined by
entering the three semi-axes lengths (a, b and c), Figure 6.1.10.1. The void is displayed in
the local orientation and centered at the Cartesian origin.
Figure 6.1.10.1 New Flaw Wizard ellipsoidal void parameters panel.
49
6.1.11 Flaw translation and rotation panel
Once a flaw (crack or void) is defined, it must be inserted (translated and rotated) into the
proper location relative to the unflawed body. The flaw orientation panel displays the
flaw and the model in a 3D graphics window, along with controls to translate and rotate
the flaw, Figure 6.1.11.1.
The translations move the local origin of the flaw to a location in the Cartesian space of
the body. It is usually simpler to specify the translations first and then "zoom in" on the
display of the flaw before specifying the rotations.
Up to three rotations about the local (rotated) Cartesian axes can be specified. These are
essentially Euler angles, but the order of the rotation axes can be specified. The rotations
follow a "right-hand-rule" where the thumb points in the positive direction along the axis
and the fingers curl in the positive rotation direction.
There is an Orient with Vectors button at the bottom of the flaw rotations panel. This
button is described in the next sub-section.
Figure 6.1.11.1 New Flaw Wizard orientation panel.
6.1.11.1 Orient with Vectors
The Orient with Vectors button provides another way to specify the flaw orientation,
Figure 6.1.11.2. This button invokes a dialog box that allows one to specify the local x-
and y-axes of the flaw oriented relative to the Cartesian coordinates of the body.
50
Figure 6.1.11.1 New Flaw Wizard orientation vectors dialog.
6.1.12 Crack Front Mesh Template Panel
For accurate stress-intensity factor computations, a pattern or "template" of elements with

controlled sizes and shapes is placed about all crack fronts. The template takes the form
of generalized cylindrical tubes of elements with the crack fronts serving as the axes of
the cylinders. Wedge shaped elements are placed immediately adjacent to the crack
fronts. These are surrounded by rings of brick elements.
Figure 6.1.12.1 shows the Crack Front Mesh Template wizard panel with an elliptical
surface crack being inserted into a cube. The user can turn off the crack front template
elements with the use crack-front template toggle. In some cases, a crack front template
mesh cannot be added to the model; a crack front that touches or crosses a material
boundary currently is one such case.
The overall radius of the template can be adjusted with the Template Radius field. The
default value of the radius is based on the crack size and might be inappropriate. In
addition, the template radius can be decreased if a user wishes to do a mesh
refinement/convergence study.
The template elements are displayed in the 3D graphics window superimposed on the
flaw and model geometry. By default only one half of the template elements are shown.
This allows one to view the progression of element sizes as the elements transition from
the crack front to the outer boundary of the template. One can view the full template by
turning on the Display Full Template toggle.
The Simple Template Intersections Only toggle allows the user to terminate the template
inside the model surfaces. For cases where the template will intersect the model surface
at shallow angles or at corners, this option allows a crack to be inserted with template
elements along the bulk of the crack front.
The Meshing Parameters button at the bottom left is used to specify surface and volume
meshing parameters as well as choosing the volume mesher; this is described in Section
51
6.1.12.1. The Advanced Options button allows the user to adjust the template elements
and is described in Section 6.1.12.2.
Figure 6.1.12.1 Crack front mesh template panel.
Note that this panel is displayed even if the flaw does not have any crack fronts (e.g. an
elliptical void). In this case, simply ignore this panel and select finish.
6.1.12.1 Meshing Parameters Dialog
The Meshing Parameters dialog, Figure 6.1.12.2, is very similar to the Preferences
meshing tab described in Section 5.3.9. The user can control some aspects of the surface
and volume meshing.
The first parameter, Maximum Generated Elements, limits the total number of volume
elements that FRANC3D will create during volume meshing. The second parameter,
Maximum Volume Mesh Restarts, limits the number of volume meshing restarts. These
two options only work when FRANC3D is used for volume mesh. FRANC3D uses an
advancing front volume meshing algorithm; this algorithm can get stuck sometimes and
the algorithm is designed to backtrack (i.e., remove elements) and restart the meshing. If
the program fails to create a volume mesh after several restarts, then one can try volume
meshing with ANSYS or ABAQUS.
The next two options allow the user to control surface mesh refinement: on the crack
surface, using the Do Coarsen Crack Mouth Mesh option, and on the model surface in
areas where adjacent region boundaries are near, using Do Local Surface Refinement.
52
The user can force FRANC3D to condense and renumber the nodes and elements.
Turning on the Condense option activates the Start node id and Start element fields. The
default is to start the numbering at 1, but any integer value can be entered.
FRANC3D, by default, is used to mesh the volume, but ANSYS and ABAQUS can also
be used by selecting the appropriate radio button for Volume mesh using. Note that the
user must have a licensed working copy of these programs to use their meshing
algorithms. The user can select the ANSYS and ABAQUS executables, using the
Browse button, if not already set in the Preferences (see Section 5.3).
For ANSYS/ABAQUS write files only allows the user to write the surface mesh and the
commands to generate the volume mesh from the surface mesh to files without actually
running ANSYS or ABAQUS. This gives the user the option of sending the files to a
different computer or modifying the commands.
Figure 6.1.12.2 Meshing parameters dialog.
6.1.12.2 Advanced Template Options Dialog
The Advanced Template Options dialog allows the user to adjust some of the default
crack front mesh template parameters, Figure 6.1.12.3. The parameters are described
below and illustrated in Figure 6.1.12.4, which shows a typical cross-section of a crack-
front template.
Progression Ratio sets the relative width of the element (in the direction perpendicular to
the crack front) going from the crack front to the outer surface of the template. For
example, a ratio of 1 means that all the rings of elements will have the same width. For a
53
ratio of 1.5, the width of the elements in a ring will be 50% greater than the width of the
elements in the next ring as we approach the crack front.
Num Rings sets the number of rings of elements in the template.
Num Circumferential Elem sets the number of elements in the circumferential direction
around the crack front.
Max Aspect Ratio controls the aspect ratio of the quadrilateral faces on the outer surface
of the template that will trigger 1:2 or 1:3 transitions in the outer ring of elements.
Figure 6.1.12.3 Meshing parameters dialog.
template radius
num rings = 3
num circumferential elems = 8
progression ration = /
 
first ring
second ring
third ring
Figure 6.1.12.4 Crack front template cross-section.
54
6.1.13 Flaw Insertion
After one selects Finish on the crack front mesh template panel (see Figure 6.1.12.1), the
flaw is inserted into the body and the model is remeshed. This can be a computationally
intense process and might take a significant amount time for large models. An
information box is displayed to give a sense of the current status of these operations,
Figure 6.1.13.1. The crack geometry is inserted into the model geometry first,
represented by the Doing geometric intersections... status. Once the crack geometry has
been inserted, trimmed, and tied to the model geometry, surface and then volume
meshing occurs. The final mesh is smoothed to improve the element quality.
Figure 6.1.13.1 Flaw Insertion Status dialog.
6.2 Flaw from Files

The user has the option of saving the flaw to a .crk file when defining a new flaw (see
Figure 6.1.1.1). The Flaw from Files menu option allows the user to read one or more
.crk files and insert the crack(s) into the model. The Locate .crk flaw file dialog, Figure
6.2.1, is displayed, which allows the user to select one or multiple .crk files.
The flaw is displayed with the model using the Flaw Insertion wizard panels, starting
from the Translations & Rotations panel (see Figure 6.1.11.1).
55
Figure 6.2.1 Locate .crk flaw file dialog.
Note that the rotations are only valid for cracks with an origin at (0,0,0); a message is
printed to the console window, Figure 6.2.2, to remind the user of this.
Figure 6.2.2 Console window message regarding flaw-from-file rotations.
6.3 Multiple Flaw Insert

The Multiple Flaw Insertion wizard allows the user to add multiple cracks to a model,
Figure 6.3.1. The user defines each crack using the Flaw Insertion wizard panels
described in Section 6.1. When all cracks have been defined, they can be added to the
model and/or saved to a file.
The user starts by selecting the Add button in the dialog shown in Figure 6.3.1. This
leads to the flaw insertion wizard panels described in Section 6.1. Either voids or zero-
volume cracks can be added.
Once a crack has been added to the list, it can be edited or deleted by selecting the flaw
name and then selecting the Edit or Delete button. All of the added flaws can be
displayed in the model, Figure 6.3.2, to ensure that cracks do not overlap or intersect.
The set of radio buttons at the bottom of the panel allow one to: 1) add the flaws to the
model without saving to a file, 2) add the flaws to the model after prompting for a file
name to save the flaws, or 3) save the flaws to a file without adding them to the model.
Select Accept to close the dialog and begin the process of crack insertion and re-
meshing. The flaw insertion status window described in Section 6.1.13 will be displayed.
56
Figure 6.24 Multiple flaw insertion - top level dialog.
Figure 6.25 Multiple flaw insertion – flaw display window.
57
6.4 Stress-Intensity Factor
The user can compute and plot the stress intensity factors (SIFs) after performing an
analysis of the cracked model; the analysis menu is described in Section 9. SIFs are
computed at mid-side nodes along the crack front.
6.4.1 M-integral or Displacement Correlation Panel
The Compute SIFs menu option brings up the SIF Computation dialog box, Figure
6.4.1. Either the M-integral or displacement correlation method can be chosen to
compute the SIFs. The displacement correlation option generally is used only for
checking the M-integral values and is valid for isotropic materials only. For models
where a crack front template cannot be added, displacement correlation currently is the
only option.
Figure 6.4.1 Compute SIFs panel allows one to choose either M-integral or displacement
correlation computations.
Include Thermal Terms: The thermal terms can be included in the M-integral
computation. The nodal temperatures must exist in the results database and the user
should supply the reference temperature if not already given with the initial input file.
Include Applied Crack Traction: Any applied crack face traction/pressure terms should
be included in the M-integral.
Include Contact Crack Pressure: Any induced crack face contact pressure should be
included in the M-integral.
58
Note that it is possible to have both applied pressure and contact pressure on a crack
surface and these terms will be summed. Note that the ABAQUS Version 6.10 contact
pressures have been found to be incorrect.
Plot Stress Intensity Factors: Turn on/off the display of the SIF plot dialog, which is
6.4.1.1 Compute SIFs for Multiple Load Cases
For models with multiple load cases, if the user chooses to read results for more than one
of the load cases, the Compute SIFs panel has an extra set of options, Figure 6.4.1.1.
The load cases in FRANC3D are numbered from 1 to n. The user can choose to include
one or more of the load cases when computing SIFs using the check boxes under the
Include column. Load factors can be applied to each of the included load cases as well.
There are three options for combining the SIFs from multiple load cases. The first option
is to keep the SIFs separate, the second is to sum all SIFs, and then third option is to
sequence the SIFs. This last option combines the SIFs such that each load case
contributes to the crack growth direction based on a vector sum, Figure 6.4.1.2.
If the user wishes to plot the SIFs for a particular load case, only that load case should be
selected before clicking the Finish button. Otherwise the first load case, the summed, or
the sequenced SIFs will be displayed depending on the selected (bottom) radio button.
Figure 6.4.1.1 Compute SIFs panel for a model with multiple load cases.
59
Figure 6.4.1.2 Sequence of SIFs from multiple load cases used to predict cumulative
crack growth direction (from Spievak et al., EFM, 68, 2001).
6.4.2 SIF Plot Panel
Stress-intensity factor distributions are displayed in this dialog, Figure 6.4.2.1. The left
side of the dialog is a 3D graphics window that displays the model. The right side of the
dialog is a tab box that shows graphs of the computed stress-intensity factor distributions
along the crack front. The mode I, II, and III stress-intensity factors (KI, KII and KIII
tabs) are computed using the M-integral by default.
Figure 6.4.2.1 SIF plot panel.
60
The J-integral tab displays a plot of the total J-integral distribution (total energy release
rate not segregated into modal components). The T-Str tab displays a plot the T-stress.
The Table tab shows a table of the three SIF modes along with the parametric location
along the crack front, the N Coord value in the left panel of Figure 6.4.2.1.
The Export tab allows one to export the SIF data in tabular form, Figure 6.4.2.1 – right
panel. The user can specify the type of delimiters to use, the grouping of the data, and
order of the data. The program initially assigns one end of the crack front as A and the
other end as B. The data is plotted along the crack front, normalized from 0 to 1.0 by the
crack front length, starting from point A.
Figure 6.4.2.2 SIF table tab (left panel) and export tab (right panel).
6.5 Grow Crack

When the Grow Crack menu option is selected, if stress intensity factors have not yet
been computed for the current model the Compute SIF's wizard is presented first. This
wizard was described in Section 6.4.
The Crack Growth Parameters wizard is presented next if crack growth has not yet
been performed for the model. This wizard allows the user to specify algorithms and
parameters to determine the local direction and relative extension of crack growth. This
base wizard presents simplified models appropriate for most crack growth scenarios. It
also gives one the option to invoke the Advanced Crack Growth Parameters wizard,
which gives additional options. The Crack Growth Parameters wizard is described in
section 6.5.1. The Advanced Crack Growth Parameters wizard is described in section
6.5.2.
After the Compute SIF's and Crack Growth Parameters wizards are presented, if
necessary. The Crack Growth wizard is presented. This wizard allows one to specify
61
the amount of crack extension, crack front fitting algorithm and parameters, and crack
front element template parameters. This wizard is described in section 6.5.3.
6.5.1 Crack Growth Parameters Wizard
The Crack Growth Parameters wizard allows one to specify algorithms and associated
parameters that are used to predict the local direction of crack propagation and the
relative local amount of crack extension. The direction and extension are computed for
all growth evaluation points, which in most cases are the mid-side nodes of all crack front
elements.
6.5.1.1 First Growth Parameters Panel
The first panel in the wizard presents options for units, type of crack growth, algorithms
for predicting kink angles, and beta factors for mixed-mode kink angle algorithms, Figure
6.5.1.1.1.
Figure 6.5.1.1.1 First growth parameters wizard panel.
62
6.5.1.1.1 Crack Growth Units
The first option in the panel is Units. This tells the program how to interpret the
dimensions and boundary conditions in the FEM model. It is not a units conversion
feature. The options include metric (stresses in MPa, lengths in mm) and two options for
US customary units (stresses in psi, lengths in inches, and stresses in ksi, lengths in
inches). The unit information is used primarily for labeling plots. They are also used to
select the appropriate parameter values if the NASGRO v3.0 crack growth rate model is
specified and the material is selected from the built-in material database.
6.5.1.1.2 Growth Type
Crack growth predictions are made assuming either fatigue driven or quasi-static crack
growth. The fatigue growth algorithm uses a fatigue crack growth rate model ( da dN vs.
K ) in conjunction with the computed stress intensity factors in order to predict the
relative amount of crack growth for all crack front points. Currently there is only one
quasi-static model available, which uses an exponential function to determine relative
amount of growth for font points (§6.5.1.3). 

For fatigue crack growth, one must also specify whether the crack will be subjected to
constant or variable (spectrum) load cycles.
6.5.1.1.3 Kink Angle
The local direction of crack propagation is determined by the "kink" angle, which is
defined by the amount that the crack will deviate from the self-similar direction measured
in a plane perpendicular to the crack front. The kink angle is the  angle illustrated in
Figure 6.5.1.3.1.
Figure 6.5.1.3.1 Schematic illustration of the definition of the kink angle.
FRANC3D provides five algorithms for determining the kink angle, Maximum Tensile
Stress (MTS), Maximum Shear Stress (MSS), maximum generalized stress, maximum
strain energy release rate, and planar growth.
63
Maximum Tensile Stress
The MTS theory predicts that a crack will propagate in the direction where the "hoop"
stress,  , is maximum. For materials with isotropic stiffness properties, the hoop stress
is related to the resolved mode I stress intensity factor, K Ir , by the relation
   3 
 K Ir ( )   2r  cos K I cos 2  K II sin  (6.5.1.1.1)

2 2 2 
The expression for materials with anisotropic stiffness properties is considerably more
complex (see for example Banks-Sills, Wawrzynek, Carter, Ingraffea, and Hershkovitz,
"Methods for computing stress intensity factors in anisotropic geometries: Part II –
arbitrary geometry," Engng. Fracture Mech., 74, 9, 1293-1307, 2007) but can be
expressed symbolically as
K Ir ( )   2r  f I K I ,K II ,K III ,, (6.5.1.1.2)
where  characterizes the angle cosines between the material property axes and the local
crack-front coordinate system.

If an isotropic material toughness is specified (the default behavior), a numerical

algorithm is used to find the  angle that maximizes K Ir (and  ) in equation 6.5.1.1.1 or
6.5.1.1.2. If anisotropic toughness properties are specified, the kink angle is defined as
the angle that maximizes the ratio K Ir ( ) K p ( ) , where K p ( ) is a measure of the
materials directionally dependent resistanceto crackgrowth (§6.5.2.3).
Maximum Shear Stress  
Some materials exhibit crack growth in the direction of high shear stress, especially for
conditions of high shear loading at the crack front. The MSS theory predicts that a crack
will propagate in the direction where the resolved shear stress, s  r2  z2 , is
maximum. For materials with isotropic stiffness properties, the components of the shear
stress are related to the resolved mode II and III stress intensity factors by the relations
1  
K IIr ( )   r 2r  cos K I sin  K II (3cos  1)
2 2
(6.5.1.1.3)

K ( )   z 2r  K III cos
r
III
2
Symbolic expression for materials with anisotropic stiffness properties are


64
K IIr ( )   r 2r  f II K I ,K II ,K III , ,
(6.5.1.1.4)
K IIIr ( )   z 2r  f III K I ,K II ,K III , ,
where  characterizes the angle cosines between the material property axes and the local
crack-front coordinate system.

If an isotropic material toughness is specified (the default behavior) a numerical
 algorithm is use to find the  angle that maximizes the expression
 K ( )  III K IIIr ( )
2 2
K sr ( )  II
r
II (6.5.1.1.5)
where II and III are user supplied parameters that can be used to tailor predicted shear
crack growth direction to match assumed or predicted behavior (§6.5.1.1.4). Note that
MSS driven crackgrowth is not currently fully understood and there is no general
agreement on how to select the beta factors.
 
If anisotropic toughness properties are specified, the kink angle is defined as the angle
that maximizes the ratio K sr ( ) K p ( ) .
Maximum Generalized Stress


The generalized stress criterion predicts that the crack will grow in the direction that
corresponds the greater resolved stress intensity factor ( K Ir or K sr ) from the MTS or MSS
criteria. The beta factors (§6.5.1.1.4) can be set to tune the point of transition from
tensile to shear fracture, which will vary for different materials.
As a practical matter, if one portion of a crackfront is

 determined to be in tensile fracture
while another part is in shear fracture, there will likely be an abrupt discontinuity in the
predicted kink angles. Such a crack will probably not mesh successfully and if it does the
crack geometry probably will not be realistic. In such a case, the user should select either
the MTS or MSS criteria explicitly.
Maximum Strain Energy Release Rate
The maximum strain energy release rate criterion predicts that the crack will grow in the
direction that maximizes the rate of change of potential energy in the system due to crack
growth. For materials with isotropic toughness, this angle is determined by numerically
maximizing the expression
G( )  K Ir ( )  II K IIr ( )  III K IIIr ( )

2 2 2
(6.5.1.1.6)

65
where the resolved stress intensities are defined in equations 4.7.1.2.1 - 4.7.1.2.4. For
materials with anisotropic toughnesses (§6.5.2.3) the expression
K r ( ) 2  K r ( ) 2  K r ( ) 2

G( )  
K ( ) 
I
  
 K ( ) 
II II
  
 K ( ) 
III III
 (6.5.1.1.7)
 p   p   p 
is maximized. The beta factors (§6.5.1.1.4) can be used to tune the behavior for assumed
or observed material behavior.

Planar
The planar crack growth option forces the crack to grow with a zero kink angle (self
similar growth). It is recommended that this option be selected if it is known that the
crack is expected to grow in a plane. This will avoid small undulations that may develop
in the predicted crack surface due to numerical "noise" that can arise when computing the
kink angles using one of the other criteria.
6.5.1.1.4 Mixed Mode Beta Factors
The mixed mode beta factors, II and III are used to tune the maximum shear stress and
maximum strain energy density kink angle criteria for specific assumed or observed crack
growth behavior. The values are also used if the mixed-mode option is selected for
defining an equivalent stress intensity factors (§6.5.2.4.1).
 
6.5.1.2 Fatigue Growth Rate Model
If the Fatigue crack growth option is selected (§6.5.1.1.2), the second wizard panel
presented allows one to select a fatigue crack growth rate model and set the appropriate
parameters, Figure 6.5.1.2.1.
66
Figure 6.5.1.2.1 Fatigue crack growth rate model panel.
Paris
The Paris growth rate model defines a simple power-law relationship between the crack
growth rate and stress intensity factor range
da dN  C(K)n (6.5.1.2.1)
where da dN is the crack growth rate, K is the stress intensity factor range, and C and
n are user supplied parameters. Note that in the Paris the crack growth rate is not an
 ( R  K K ). In general, the value of the C parameter
explicit function of the R-ratio min max
will change for different R-ratios and it is up to the user to provide an appropriate value.

 The Paris model is not sensitive to near-threshold or near-critical crack growth behavior.

Walker
The Walker growth model augments the Paris model to introduce a R-ratio sensitivity. It
is expressed as
da  K n
 C   (6.5.1.2.2)
dN (1  R)1m 

67
where m is a material dependent parameter that usually has a value near 0.5. The R
dependence drops out at R = 0, so the C value provided should correspond to the C for R
= 0. The Walker model is not sensitive to near-threshold or near-critical crack growth
behavior.
NASGRO version 5
NASGRO is a fatigue life prediction program initially developed at the NASA Johnson
Space Flight Center and now supported and maintained by Southwest Research Institute.
Built into the NASGRO program is an analytical crack growth rate equation that
incorporates a number of features observed in real materials such as sensitivity to near-
threshold and near-critical growth, sensitivity to the R-ratio, and some small crack
sensitivity. The cost for the flexibility in the growth model is that there are sixteen fitting
parameters. Some are common material properties (e.g., yield stress), but most must be
determined by performing regression on empirical data.
The NASGRO package includes a database of pre-computed parameters for a wide range
of materials and product forms. However, as of NASGRO version 4, this database is
only accessible to members of the NASGRO consortium. As a practical matter, this
means that this model will be most useful to users who have access to the NASGRO
program and can access the parameters for a material of interest (see NASGRO version 3
below).
The NASGROv5 crack growth rate equation is:

 K th p
1
1  f n  
da  K 
 C   (6.5.1.2.3)
1  R   K max 
q
dN
1  
 K c 
where C, n, p and q are empirical constants. C and n are similar to the constants in the
Paris and Walker equations. However, while C in the Paris model should be selected to

correspond to the R-ratio of interest, and C in the Walker equation should be for R = 0, in
the NASGRO equation the C should correspond to a high R where closure effects are no
longer significant (usually an R of about 0.7)
f is a function that accounts for the crack front being open for only a portion of the load
cycle due to plasticity induced crack front closure. It is defined as
K op max( R, Ao  A1R  A2 R 2  A3 R 3 ) R 0
f    (6.5.1.2.4)
K max  A0  A1R 2  R  0
where the coefficients are given by:


68
  S 1 
A0  (0.825  0.34   0.05 ) cos max 
2
 2  0 
Smax
A1  (0.415  0.071 ) (6.5.1.2.5)
0
A2  1  A0  A1  A3
A3  2A0  A1 1
In these equations,  is a plane stress/strain constraint factor and Smax 0 is the ratio of
the maximum applied stress to the flow stress. Both are assumed to be fitting parameters

in this application.

K th is the threshold stress intensity factor range, belowwhich there is no crack growth.
It is approximated by the following empirical equations:
  
p
(1RC th )
 1
 K *   R p
 (1  A0 )(1R )C th R 0
 1
1  f 
K th   (1RC m )
(6.5.1.2.6)
 * 1  R  th p m
K1 1  f  (1  A0 )(C th RC th ) R 0

  
where
  a 1 2
K  K1 
*
 (6.5.1.2.7)
a  a0 
1
and Cth is an empirical constant, K1 is the observed threshold for a high R-ratio, and a0
is a small crack parameter (usually 0.0015in, 0.0381 mm).

K c is the fracture toughness. In FRANC3D, one has the choice to use the plane strain
  
fracture toughness, K Ic , the part-through toughness, K Ie , or compute it from:
t 0 )2
 K c  K Ic (1 Bke (Ak t ) (6.5.1.2.8)
 
where

 
2
t0  2.5 K Ic ys (6.5.1.2.9)
Ak and Bk are empirical constants, and t, the "thickness" is specified by the user (in many
3D applications the notion of thickness is not well defined and engineering judgment

must be used to set this value).
 
69
More details about this model can be found in the NASGRO theory manual.
The View/Edit Parameters button brings ups the NASGRO v5 Parameters dialog box
shown in Figure 6.5.1.2.2. The NASGRO model parameters can be entered in this dialog
box. There are also options to load parameters from a file and write the current
parameters to a file. The Label field is a user assigned text string.
Figure 6.5.1.2.2 The NASGRO v5 Parameters
NASGRO version 3
NASGRO version 3 is an earlier version of the NASGRO crack growth rate equation.
The current version of the equation (version 5) does a better job of modeling observed
crack growth rates for some conditions. This earlier version is included in FRANC3D
because version 3 of NASGRO, the last public domain version, included a database of
equation parameters for a wide variety of materials and product forms. That database is
accessible from within FRANC3D.
The main difference between the NASGROv3 equation and the NASGROv5 equation is
the expression for the threshold stress intensity factor range. In version 3, the expression
 a 
12
4 1
K th  K 0  tan (1  R)   (6.5.1.2.10)
 a  a0 
is used rather than eqns. 6.5.1.2.6 and 6.5.1.2.7.


The View/Edit Parameters button brings ups the NASGRO v3 Parameters dialog box
shown in Figure 6.5.1.2.3. The NASGRO model parameters can be entered in this dialog
70
box. There are also options to load parameters from a file and write the current
parameters to a file. The From Database button brings up a wizard, which allows one to
select a material and product form from a database. Figure 6.5.1.2.4 shows as series of
panels from this wizard.
Figure 6.5.1.2.3 The NASGRO v3 Parameters
Figure 6.5.1.2.4 Panels from the NASGRO v3 material parameters database wizard.
71
User Table
The User Table option allows one to read table of crack growth rates. The program will
interpolate within this equation to find a crack growth rate for a given K and R. The
table data must be read from a file. The Browse button allows one to select a file. The
required format for the file is described at the end of this subsection. The model label is a
user supplied text string. The View Table button brings up a dialog box showing the
prescribed growth rate data in a graphical and tabular form (Figure 6.5.1.2.5).
Figure 6.5.1.2.5 The User Growth Model display dialog box.
Given query values K query and Rquery , crack growth rates are extracted from the table
using the following algorithm:
1. Rl and Ru values are found that bracket the query value, Rl  Rquery  Ru .
 
2. K ll , K lu , K ul , and K uu are found where Kll  Kquery  Klu and
  Kul  Kquery  Kuu, with K ll and K lu values  associated with Rl and K ul and
K uu values associated with Ru .
    
3. Linear interpolation  in log/log
 space is used to find intermediate
 growth rate data,

 
72
 da 
da 
log
da 
 log (K ll ,Rl ) log
 
dN (K lu,Rl ) log K query K ll

 (K ll ,Rl )  logK lu /K ll 
dN l  dN  da
dN 
and
  da 
da 
log
da  
 log (K ul ,Ru ) logdN
(K uu,Ru ) 
log K query K ul 

 (K ul ,Ru )  logK uu /K ul 
dN u  dN  da
dN 
4. Finally, normal linear interpolation is used to find the final growth rate
 da da da da (Rqueary  Rl )
    
dN dN l dN u dN l  (Ru  Rl )
If during the interpolation process a query value ( Rquery or K query) is found to be larger
or smaller than the largest or smallest corresponding value in the table, the query value is

replaced with the largest or smallest, respectively, available value.

Not that, as with all interpolation procedures, theaccuracy of the results is dependent on
the density of the data available for interpolation. Very sparse tables can lead to
inaccurate and in some cases unrealistic crack growth predictions.
User Table File Format
The user table file format consists of a table of da/dN versus dK1 for given R values.
The R-ratio is used to label the columns of dK1 data. The rows represent the da/dN vs
dK1 data. The file is an ASCII text file.
dadN/R -1 -0.6 0 0.6

1.0000e-12 2.0469 2.1150 2.3531 2.6193
4.5249e-11 2.6618 2.6828 2.8066 2.8113
3.0422e-10 3.3872 3.3906 3.4624 3.2371
2.0454e-09 4.6844 4.7119 4.8342 4.4684
9.2459e-08 10.0399 10.4677 11.6805 12.6507
6.2164e-07 13.9172 14.6618 16.6286 17.2132
7.8884e-06 18.9059 19.8545 21.9998 20.0972
5.3036e-05 21.7701 22.6584 24.4075 20.8054
1.0000e-04 22.5218 23.3648 24.9475 20.9193
73
6.5.1.3 Quasi-Static Growth Model
If the Quasi-Static crack growth option is selected (§6.5.1.1.2), the second wizard panel
presented is shown in figure 6.5.1.3.1. Currently, the only quasi-static growth model
available in FRANC3D is based in a power law relationship among the crack front
points. The crack extension for any crack front point i is computed as
 K i n
ai  amedian  (6.5.1.3.1)
K median 
where amedian is the specified crack extension for the crack-front point with the median
K value, K median is the median K value, and K i is the stress intensity factor at crack front

point i, and n is a user supplied parameter that can be set on the panel.
 There is no theoretical basis for selecting an n value. In practice, values in the range of 2
to 3 seem to match observed crackshapes reasonably well.
Figure 6.5.1.3.1 Quasi-static crack growth rate model panel.
6.5.1.4 Constant Amplitude Panel
If the Fatigue and Constant Amplitude crack growth options are selected (§6.5.1.1.2), the
third wizard panel presented is shown in figure 6.5.1.4.1.
74
Figure 6.5.1.4.1 Constant amplitude fatigue model panel.
6.5.1.4.1 Crack Extension Type
There are two options for specifying the amount of crack extension at each crack growth
step: specified median extension or specified applied cycles. For specified median
extension, the crack extension at crack front point i is computed from the expression
 da 
 (K i ,Ri ,...) 
ai  amedian dN i
 (6.5.1.4.1)
da
 (K median,Rmedian,...) 
dN median 
where amedian is the crack extension specified for the point with the median stress
intensity factor range, da dN i is the crack growth rate computed at point i using the

specified growth rate model (§6.5.1.2), and da dN median is the crack growth rate
 computed at the crack front point with the median stress intensity value. The crack
growth rates at crack front points will be functions of the corresponding K , R (with the

exception of the Paris model), and other model dependant parameters.

Note that selection of the reference K value to use in equation 6.5.1.4.1 is somewhat
arbitrary. The maximum, minimum, and average K are reasonable  values to consider.
The median value is used in FRANC3D because experience shows that the maximum and
minimum values frequently occur where a crack front meets a free surface where the
accuracy of the computed stress intensity factors are known to be least accurate. In some
cases, the inaccuracy of these maximumand minimum values can lead to a very
unintuitive relationship between the reference specified amount of crack extension and
75
the actual predicted crack front. In extreme cases, inaccurate maximum and minimum
values can have a significant impact on the average value leading to an unintuitive
behavior for this measure also.
The expression for crack extension at crack front point i using the specified cycles option
is
da
ai  N  (K i ,Ri ,...) (6.5.1.4.2)
dN i
where N is the specified number of cycles and da dN i is the crack growth rate computed
at point i using the specified growth rate model (§6.5.1.2).

The Specified number of applied cycles approach seems more intuitive than the Specified
median crack front extension approach for many analysts. However, the fatigue crack
growth model are highly nonlinear functions so trial-and-error might be required when
using the applied cycles approach to find a number of cycles that will not give
exceedingly large or exceedingly small predicted crack extensions. Exceedingly large
values might give inaccurate results, while exceedingly small crack extensions might
require many crack growth steps or, in some cases, might cause meshing problems.
WARNING, if the Specified number of applied cycles is used to grow the crack, it is
strongly suggested that one does not use the sum of the specified cycles for a series of
crack growth steps as an accurate prediction of the fatigue life. Crack extensions
computed using this approach are made assuming that the stress intensity factor range
will remain constant over the step. In the vast majority of crack growth analyses the
stress intensity factors increase over each step. This means that the sum of the cycles
specified for all the steps will be a lower bound (unconservative) estimate of the fatigue
life. It is suggested that the FRANC3D Fatigue Life wizard (Section 10.2) or an external
fatigue life prediction program be used to calculate life (e.g., NASGRO or AFGROW).
These programs allow for a variation of the stress intensity factor over a crack growth
step.
6.5.1.4.2 Constant Amplitude R
For constant amplitude loading, the user must specify an R value that relates the stress
intensity factors computed in the analysis, K comp , to the stress intensity factor range used
to compute crack growth rates. The corresponding expressions are
K max  K comp , Kmin  RK max , and K  Kmax  Kmin (6.5.1.4.3)


If multiple load cases are being used, there are additional options for setting these values.
These are described in section 6.5.2.1.
  
76
6.5.1.4.3 Advanced Options
The Advanced Options button brings up the Advanced Options wizard described in
section 6.5.2.
6.5.1.5 Variable Amplitude Panel
If the Fatigue and Variable Amplitude crack growth options are selected (§6.5.1.1.2), the
third wizard panel presented is shown in figure 6.5.1.5.1.
Figure 6.5.1.5.1 Variable amplitude fatigue model panel.
6.5.1.5.1 Crack Extension Type
The Crack extension type options are described in Section 6.5.1.4.1.
6.5.1.5.2 Load Spectrum
The Load spectrum section allows one to specify a load spectrum (variable amplitude
load schedule) that is used when computing crack growth rates. A spectrum is defined as
a series of load ranges. Associated with each load range is an optional repeat count (the
default value is one). One can also specify a multiplier and offset that will be applied to
all values in the spectrum (e.g., to support the use of a normalized spectrum).
77
raw
If only one load case is used in the analysis, and load range i has specified values Smax,i
raw
and Smin,i the expressions used for computing the stress intensity factor ranges and R ratio
crack for range i are

Smax,i  sSmax,i
raw
 t , Smin,i  sSmin,i
raw
t (6.5.1.5.1)

Kmax,i  Smax,i Kcomp , Kmin,i  Smin,i Kcomp (6.5.1.5.2)
 
Ki  Kmax,i  Kmin,i and Ri  Kmin,i Kmax,i (6.5.1.5.3)
 
where s is the spectrum multiplier and t is the spectrum offset. The K i and Ri are used
to compute the crack growth rate for stress range i. If multiple load cases are being used
 
there are additional options for setting these values. These are described in section
6.5.2.1.
 
For variable amplitude loading, the crack growth rates used for computing the relative
amounts of crack growth for crack front points (eqns. 6.5.1.4.1 and 6.5.1.4.2) are the
average crack growth rates computed for one pass through the spectrum. That is
n
da
da
 dN i
(K i ,Ri ,...)
 i1
(6.5.1.5.4)
dN n
where da dN is the crack growth rate computed for any given crack front point n is the
number of load ranges in the spectrum.

The corresponding predicted kink angle is weighted average kink angle computed as

n
da
 dN i
(K i ,Ri ,...)   kink,i (K I ,i ,K II ,i ,K III ,i ,...)
kink  i1
n (6.5.1.5.5)
da
 dN i (K i ,Ri,...)
i1
where  kink,i is the kink angle determined (implicitly) for range i using one of the criteria
described in section 6.5.1.1.3.

In the Variable amplitude panel, the Spectrum File field gives the path and file name for
 the currently specified spectrum file (it is not editable). The Spectrum Label is a user
specified text string that can be used to identify the spectrum data. The Spectrum
multiplier and Spectrum offset are the s and t values, respectively, used in equation
6.5.1.5.1.
78
The Groups in spectrum and Group units values allow the user to set how plots and
reports are labeled. Analysts often find it convenient to group spectrum ranges into
larger units that represent meaningful engineering concepts (e.g. hours, flights, blocks,
etc.). The Groups in spectrum value specifies how many such groups are in the spectrum.
The Group units value is a label that identifies the group type. These values are primarily
useful in the Fatigue Life wizard (Section 10.2) where, for example a fatigue life plot
might show the crack length as a function of the number of flights, hours, blocks, or in
user specified units. The default value for the Groups in spectrum is one, and the default
value of Group units is "passes". The spectrum groups information is not used during
crack growth predictions, but the information can be specified in this wizard because, if
set, the load spectrum data will be transferred to the Fatigue Life wizard automatically.
The Read Load Spectrum button brings up the load spectrum input wizard. Load
spectrum data is assumed to be stored as columns of data in a text file. The columns can
be separated either by white space (spaces and tabs) or commas. The delimiters need to
be used consistently throughout the whole file.
The first panel in the wizard is a standard file selection dialog. The second panel is
shown in Figure 6.5.1.5.2.
Figure 6.5.1.5.2 The second load spectrum wizard panel.
The first option specifies if the data in the file represents sets of maximum and minimum
values from an already "counted" spectrum or if the data represents load points that will
be cleaned and counted by the program using a range-pair algorithm. If the file contains
only one column of data, only the latter option will be available.
The second option allows column delimiter to be specified.
79
The Data preview section displays how the file data will be segregated into columns
based on the specified delimiter type. It also gives the option to ignore the first line in the
file so that the first line can be used for identifying information or column labels.
If the Read a paired spectrum option is selected, the third panel is that shown in Figure
6.5.1.5.3.
Figure 6.5.1.5.3 The third load spectrum wizard panel for a paired file.
The pull-down boxes over each column are initially all set to "ignore". These can set to
identify the columns that specify the maximum, minimum, and, optionally, the repeat
count associated with each load range.
If the clean and pair option is selected and there is more than one column in the file then
the third panel is that shown in Figure 6.5.1.5.4. A pull-down box can be used to identify
the column that contains the load point data.
80
Figure 6.5.1.5.4 The third load spectrum wizard panel for a unpaired file.
The Plot Load Spectrum button brings up the Load Spectrum Display dialog. This is
shown in Figure 6.5.1.5.5. The Scaled Cycles tab shows the spectrum values after they
have been scaled and offset (eqn. 6.5.1.5.1). The tab shows the values as they appear in
the spectrum file. The magnifying glass icons allow one to view a smaller or greater
segment of the spectrum and the arrow icons allow one move forward and backward
through the spectrum.
Figure 6.5.1.5.5 The load spectrum display dialog box.
81
6.5.1.5.3 Advanced Options
The Advanced Options button brings up the Advanced Options wizard described in
section 6.5.2.
6.5.2 Advanced Crack Growth Parameters Wizard
The Advanced Crack Growth Parameters wizard allows one to specify advanced
algorithms and associated parameters to be used to predict the local direction of crack
propagation and the relative amount of crack extension. Because these algorithms are
only used in a minority of crack growth simulations, their selection and configuration has
been moved to the advanced wizard. This simplifies the basic crack growth parameters
wizard used for most crack growth scenarios.
6.5.2.1 First Advanced Growth Parameters Panel
One Load Case
The first panel presented by the advanced growth parameters wizard will depend on if the
program detects that there are results available for a single load case or for multiple load
cases. If results for only one load case are available, the first panel presented is shown in
Figure 6.5.2.1.1.
Figure 6.5.2.1.1 The first panel presented when only one case is available.
82
The Scale option allows the user to specify a linear scaling for the computed stress
intensity factors. This can be used, for example, if stress analysis was performed using
normalized or otherwise scaled loads and one now wishes to scale the loads (and
computed stress intensity factors) to be scaled to the actual in-service values.
Multiple Load Cases, Constant Amplitude
If there are results available for more than one load case and constant amplitude loading
is selected (§6.5.1.1.2), the first wizard panel that will be presented is shown in Figure
6.5.2.1.2.
Figure 6.5.2.1.2 The first panel presented for constant amplitude and multiple load cases.
The purpose of this panel is to allow the analyst to specify how the stress intensity factors
that correspond to the various load cases will be grouped together to define K max and
K min , which are used to determine the K and R values used in the fatigue crack growth
rate model (§6.5.1.2).

The first option is to set K max equal to the sum of the stress intensity factors for all load
 
cases and K min equal to the K max times the constant amplitude R-ratio (§6.5.1.4.2):
n
 K max   K i and Kmin  RK max . (6.5.2.1.1)
  i1

 83
This is the default behavior.
The second option sets K max equal to the sum of the stress intensity factors from one or
more load cases and K min equal to sum from one or more different load cases:
n m
 K max   K i and K min   K j (6.5.2.1.2)
 i1 j1
This option is useful for cases where there is there is a nonlinear relationship between the
structural response in the maximum and minimum loading configuration. This might
  nonlinearities are present.
happen, for example, if contact or other
Actually selection of load cases for the max and min groups is done on the following
wizard panel.
The third option sets K fixed equal to the sum of the stress intensity factors from one or
more load cases and K variable equal to sum from one or more different load cases:
n m
 K fixed   K i
and K variable   K j . (6.5.2.1.2)
 i1 j1
These are combined to define K max and K min as

 
Kmax  Kfixed  Kvariable and Kmax  Kfixed  Rrel Kvariable (6.5.2.1.3)
 
where Rrel can be specified on the following wizard panel.
Twocommon applications for this option

 are to model combined high and low cycle
fatigue (HCL/LCF) and a fixed "dead" load with an alternating "live" load. These are
 illustrated in Figure 6.5.2.1.3.
(a) (b)
Figure 6.5.2.1.3 Common applications for the fixed/variable load option: (a) combined
high and low cycle fatigue, and (b) fixed dead load and variable live load.
84
The fourth option is for Sequentially applied load cases. Typical examples of this are
rolling contact or meshing of gear teeth, where a continually varying load location and
magnitude is approximated by a series of load steps with each step in its own load case.
The sequential loading algorithm assumes that Kmin  0 and K max is equal to the
maximum K I of all the load cases and
Kmax  MAX(KI, i ) . (6.5.2.1.4)

 

In many such applications, the mode mixity changes thought the load sequence, which
affects the predicted kink angle. An algorithm has been implemented that predicts the
total effective kink anglefor the full loading sequence from the vector sum of the
predicted crack growth angles and extension from each of the load steps in the sequence
(see Figure 6.4.1.2). That is:
y 
 kink  tan1  (6.5.2.1.5)
x 
with
n n
x   ai  cos  i and y   ai  sin i . (6.5.2.1.6)
i1 i1
where i is the current step in the sequence and n is the total number of steps in the
sequence (number of load cases). The kink angle for step i
 
i  f (KI , i ,KII , i ,KIII , i ) (6.5.2.1.7)
is computed using the selected kink angle algorithm (§6.5.1.1.3). The crack extension for
step i is computed as

 K I , i  K I , i1
atotal  K I , i  Kopening
ai   MAX(K I , i ) (6.5.2.1.8)
 0 K I , i  Kopening

with atotal computed from the selected crack growth rate model (§6.5.1.2) using
K  MAX(KI, i ) , R  0, N 1. In eqn. 6.5.2.1.7 K I, 0  0 and

 f  MAX(K I , i ) NASGRO v3 & v5

Kopening   (6.5.2.1.9)
    0  Paris, Walker, Table
where f is defined in eqn. 6.5.1.2.4.


85
Multiple Load Cases, Variable Amplitude
If there are results available for more than one load case and constant variable loading is
selected (§6.5.1.1.2), the first wizard panel that will be presented is shown in Figure
6.5.2.1.4.
Figure 6.5.2.1.4 The first panel presented for variable amplitude and multiple load cases.
The first option is to set K max equal to the sum of the stress intensity factors from one or
more load cases times the load spectrum maximum value for the current load range,
Smax , and K min equal to the sum from one or more different load cases time the
minimum load range value:

n m
  K max  Smax  K i
and K min  Smin  K j . (6.5.2.1.8)
i1 j1
The second option sets K fixed equal to the sum of the stress intensity factors from one or
 and K variable equal tothe sum from one or more different load cases
more load cases
(eqn. 6.5.2.1.2) and computes the maximum and minimum values as

K  Kfixed  Smax Kvariable and Kmin  Kfixed  SminKvariable . (6.5.2.1.9)
 max
This allows one to model a static load with a superimposed variable amplitude load.
 
86
6.5.2.2 Second Advanced Growth Parameters Panel
The second Advanced Growth Parameters wizard panel presented will appear slightly
different depending on which load case strategy (§6.5.2.1) was selected. The various
panels are shown in Figures 6.5.2.2.1 through 6.5.2.2.3.
Figure 6.5.2.2.1 The second wizard panel if a simple sum load strategy was selected.
Figure 6.5.2.2.2 The second wizard panel if a Max/Min sum load strategy was selected.
87
Figure 6.5.2.2.2 The second wizard panel if a Fixed/Variable sum load strategy was
selected.
6.5.2.2.1 Load Case Multipliers and Offsets
The Load Case Multipliers and Offsets allows the user to set parameters for each of the
load cases. By default, all load cases are selected to be Active. If the load case is set to
be "inactive" it is not considered when computing stress intensity factor ranges.
The Scale is a load factor or multiplier that will be applied to the load cases. The load
and the corresponding stress intensity factors will be scaled by this amount.
If the Max/Min sum or Fixed/Variable load case strategies are selected then the Grouping
options allows one to assign load cases to the appropriate group. In this case, one cannot
proceed to the next panel until at least one load case is assigned to each of the groups.
6.5.2.2.2 Relative R for Fixed/Variable Loads
If constant amplitude loading (§6.5.1.1.2) and a fixed/variable load case strategy have
been selected, the Relative R for Fixed/Variable Loads item will be enabled. This value
will be used to determine the minimum stress intensity factor as described in section
6.5.2.1 and illustrated in Figure 6.5.2.1.3.
88
6.5.2.3 Third Advanced Growth Parameters Panel
The third Advanced Growth Parameters panel allows one to specify the nature of a
material’s resistance to crack growth. This panel is shown in Figure 6.5.2.3.1. The
default setting is that a material is isotropic in toughness. In this case, the direction of
crack growth will be predicted based on the near crack-tip stress fields only. As
mentioned in section 6.5.1.1.3, if an anisotropic resistance to crack growth is specified
then the kink angle will be the angle that maximizes the expression K r ( ) K p ( ) , where
K r is the appropriate resolved stress intensity factor (see §6.5.1.1.3) and K p is the
resistance to crack growth.

 
Figure 6.5.2.3.1 Third advance crack growth parameters wizard panel.
Currently, FRANC3D supports one anisotropic crack growth resistance model. It is an

orthotropic model based on six principal material toughnesses. These toughnesses are
illustrated in Figure 6.5.2.3.2. In the figure, the e's are the material property axes, which,
in general, will not be aligned with the global Cartesian or the crack front coordinate
systems. The first toughness subscript identifies the material axis perpendicular to the
crack plane and second subscript gives the direction of propagation.
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Figure 6.5.2.3.2 Orientations for the six principal material toughnesses.
Figure 6.5.2.3.3 shows the crack-front orientation and defines the a and n vectors. x, y,
and z are local crack-front coordinate axes that, in general, are not aligned with the global
Cartesian coordinate axes.  is the local kink angle.

Figure 6.5.2.3.3 Definition of the crack-front a and n vectors.
The crack orientation and kink angle sensitive local resistance to crack growth K p ( ) is
given by
 2 l  2 l  2 l 1 2l

n1 n2 n 3  
K p (n,a)          (6.5.2.2.1)
K 2  K 2  K 2 
     
 1 2 3  
 90
 2 n 2 n
1 2n
a 
 j   ak  
Ki (a)  1  ai2 
K 2   K 2  
(6.5.2.2.2)
 ik  
 ij 
 
where Kij and Kik are the principal toughnesses (no summation on repeated indices), ai
and ni are the Cartesian
 components of the a and n vectors, and l and n (no subscript)
are shape parameters. The n shape parameters control the shape of the toughness
envelope
 in the principal planes. For example, Figure 6.5.2.3.3 shows the variation
 in K 3

as function of  assuming that crack front coordinates are aligned with the Cartesian
 coordinates. The l shape parameter has a similar effect on the variation of the toughness
between the principal planes.


Figure 6.5.2.3.3 The variation in K 3 as function of  assuming that crack front

coordinates are aligned with the Cartesian coordinates.
 
6.5.2.4 Fourth Advanced Growth Parameters Panel
The fourth Advanced Growth Parameters panel is shown in Figure 6.5.2.4. This panel
allows one to set how mixed model loading and negative minimum stress intensity
factors are handled when computing crack growth rates. Within FRANC3D, crack
growth rates are computed as:
da
dN equivalent equivalent
 f Keffective ,Reffective , ... ,  (6.5.2.4.1)
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
where the equivalent values account for mixed mode behavior and the effective values
account for the possibility that the crack might be closed for a portion of the cycle.
Figure 6.5.2.4.1 Forth advance crack growth parameters wizard panel.
6.5.2.4.1 Mixed-mode equivalent K
FRANC3D computes separate stress intensity factors for all three modes of fracture ( K I ,
K II , and K III ). However, conventional crack growth rate models (§6.5.1.2) consider
only one stress intensity factor range. By default, FRANC3D uses the mode one stress
intensity factors when computing the maximum and minimum effective stress intensity
factors 
 
equivalent
K max  K I ,max
. (6.5.2.4.2)
equivalent
K min  K I ,min
FRANC3D also provides the option to use an equivalent stress intensity factors that is a
function of all three modes of fracture

   (III KIII ,max )2

equivalent 2
K max  K I2,max  II K II ,max
(6.5.2.4.3)
K I2,min  II K II ,min   (III K III ,min) 2
equivalent 2
K min 
 92
where II and III are user defined modal weighting parameters. Note that these are the
same values described in section 6.5.1.1.4. If the values are modified on this panel it will
affect the values used to compute kink angles.
 In both
 cases, the equivalent stress intensity factor range and R-ratio are computed as
equivalent
K equivalent  K max
equivalent
 K min
. (6.5.2.4.4)
equivalent
Requivalent  K min equivalent
K max
6.5.2.4.2 Effective Delta K


Effective values of the stress intensity factor range and the R-ratio account for the
situation where the crack is actually closed during a portion or all of a load cycle. The
default behavior in FRANC3D is to check for a closed crack for the complete cycle and
to set the stress intensity factor range and R-ratio to zero:
 0 equivalent
K max 0
equivalent
Keffective   equivalent equivalent (6.5.2.4.5)
K K max 0
and
  equivalent
equivalent 0 K max 0
Reffective   equivalent equivalent . (6.5.2.4.6)
R K max 0
This default behavior allows for negative R-values.
FRANC3D allows the option to truncate the stress intensity factor range to eliminate the
negative (closed) portion of the cycle. In this case, the expressions are
 0 equivalent
K max 0
equivalent
 equivalent equivalent
Keffective  K K min 0 (6.5.2.4.7)
 equivalent equivalent
 K max K min 0
and
  equivalent
0 K max 0
equivalent
 equivalent
Reffective  Requivalent K min 0 (6.5.2.4.8)
 equivalent
 0 K min 0

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Note that there are a number of mechanisms that have been identified as being able to
keep the crack closed even when the current "remote" loading is positive. The most
significant being plasticity induced crack closure. This is one proposed explanation for
the observed dependency of crack growth rates on the R-ratio. The effective values
computed here do not explicitly take this into account (plasticity induced closure is
handled implicitly by some of the available crack growth rate models), they only consider
"global" closure where the currently applied "remote" load is negative.
6.5.3 Crack Growth Wizard
The Crack Growth wizard allows one to specify the amount of extension and the fitting
and crack front template mesh parameters. There are two panels, both of which display
the model and allow the user to view the new crack front as the parameters are adjusted.
This wizard will be invoked once SIFs have been computed and growth parameters have
been set.
6.5.3.1 First Crack Growth Panel
The first crack growth wizard panel, Figure 6.5.3.1.1 allows one to adjust the median
extension or number of cycles and to set the fitting and extrapolation parameters to
provide the best fit function through the computed new crack front points. The model is
displayed in the upper 3D model view window and the user can select a camera position
that shows the computed new crack front points.
The lower third of the window usually contains two panes: the crack extension and the
front fitting options pane. For multiple crack fronts, there is an extra Grow crack fronts
pane, Figure 6.5.3.1.2.
6.5.3.1.1 Crack Extension Pane
The Crack extension pane allows one to switch between median extension and number of
cycles. The user can also set the values for these two parameters here. The crack front
points will be redrawn in the model view window as these values are adjusted.
The Edit Growth Params button allows the user to modify the crack growth parameters
that were previously defined, see Section 6.5.1.
The Show SIFs button allows the user to display the SIFs, see Section 6.4.
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6.5.3.1.2 Grow Crack Fronts Pane
When there are multiple crack fronts in a model, an extra Grow crack fronts pane (see
Figure 6.5.3.2) allows one to grow specific crack fronts using the grow check-boxes. In
addition, the extension for a selected crack front can be scaled up or down by adjusting
the associated factor.
Figure 6.5.3.1.1 First crack growth wizard panel – extension and fitting options.
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Figure 6.5.3.1.2 Crack growth wizard extension and fitting options for multiple crack
fronts.
6.5.3.1.3 Front Fitting Options Pane
The Front fitting options pane includes seven options for curve fitting, fields for
extrapolating the ends of the fitted curves, and the option to discard crack front points at
either end. The curve fits options are: 1) kink angle/extension poly, 2) fixed order poly,
3) Hermitian, 4) cubic spline, 5) moving poly, 6) partial smoothing, and 7) no smoothing.
There are described in more detail below.
The polynomial order for any of the poly-fitting options can be set in the fixed poly order
field. The default order is 3.
The ends of the fitted curves can be extrapolated to ensure that the curves intersect the
model surface. It is required that the crack surface geometry intersect the model surface.
New crack surface geometry is created between the current and new crack fronts.
FRANC3D tries to ensure that the curves are extrapolated far enough, but the user also
can visually determine whether the extrapolation is sufficient.
A set of points at either end of the crack front can be ignored. If the end points cause
problems in fitting or extrapolating, the user can ignore some of these end points.
The create .crk file option allows the user to save the new crack geometry to a file before
inserting it into the model. The write .frt file button allows the user to save the front
points on the current and new front to an ASCII file. This file can be read using the Read
Crack Growth wizard, which is described in Section 6.6.
The Kink Angles and Extension buttons bring up plots of the computed kink angle,
Figure 6.5.3.1.3 – left panel, and crack front extension, Figure 6.5.3.1.3 – right panel,
along the crack front, respectively.
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Figure 6.5.3.1.3 Plots of kink angle and crack front extension along the crack front.
Kink Angle/Extension Poly Fit
Using the kink angle and extension data, a best fit polynomial is fit through the data,
using polynomial orders up the value entered in the fixed poly order field. The curve-fits
can be extrapolated and then new extrapolated crack front points are defined based on
these and also on the existing crack front geometry.
As an example, consider a penny-surface crack with the kink angle and extension shown
in Figure 6.5.3.1.3. Figure 6.5.3.1.4 shows the initial crack boundary edges, the actual
crack surface, which is shaded grey, the new front points as green dots, and the curve fit
shown as a blue line. The black dots on the original crack front correspond to the fitted
front points, where the extension and kink angle are applied to produce the new fitted
points. The kink angle and extension curves are extrapolated to compute these new end
points that fall outside the model.
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Figure 6.5.3.1.4 New front fit based on kink angle and extension curve-fits.
Fixed order poly through points
The fixed order polynomial option is the simplest and most commonly used fitting
option. A polynomial is fit through the new front points in Cartesian space based on a
least-squares fit. The order of the polynomial is provided in the fixed poly order field.
This polynomial can be extrapolated a small distance to make sure the new front
intersects the model surface. Best results are obtained with low order polynomials and
limited extrapolation; if the crack front does not suit a simple polynomial, one of the
other fitting options should be chosen.
Hermitian closed poly
The Hermitian polynomial is used for fitting closed crack fronts such as interior cracks.
It is not active if all of the cracks are open-ended surface cracks. The Hermitian fit is
performed using four equal segments, thus it works best for circular or elliptical shapes.
Cubic spline
A cubic spline fit can be used for crack fronts that do not allow for a simple low order
polynomial fit. A cubic spline will follow arbitrary curves. The ends of the crack front
are extrapolated using a linear segment through the end points for open-ended surface
cracks.
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Moving polynomial
A moving polynomial fit uses the polynomial order given in the fixed poly order field. A
subset of the crack front points is used for successive curve fits, moving along the full
crack front in increments from one end to the other. Like the cubic spline fit, this option
is good for arbitrary curves. The ends of the crack front are extrapolated using a linear
segment through the end points for open-ended surface cracks.
As an example of crack fronts that do not work well with a simple polynomial fit,
consider the crack fronts in Figure 6.5.3.1.5. Figure 6.5.3.1.6 shows these same crack
fronts using a moving polynomial fit; similar results can obtained for cubic spline fits. In
the first example in Figure 6.5.3.1.5, am 8th order polynomial fits the data, but
extrapolating a high order polynomial does not work well; in this case the extrapolated
curve does not intersect the model surface. A low order polynomial does not provide a
good fit through the data. In the second example, a 12th order polynomial cannot capture
the curve. As shown in Figure 6.5.3.1.6, a moving polynomial (or spline fit) follows the
data and provides good extrapolated end points.
Figure 6.5.3.1.5 New front fit based on a simple polynomial fit.
Figure 6.5.3.1.6 New front fit based on a moving polynomial fit.
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Partial smooting/extrapolation
Partial smoothing is designed for crack fronts where part of the crack front does not
advance. An example of this is a through crack in a plate subject to bending where half
of the crack is open and half is closed.
Figure 6.5.3.1.7 New front fit based on a partial smoothing fit.
No smoothing or extrapolation
The final option removes all smoothing and extrapolation. This option will generally
only be used when reading crack growth from a file where the front points have been
defined by the user and no fitting or extrapolation is desired.
6.5.3.2 Second Crack Growth Panel
The second crack growth wizard panel, Figure 6.5.3.2.1 allows one to set the crack front
mesh template parameters. The model is displayed in the upper 3D model view window
and the user can select a camera position that shows the template. The lower third of the
window contains one pane for the template parameters. The template parameters and
buttons are identical to those for inserting a new crack, see Section 6.1.12.
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Figure 6.5.3.2.1 Second crack growth wizard panel – crack front mesh template options.
6.6 Read Crack Growth Wizard

The Read Crack Growth wizard consists of two panels. The first, Figure 6.6.1, allows the
user to specify the file name containing the new crack front points.
Figure 6.6.1 Read new crack front - file import dialog.
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The format for this file is simply: "x y z" ; one set of coordinates per line.
The second panel, Figure 6.6.2, displays the new front points within the model and allows
the user to specify the fitting, extrapolation and template parameters. The front fitting
options pane is identical to that described in Section 6.5.3.1.3. The flaw template pane is
identical to that described in Section 6.5.3.2.
Figure 6.6.2 Read new crack front - display panel.
6.7 Grow/Merge Cracks Wizard

The Grow/Merge Cracks wizard is not activated yet. The current implementation
allows co-planar cracks whose advancing crack fronts intersect, Figure 6.7.1, to be
merged to create a single crack, Figure 6.7.2. The implementation requires manual
selection of the front points that will be merged. These front points are written to a text
102
file that can be read using the new flaw user-defined crack algorithm that was described
in Section 6.1.8. This capability will be enhanced before it is finally activated.
Figure 6.7.1 Grow/Merge Cracks – two co-planar cracks whose advancing fronts
intersect.
Figure 6.7.2 Grow/Merge Cracks – two co-planar cracks merged.
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7. Materials Menu Wizards and Dialog Boxes
The wizards and dialog boxes for the Materials menu options are described in this
section.
7.1 Material Properties

This wizard allows one to define a new material or to view the existing materials, Figure
7.1. If model that is read into FRANC3D contains material data, the user can view the
material data but cannot define a new material. If the model does not contain material
data, the user can add a material. The left panel of Figure 7.1.1 corresponds to the case
where material data exists, and the right panel corresponds to the case where there is no
material data.
Figure 7.1.1 Material properties dialog – view material or define a new material.
7.1.1 View Material
For the first case, where a material is defined, the user can view the material data. A list
of materials identified by name or number is presented, Figure 7.1.2 – left panel. The
user selects the material name and the properties and their values are then displayed,
Figure 7.1.2 – right panel. Temperature dependent material data is displayed based on
ascending temperatures.
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Figure 7.1.2 View material properties dialogs; left panel lists the materials identified by
name or number and right panel displays the properties.
7.1.2 New Material
For the case of no defined material, the user is presented with a different set of dialog
boxes that allow a material to be defined. The user first must choose between isotropic
and orthotropic material types, Figure 7.1.3. The user can set the material id and the
temperature value also. Depending on the selection of the material type, the dialog
shown in the left or the right panel of Figure 7.1.4 will be displayed. The user can set the
appropriate values and then Finish.
Figure 7.1.3 New material – isotopic or orthotropic.
105
Figure 7.1.4 New material properties for isotropic (left panel) or orthotropic (right
panel).
7.2 Apply Material

The Apply Material dialog, Figure 7.2.1, allows one to apply a material id to all the
elements in the current model. Select the material from the list and its id will be attached
to all of the elements in the model.
In practice, this option is rarely used. The elements created during crack insertion and
remeshing will obtain their material data from the original uncracked finite element
model.
Figure 7.2.1 Apply Material id panel.
7.3 Apply Coordinate System

This Apply Coordinate System dialog, Figure 7.3.1, allows one to apply a coordinate
system id to all the elements in the current model. Select the coordinate system from the
list and its id will be attached to all of the elements in the model.
In practice, this option is rarely used. The elements created during crack insertion and
remeshing will obtain their coordinate system from the original uncracked finite element
model.
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Figure 7.3.1 Apply Coordinate System id panel.
8. Wizards and Dialog Boxes for Loads Menu

The wizards and dialog boxes for the Loads menu options are described in this section.
8.1 Map Current State

The Map Current State option is intended to allow one to map initial conditions or current
state information, such as stress or strain, from the current model to the model after crack
insertion or growth. Mapping is done by interpolating data from the current mesh based
on element shape functions to points, either nodes or gauss points, of the new mesh.
This menu item is currently disabled.
Temperatures and other boundary condition data that must be transferred from one model
to the next occurs automatically.
8.2 Crack Face Pressure/Traction

The Crack Face Pressure/Traction option allows one to define crack face pressures or
tractions. This capability is often used to simulate residual stresses. It can also be used
in a local/global modeling approach where the local model containing the crack is
analyzed using crack face tractions based on the stresses from the uncracked global
model.
The first panel of the wizard is shown in Figure 8.2.1. The user selects Add to create a
new entry in the list. Once an entry has been added, it can be edited or deleted by
selecting the name and then the Edit or Delete button.
The Crack Face Traction/Residual Stress Type panel is displayed next, Figure 8.2.2; it
allows one to choose the type of crack face loading. The choices are: 1) Constant crack
face pressure, 2) 1-D Radial residual stress distribution, 3) 2-D Radial residual stress
distribution, 4) Surface treatment residual stress distribution, and 5) Residual stress
defined on a mesh. These types will be described in more detail below.
107
In addition to choosing the type of crack face traction, the user can specify the load case
(or load step) for this boundary condition. The default is load case 1. The user must
ensure that sufficient constraints exist for this load case before analyzing.
Figure 8.2.1 Crack Face Tractions – top level dialog.
Figure 8.2.2 Crack Face Tractions – type dialog.
8.2.1 Constant Crack Face Pressure Panel
The constant crack face pressure panel allows one to specify a uniform pressure on the
crack face, Figure 8.2.3. A positive pressure value will tend to open the crack.
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Figure 8.2.3 Constant Crack Face Pressure panel.
8.2.2 1-D Radial Residual Stress Distribution Panel
The 1-D radial residual stress distribution panel allows one to specify a radial distribution
of stress that can be applied to the crack face, Figure 8.2.4. The stress varies along a
radius from some origin. The user can specify the distribution axis as well as the axis
offset. The user can select the Define Distribution button to interactively define the
distribution, Figure 8.2.5.
Figure 8.2.4 1-D radial residual stress distribution panel.
109
Figure 8.2.5 User defined 1-D radial residual stress distribution plot.
As an example, consider a corner crack in a brick, Figure 8.2.6 – left panel. The crack
has a radius of 2.0 and the corner is located at x=0, y=5, and z=5. A 1-D radial
distribution is defined, Figure 8.2.7 – right panel, with the distribution axis set to y and
the axis offset defined as x=0 and z=5. The crack face traction distribution is shown in
Figure 8.7 – left panel. To visualize the pressure that is applied to the crack, the ANSYS
color contours for the pressure values are shown in Figure 8.2.7 – right panel. This
image shows how the radial pattern of the pressures with the origin at the crack corner.
Figure 8.2.6 A corner crack in a brick (left panel) with a 1-D radial residual stress (right
panel).
110
Figure 8.2.7 A 1-D radial residual stress distribution (left panel) applied to the corner
crack and shown as color contours in ANSYS (right panel).
8.2.3 2-D Radial Residual Stress Distribution Panel
The 2-D radial residual stress distribution panel allows one to specify a stress distribution
that varies in 2 directions (axial and radial) that can be applied to the crack face, Figure
8.2.8. The stress varies with radius from some origin. The user can select the Define
Distribution button to interactively define the distribution, Figure 8.2.9.
Figure 8.2.8 2-D radial residual stress distribution panel.
111
Figure 8.2.9 User defined 2-D radial residual stress distribution plot.
8.2.4 Surface Treatment Residual Stress Distribution Panel
The surface treatment residual stress distribution panel, Figure 8.2.10, allows one to
specify a stress distribution that varies in a direction that is normal to a surface that has
been retained as a “residual stress surface” when reading the finite element file. The
stress varies with distance from the surface. The user can select the Define Distribution
button to interactively define the distribution, Figure 8.2.11.
Figure 8.2.10 User defined surface treatment residual stress panel.
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Figure 8.2.11 Surface treatment residual stress distribution plot.
As an example, a brick model is defined with the top surface (positive y-axis) defined as
a “treated_surface” node component, Figure 8.2.12 – left panel. When reading the model
into FRANC3D, this component is retained as a residual surface (see Section 4.1.10).
The stress distribution shown in Figure 8.9 is applied as the surface treatment crack face
traction. The distribution acts normal to the “treated_surface”, and distance will be
measured in the -y direction. The resulting crack face traction distribution on the crack
shown in Figure 8.2.12 (left panel) can be visualized using ANSYS, Figure 8.2.12 – right
panel.
Figure 8.2.12 Example of a surface treatment residual stress crack face traction.
There are a number of things that will be noted here. Consider the crack shown in the left
panel of Figure 8.2.13 and the residual stress distributions shown in the right panel of
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Figure 8.2.13. First, if the nodes on the crack surface are at a depth that is greater than
the residual stress, no crack face tractions are computed. Using distribution ‘a’, the lower
third of the crack will not have crack face tractions. Second, if the mesh on the crack
surface is coarse compared to the residual stress distribution, the computed crack face
traction will not adequately capture the residual stress distribution. Based on the coarse
mesh shown in the left panel of Figure 8.2.14, the computed traction value at the node
indicated by the red circle, using distribution ‘a’ from Figure 8.2.13, would be close to
zero. If a pseudo-refined mesh is defined, as in the middle and right panels of Figure
8.2.14, then the ‘a’ distribution can be captured and appropriately distributed onto the
nodes of the actual coarse mesh. Ideally, one would use a suitably refined mesh in the
model to avoid this problem.
Figure 8.2.13 Surface treatment residual stress applied as crack face traction up to the
defined depth of the distribution.
Figure 8.2.14 Surface treatment residual stress applied as crack face traction with
automatic pseudo-mesh refinement to capture the distribution.
8.2.5 Mesh-Based Stress Distribution Panel
The mesh-based stress distribution panel allows one to specify a stress distribution based
on a finite element mesh and stress file, Figure 8.2.15. The user chooses the mesh and
associated stress file, normally an uncracked model. The program queries this data to
compute tractions on the crack face. The uncracked model element shape functions are
used to interpolate the results onto nodes of the remeshed cracked model.
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Figure 8.2.15 Mesh based stress distribution panel.
9. Wizards and Dialog Boxes for Analysis Menu

The wizards and dialog boxes for the Analysis menu options are described in this section.
9.1 Static Crack Analysis

This Static Crack Analysis menu item allows one to set up and run a static (single step,
no crack growth) deformation analysis. One would use this, for example, if one had
inserted a crack into a body and wanted to compute stress-intensity factors for this crack
without performing any crack growth. The ANSYS, ABAQUS and NASTRAN wizard
panels are discussed below; most of the wizard panels are the same for all of the analysis
codes, but there are some differences as will be noted below.
9.1.1 Fdb File Name Panel
The first panel, Figure 9.1, allows one to specify the name of the .fdb file, which stores
the mesh and flaw information for this model. This file name will be used for all the files
created for this static analysis, with different file extensions applied. The .fdb extension
will be added if the user does not type it into the File Name field.
Note that the uncracked file name must not be re-used here; the uncracked model is
needed for crack growth and should not be overwritten.
115
Figure 9.1 Fdb file name dialog.
9.1.2 Analysis Code Panel
The user next must choose the analysis code, Figure 9.2. ANSYS, ABAQUS or
NASTRAN can be chosen, and subsequent panels will differ slightly.
Figure 9.2 Analysis code panel.
9.1.3 ANSYS Options Panel
If the user chooses ANSYS in Figure 9.2, the next wizard panel, Figure 9.3, allows the
user to set options and analysis parameters for ANSYS.
The first box in Figure 9.3 contains a number of options. Quadratic elements are required
to compute SIFs, thus linear elements are disabled. The element series can be selected,
either the older Solid-92 or the newer Solid-186 elements. The user can choose between
quarter-point and midside nodes for the wedge elements at the crack front. The material
116
data and coordinate systems can be written to the cdb file; for a local/global model, this
data is typically contained in the global .cdb file. The user can choose to have ANSYS
write nodal temperatures when the solution is done; the nodal temperatures will be
written to the results file (.dtp extension) if any nodal temperature is not equal to the
reference temperature.
The second box contains the ANSYS executable file name and license string. These
values should be set in the Preferences (see Section 5.3.5) but can be modified or set
here.
The third box allows the user to select the global model to connect to the local cracked
model. If there is no global model, this option should be unchecked as in Figure 9.3.
The fourth box allows the user to define boundary conditions. Retained boundary
conditions can be transferred. Crack face tractions, if defined (see Section 8.2) can be
applied. Crack face contact conditions can be applied also.
The fifth box allows the user to specify the solution information. The default is to use
solution information from the input .cdb files. This information can be suppressed or
defined in an external file.
The final box contains two buttons, View/Edit Command and View/Edit Script, which
will be described in Sections 9.1.5-6. The user also can choose to write the files only,
without running ANSYS. This can be used to verify the files before running, or if the
files will be transferred to a different computer before running.
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Figure 9.3 ANSYS options and analysis parameters.
9.1.4 ANSYS local/global model connection Panel
If the user checked Connect to global model in Figure 9.3, the global model file must be
selected, Figure 9.4. The Browse button can be used to find the file.
Figure 9.4 ANSYS connect to global model box.
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If the user connects to a global model file, the Finish button in Figure 9.3, switches to a
Next button. The Local/global model connection panel, Figure 9.5, defines how the local
and global models will be combined. Note that the user cannot proceed to this panel if
the Connect to global box is checked and the Global model filename has not been
entered.
Figure 9.5 ANSYS local/global model connection panel.
The simplest method to connect a local crack model to a global model is through node-
merging. If the user retained surface mesh facets on the cut-surfaces for the local model,
then these surfaces can easily be glued together by merging nodes. Alternatively,
constraint equations or contact conditions can be defined between the cut-surfaces of the
local and global models. The ANSYS macro that FRANC3D generates will contain
necessary commands to join the two .cdb files together.
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Extra local/global contact/constraint can be defined, lower box of Figure 9.5, for surfaces
other than the crack faces and cut-surfaces. The user chooses the master and slave
surfaces from the list of components. The material id, real properties id, and element
type id can be set.
9.1.5 ANSYS Script Panel
An ANSYS script is generated that will instruct ANSYS to merge the local model with
the global model, if necessary, and perform a deformation/stress analysis. If the user
selects the View/Edit Script button in Figure 9.5, the script is displayed in a separate
panel, Figure 9.6, and can be edited if desired.
Figure 9.6 ANSYS Script panel.
9.1.6 ANSYS Command Line Panel
If the user selects the View/Edit Command button in Figure 9.5, the ANSYS command
is displayed in a separate panel, Figure 9.7. The command line can be edited if desired.
Figure 9.7 ANSYS Command Line panel.
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9.1.7 ABAQUS Options Panel
If the user chooses ABAQUS in Figure 9.2, the next wizard panel, Figure 9.8, allows the
user to set options and analysis parameters for ABAQUS.
The first box in Figure 9.8 contains a number of options. Quadratic elements are required
to compute SIFs, thus linear elements are disabled. The ABAQUS solid elements can be
modified using an extra letter in the designation, either M for modified, H for hybrid, or
R for reduced. The user can choose between quarter-point and midside nodes for the
wedge elements at the crack front. The user can also choose between wedge, constrained
collapsed bricks and collapsed bricks that allow for blunted crack fronts. Note that if one
wants to have ABAQUS compute the J-integral, collapsed brick elements must be used.
The number of integration rings will correspond to the number of mesh template element
rings at the crack front.
The second box contains the ABAQUS executable file name. This should be set in the
Preferences (see Section 5.3.6) but can be modified or set here. A Python script can be
executed on the .inp file prior to running ABAQUS.
solution information from the input .inp files. This information can be suppressed or
without running ABAQUS. This can be used to verify the files before running, or if the
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Figure 9.8 ABAQUS options panel.
9.1.8 ABAQUS local/global model connection Panel
Figure 9.9 ABAQUS connect to global model box.
Next button. The Local/global model connection panel, Figure 9.10, defines how the
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local and global models will be combined. Note that the user cannot proceed to this
panel if the Connect to global box is checked and the Global model filename has not been
entered.
Figure 9.10 ABAQUS local/global model connection panel.
local and global models.
9.1.9 ABAQUS Script Panel
An ABAQUS script can be created that will be added to the .inp file that FRANC3D
generates. If the user selects the View/Edit Script button in Figure 9.10, the script is
displayed in a separate panel, Figure 9.11, and can be edited if desired. The additional
instructions to ABAQUS should be added to the appropriate section; commands that will
include other files can be added here.
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Figure 9.11 ABAQUS Script panel.
9.1.10 ABAQUS Command Line Panel
If the user selects the View/Edit Command button in Figure 9.10, the ANSYS command
is displayed in a separate panel, Figure 9.12. The command line can be edited if desired.
Figure 9.12 ABAQUS Command Line panel.
9.1.11 NASTRAN Options Panel
If the user chooses NASTRAN in Figure 9.2, the next wizard panel, Figure 9.13, allows
the user to set options and analysis parameters for ABAQUS.
The first box in Figure 9.13 contains a number of options. Quadratic elements are
required to compute SIFs, thus linear elements are disabled. The user can choose
between wedge and constrained collapsed bricks, as well as choosing between quarter-
point and mid-side nodes for the crack front elements. Note that MSC NASTRAN does
not support pyramid elements whereas NX NASTRAN has implemented a CPYRAM
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element. The pyramid elements are preferred, but if the user has MSC NASTRAN, the
pyramid elements must be split into two tetrahedral elements.
The second box contains the NASTRAN executable file name. This should be set in the
Preferences (see Section 5.3.7) but can be modified or set here.
solution information from the input .bdf file. This information can be suppressed or
without running NASTRAN. This can be used to verify the files before running, or if the
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Figure 9.13 NASTRAN options panel.
9.1.12 NASTRAN local/global model connection Panel
Figure 9.14 NASTRAN connect to global model box.
Next button. The Local/global model connection panel, Figures 9.15-16, defines how the
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local and global models will be combined. Note that the user cannot proceed to this
panel if the Connect to global box is checked and the Global model filename has not been
entered. For NASTRAN, the global model file can be either a .bdf or a .dat file. The .dat
file will include the .bdf files. In Figure 9.14, the global model file is a .dat file, which
leads to the panel shown in Figure 9.15. If the user selects a .bdf file, the connection
panel will list the node sets and allow the user to choose the sets for merging, Figure
9.16.
Figure 9.15 NASTRAN local/global model connection panel – with a .dat file.
Figure 9.16 NASTRAN local/global model connection panel – with a .bdf file.
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local and global models.
9.1.13 NASTRAN Script Panel
A NASTRAN script is not yet supported.
9.1.14 NASTRAN Command Line Panel
If the user selects the View/Edit Command button in Figure 9.13, the NASTRAN
command is displayed in a separate panel, Figure 9.17. The command line can be edited
if desired.
Figure 9.17 NASTRAN Command Line panel.
9.2 Crack Growth Analysis

This wizard allows one to set up and run a series of crack growth analyses. The first set
of wizard panels are the same as for the Grow Crack wizard described in Section 6.5.
The SIF computation and interpretation along with the crack growth direction and
extension criteria must be defined. The subsequent panels are described next.
9.2.1 Crack Front Smoothing Panel
The crack front smoothing panel, Figure 9.2.1, provides crack front fitting and template
options.
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Figure 9.2.1 Crack growth analysis wizard panel for fitting and template parameters.
9.2.2 Crack Growth Increments Panel
The next panel, Figure 9.2.2, allows the user to specify the number of crack growth steps
and the median crack growth increment per step or the number of cycles per step
depending on the choice for extension type made in the previous panel. There are three
possible choices for entering the data per step: a constant value for all steps, a linear
variation, and a user-defined set of values.
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Figure 9.2.2 Crack growth analysis wizard panel for median crack growth increments.
9.2.3 Analysis Code Panel
The next panel, Figure 9.2.3, allows one to specify the analysis code - either ANSYS,
ABAQUS or NASTRAN. The user should also enter the base file name. All crack
growth steps will use this filename as the base name; a crack step number will be
appended. Finally, the current crack growth step number can be set; this number is used
to create the file name (e.g. base_name_STEP_002).
Figure 9.2.3 Crack growth analysis wizard panel for analysis code and base file name.
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9.2.4 ANSYS Analysis
If the user chose ANSYS in the previous panel, then the ANSYS analysis panels are
displayed; these are identical to those described for static crack analysis (see Sections
9.1.3-9.1.6).
9.2.5 ABAQUS Analysis
If the user chose ABAQUS in the previous panel, then the ABAQUS analysis panels are
displayed; these are identical to those described for static crack analysis (see Sections
9.1.7-9.1.10).
9.2.6 NASTRAN Analysis
If the user chose NASTRAN in the previous panel, then the NASTRAN analysis panels
are displayed; these are identical to those described for static crack analysis (see Sections
9.1.11-9.1.14).
10. Fatigue Menu Wizards and Dialog Boxes

The wizards and dialog boxes for the Fatigue menu options are described in this section.
10.1 SIF History

The SIF history dialog, Figure 10.1.1, allows the user to display SIF history data. By
default, the SIF history data is stored in the FRANC3D restart (.fdb) file. However, the
user can import data into the dialog through the Open Full History option of the File
menu in this dialog.
The crack front lines are displayed in the left-side model window and the path options are
displayed on the right-side of the dialog. The Front K’s and Path K’s tabs (above the
model window) allow one to display the SIFs along the crack front, Figure 10.1.2 – left
panel, or the SIFs along the defined path through the crack front, Figure 10.1.2 – right
panel. The Export tab allows one to save selected data to an ASCII text file and will be
described later.
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Figure 10.1.1 SIF history dialog.
Figure 10.1.2 SIF history dialog – Front K’s tab (left) and Path K’s tab (right).
10.1.1 Geometry Tab
Traditional fatigue lifing methodologies require a SIF history that consists of a single
valued stress intensity factor (K) and a single valued crack size (a) for each crack
increment. Developing such a "K-history" is straightforward for a 2-D analysis, but is
considerably more complicated for 3D analyses. In 3D, one has a distribution of K
values along a crack front, and there might not be an obvious crack dimension that
uniquely characterizes the crack “length”.
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Three different algorithms are available in the SIF History dialog (see Fig 10.1). The
results for the three algorithms are illustrated below using three different crack growth
simulations. It should be noted that while the crack growth might appear nearly planar in
these three examples, the algorithms work for non-planar growth.
10.1.1.1 Constant Normalized Distance
The first algorithm uses a constant, user-specified, normalized distance along the crack
fronts. Figure 10.1.3 shows the computed paths for 50% normalized distance. The figure
shows that this approach works very well for the first crack and reasonably well for the
third crack. For the middle crack, however, the path is somewhat sinuous; this can be
even more pronounced for crack fronts that transition from corner- to through-cracks.
Figure 10.1.3 Computed K paths for a constant normalized distance of 50%.
10.1.1.2 Nearest Point on Next Front
The second algorithm is a modification of the first approach. The analyst selects a point
on the initial crack front. The algorithm then searches for the nearest point on the next
crack front and makes this the next point in the history. The process is repeated for all
remaining crack fronts. The K's in the history are the interpolated values at the "nearest
points", and the crack length is the distance from the crack "origin" to the initial crack
front point plus the (straight line) distances between successive "nearest points".
This algorithm is illustrated in Figure 10.1.4. For all three cracks, the path was started at
locations of 10%, 20%, ... 90% along the initial crack front. The algorithm performs very
well for the first crack. For the middle crack, some of the paths converge into one path at
10% of the distance along the crack front. This is because of the path constraints, which
are described in Section 10.1.1.4. For the third crack, most of the paths merge together
due to these path constraints.
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Figure 10.1.4 Computed K paths using nearest next point. Paths are at 10% increments
with a 10% and 90% minimum and maximum threshold.
10.1.1.3 Intersection of Fronts with a Plane
The third algorithm defines a plane nominally perpendicular to the crack surface and
gives the path as the points where the crack fronts intersect the plane. This algorithm is
illustrated for the first of the three cracks above in Figure 10.1.5.
Figure 10.1.5 Computed plane intersection points for the slot crack.
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10.1.1.4 Path Constraints
There is a user-settable threshold that prevents the computed paths from getting too close
to the free surfaces where the accuracy of the computed stress intensity factors is
questionable. The user can set both the minimum and maximum thresholds in the dialog.
10.1.1.5 Path Curve Fitting
A best fit, in a least-squares sense, through the path computed by one of the three
algorithms. Figure 10.1.6 shows the least-squares fit to the paths shown in Figure 10.1.3.
A quadratic curve was used for the first crack, and as expected, there is little
improvement in the path for this case. A cubic curve was used for middle crack, which
yields a path that is aesthetically more pleasing. A fifth order curve was used for the
third crack and gives some improvement over the initial computed path by smoothing the
kinks.
Figure 10.1.6 Computed least-squares fits to the paths of Figure 10.1.3.
10.1.1.6 Input Curve Options
An issue related to computing a smooth K-history is computing a smooth K distribution

along a crack front for a single crack step. Because the K's are numerical results, they
tend to be "noisy" and frequently show spurious behavior near free surfaces where the
assumptions and numerical techniques used to compute the K can break down. In some
cases, it is desirable to fit a smooth curve through the numerical results. A least-squares
polynomial fit is applied, Figure 10.1.7. In the figure the computed K's for four crack
fronts have been fit with cubic polynomials. Note that this capability should be used with
some caution as the K distribution might not fit a simple polynomial very well.
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computed and fit SIF's
65000
60000
55000
50000
45000
K
40000
35000
30000
25000
20000
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
normalized distance
Figure 10.1.7 Computed K distributions (blue) along with polynomial fits (red).
10.1.1.7 History Starting Condition
10.1.2 Export Tab
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Figure 10.1.8 SIF history dialog – Export tab.
10.1.3 Settings Menu
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10.2 Discrete Crack Life
The Discrete Life wizard allows the user to compute fatigue cycles.
The first wizard panel that is presented after starting the program is shown in Figure 10.3.
This panel allows the analyst to first set the units, either SI or US. Note that if the SIF
history data is not in one of these two units, the history data will need to be converted.
The next option on this panel is a choice between constant amplitude and variable
amplitude loading. This choice will affect the appearance of the subsequent panel. The
third option provides a choice between one or multiple load cases. Typical uniaxial
fatigue testing utilizes a single load case, but it is possible to have multiple load cases, as
for combined low cycle and high cycle fatigue.
The analyst has the option of reading previously stored session files and/or saving the
current session file for later use, by selecting the appropriate button on this panel.
Figure 10.3 Fatigue life wizard - first panel.
If the analyst chooses Constant Amplitude for the Loading Type, the next panel is as
shown in Figure 10.4 – left panel. Alternatively, if the analyst chooses Variable
Amplitude, the next panel is as shown in Figure 10.4 – right panel. The difference is the
removal of the R ratio field and the addition of the Load Spectrum options.
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Figure 10.4 Fatigue life panel for Constant Amplitude loading (left) and for Variable
Amplitude loading (right).
The first section of either panel allows the analyst to read the SIF history data. The
default is to import FRANC3D's .spt file format, but other txt file formats are supported.
Once the data has been imported, the analyst can View (see Figure 10.4) the data in the
form of an XY plot, Figure 10.5. Note that this plot shows all three SIF modes for the
path, unlike the SIF History module described previously.
The Load Spectrum section allows the analyst to read variable amplitude (spectrum)
loads from a file. Several file formats are supported, but the simplest consists of a
column formatted .txt file where the first column is the minimum (or maximum) load, the
second column is the maximum (or minimum), and an optional third column contains the
cycle count. The third column defaults to 1 if not present. Once the spectrum data has
been imported, it can be Viewed also, Figure 10.6.
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Figure 10.5 XY plot of Mode I, II and III SIFs versus crack length
Figure 10.6 XY plot of spectrum load cycles
The next panel is shown in Figure 10.7. It allows the analyst to choose one of five
options for the crack growth rate model. The simplest is the Paris model, requiring only
two parameters. The required fields are highlighted in yellow until the analyst enters
values. The other options include Walker, NASGRO v3 and v4, and user-defined crack
growth rate data.
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Figure 10.7 Fatigue life panel for crack growth rate models. Paris model chosen in left
panel and NASGRO v3 model chosen in the right panel.
The NASGRO v3 option has more parameters than Paris, but it accounts for the non-
linear crack growth rate, in particular at the high and low ends of the crack growth rate
curve. The NASGRO v3 material database contains data for a wide variety of materials,
and this data is included in FRANC3D and accessible by selecting the From Database
button. The dialog boxes shown in Figure 10.8, for a titanium alloy as an example, allow
the analyst to automatically fill in the required NASGRO v3 parameter fields from this
database.
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Figure 10.8 NASGRO version 3 material database dialog boxes.
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The next wizard panel, Figure 10.9, allows the analyst to choose the integration
technique, the equivalent KI value, and the retardation, and then provides a number of
stopping checks (i.e., conditions that would terminate the integration). Selecting Next on
this panel leads to the final panel, preceded by the session summary sheet, Figure 10.10.
Figure 10.9 Fatigue life panel for integration and threshold options.
Figure 10.10 Fatigue life session summary sheet.
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The session summary sheet describes all of the options leading up to the final panel
where the cycle computation occurs, Figure 10.11. The analyst selects the Compute Life
button to fill the spread sheet. By selecting the Plot Results button, this data can also be
plotted in an XY plot, Figure 10.12, which shows cycles versus crack length. The data
can be saved to a file using the Save To File button. The initial crack length can be
modified from the default of 0.0 to get a cycle count starting from a prescribed initial
crack length. The entire session can be saved to a .fsn file for later reuse by selecting the
Save Session File button.
Figure 10.11 Fatigue life panel shows cycles versus crack length.
Figure 10.12 XY plot of cycles versus crack length
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11. Fretting Menu Wizards and Dialog Boxes
The Fretting menu is accessed from the FRANC3D main menu bar at the top of the
FRANC3D window, Figure 11.1.
Figure 11.1: FRANC3D main menu bar contains the Fretting menu.
11.1 Read Model and Results

FRANC3D is able to read ANSYS, ABAQUS and NASTRAN files for fretting analysis.
The finite element (FE) information is contained in .cdb, .inp and .bdf files, respectively,
Figure 11.1.1. The FE information consists of nodes, elements and usually a definition of
the contact surfaces. Once the FE model is imported, analysis results must be imported.
A typical fretting test is conducted by applying a normal load (P) and then applying a
maximum and minimum tangential (shear) load (Qmax and Qmin). The dialog box shown
in Figure 11.1.2. allows the user to select one or more of these load cases. At minimum,
the P+Qmax load is required. If the P+Qmin load is not selected, FRANC3D assumes that
the minimum stress state is at zero. The P only loading is not required for most fretting
nucleation models.
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Figure 11.1.1 Fretting dialog for importing FE model data.
Figure 11.1.2 Fretting dialog for importing FE results data.
Selecting the Browse button from the dialog in Figure 11.1.2. leads to the dialog
shown in Figure 11.1.3. The user can select the results files from ANSYS, ABAQUS
or NASTRAN. The ANSYS .str files are simply the nodal stress listings saved to a
file. Corresponding strain (.stn), displacement (.dsp) and contact status (.con) listings
should also exist with the same name prefix. ABAQUS results are read from .fil files.
NASTRAN results are read from .pch files. Note that strains are not required for
some of the fretting nucleation models.
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Figure 11.1.3: Fretting dialog for locating results files.
Selecting the FINISH button from the dialog in Figure 2.3 leads to the Data Filter dialog
shown on the left side of Figure 11.1.4. The user can let FRANC3D select all material
regions and let FRANC3D automatically determine the contact surfaces from the FE
model and results data. Selecting Next on this dialog leads to the dialog on the right,
which allows the user to either go Back to change prior selections, Cancel the entire
operation, or Finish. Selecting Finish concludes the user interaction and FRANC3D
then processes the user selections for the FE model and results.
Figure 11.1.4 Fretting dialog for choosing all or selected material regions and auto
or selected contact surfaces.
If the user chose user select for both Materials and Contact surfaces on the dialog shown
in left panel of Figure 11.1.4, a sequence of dialog boxes is displayed to allow the user to
select the required data, Figure 11.1.5. The first dialog shown in the upper left panel of
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Figure 11.1.5 displays the material identifiers and has a check box for coloring the
regions. By default, if there are multiple material regions, the regions will be given
different colors when the model is displayed in the FRANC3D window. If there is only
one material region or if the user unchecks the Color different materials box, then the
model is displayed in the default model color (grey).
The next dialog shown in the upper right of Figure 11.1.5 displays the contact surfaces
and named sets or surfaces that are part of the FE model data. The user must first select
the surface(s) that is the contact (fretting pad) surface. The next dialog shown in the
lower left of Figure 11.1.5 allows the user to select the target (fretting specimen) surface
and the final dialog shown in the lower right of Figure 2.6 allows the user to specify the
edge of contact nodes if desired. Selecting Next on this dialog leads to the dialog on the
right side of Figure 11.1.4, which will conclude the user interaction for the Fretting Read
Model and Results menu item. FRANC3D might automatically switch the definition of
the contact (or master) and target (or slave) surfaces based on the analysis results, in
particular the contact status and pressure.
Figure 11.1.5 Fretting dialog for selecting material regions and contact surfaces.
11.2 Import Nucleation Data

FRANC3D is able to import experimental fretting fatigue test data and perform curve fit
operations on this data. The first dialog box that is displayed after selecting the Import
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Nucleation Data menu item is shown in Figure 11.2.1. The user should select the file
containing the raw experimental data. The format for this text file should be:
sigma_axial cycles
---------------------------
675.3 2.23e4
655.7 2.63e4
533.8 4.45e4
Figure 11.2.1 Fretting dialog for importing experimental fretting nucleation data.
Selecting the Browse button in the dialog shown in Figure 11.2.1 leads to the file
selection dialog shown in Figure 11.2.2. The user can select the appropriate .txt file.
Once the data file is selected, the user selects Next to arrive at the dialog shown in
Figure 11.2.3. The fretting data is shown in tabular form. Selecting the Plot/Edit
button leads to the dialog shown in Figure 11.2.4.
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Figure 11.2.2 Fretting dialog for selecting the fretting nucleation data file.
Figure 11.2.3 Fretting dialog shows fretting nucleation data in tabular form.
The dialog shown in Figure 11.2.4 displays the fretting nucleation data in tabular and
graph form. The user can edit the data in the table by selecting the Edit menu item
and switching from the default Read Only mode. The user can also perform curve
fitting operations on the data using the Fit menu. The usual fretting nucleation model
uses a power law relationship with four coefficients to relate the fretting nucleation
cycles on the horizontal axis with the fretting parameter on the vertical axis. This
power law is highlighted in Figure 11.2.5, which also shows the fit through the data.
The goodness-of-fit is displayed on the top of the plot with the equation. The
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coefficients can be output along with the fitted data by selecting the Save to File
button on the dialog in Figure 11.2.3. This text file is formatted as:
y=a(x^b)+c(x^d)
parameters: a=364.771 b=-0.0532003 c=442836 d=-0.681027
fitted data:
22300 698.23168
63777 439.16081
105254 365.42131
146731 327.89836
Figure 11.2.4 Fretting dialog for plotting fretting nucleation data.
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Figure 11.2.5 Fretting dialog for plotting fretting nucleation data with power law
curve fit through the data.
11.3 Fretting Crack Nucleation

FRANC3D computes fretting fatigue crack nucleation cycles and initial crack location
(and possibly orientation) based on one or more of the fretting nucleation models that
have been implemented. These include: the equivalent stres, the critical plane shear
stress amplitude, the critical plane Smith-Watson-Topper, and a crack-analog model. The
model equations and parameters are briefly summarized here. For more details, refer to:
“Three-dimensional Simulation of Fretting Crack Nucleation and Growth”, B.J. Carter,
E.C. Schenck, P.A. Wawrzynek, A.R. Ingraffea, and K.W. Barlow, to be submitted to
Engineering Fracture Mechanics.
The equivalent stress model is defined by:
eq = 0.5 (psu)w (max)1-w (1)
where psu and max are functions of the nodal stress components and w is a material
dependent fitting parameter. Based on curve fitting of experimental data, the equation, in
the form of the power law shown in Figure 2.11:
eq = aNib + cNid (2)
relates eq to Ni, where coefficients a – d are material dependent fitting parameters. For
example, for Ti-6Al-4V, a = 52476, b = -0.6471, c = 450.85 and d = -0.03582.
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The critical plane shear stress amplitude model is defined by:
crit =max/G (1-R)m (3)
wheremax is the maximum shear stress on the critical plane, Ris the shear stress ratio, G
is the shear modulus and m is a material dependent fitting parameter. Substituting crit
for eq in equation (3), one can compute Ni given the appropriate values for the
coefficients a – d. For Ti-6Al-4V, a = 6.46, b = -0.686, c = 4.65x10-3 and d = 1.22x10-2.
The critical plane Smith-Watson-Topper model is defined by:
crit = max (f2 / E) (2Ni)2b + f2Ni)b+c (4)
where max is the maximum principal stress and represents the normal strain amplitude
on the critical plane; this equation is already in the form of equation (3). E is the elastic
modulus, f and f are material strength parameters, and b and c are fitting parameters.
For Ti-6Al-4V, f = 376.6 MPa, b = 1.78x10-4, c = -0.767 and f = 32.4.
The crack analog model is quite different from the above three models. First, the fretting
parameter (Q) is only computed at the nodes along the EOC. Second, the FE analysis
must be conducted with bonded contact conditions rather than the standard contact (that
allows for slip and requires a coefficient of friction). Q can be related to JII from linear
elastic fracture mechanics:
Q = (JII E/(1-))1/2 (6)
where  is Poisson’s ratio. Ni is computed from:
log Ni = ( – Q ) /      (7)
where and  are material dependent fitting parameters. Q = Qmax - Qmin, is determined
from the maximum and minimum load cycles.
The first dialog box that is displayed after selecting the Fretting Crack Nucleation
menu item is shown in Figure 11.3.1. The user can select one of the four fretting
nucleation models. Selecting Next leads to the dialog shown in Figure 2.13, which lets
the user define the Equivalent Stress fretting model parameters. Note that the user can
select the fitting coefficients from the previous section based on a curve fit through the
experimental data. If these coefficients are not available, this option for curve fit values
is disabled. The other three models have similar dialog boxes as shown in Figures 11.3.2
- 11.3.5.
153
Figure 11.3.1 FRANC3D Fretting dialog to select fretting nucleation model.
154
Figure 11.3.2 Fretting dialog to set equivalent stress fretting model parameters.
Figure 11.3.3 Fretting dialog to set critical shear stress model parameters.
155
Figure 11.3.4 Fretting dialog to set Smith-Watson-Topper model parameters.
Figure 11.3.5 Fretting dialog to set RAI Q model parameters.
156
The dialog boxes shown in Figures 11.3.2 - 11.3.4 have a check box for Volume
Averaging. Rather than computing the fretting parameters based on node-point stress
(and strain) values, the user can choose to do volume averaging. If this box is checked,
the next dialog box that will be displayed is shown in Figure 11.3.6. The user can adjust
the size of the displayed sphere by changing the Average over length value. Note that
stress values are not averaged across material region boundaries. Typical length values
used in the literature are based on the material grain size.
Figure 11.3.6 Fretting dialog for volume averaging of stress (and strain).
Selecting Next on the dialog shown in Figure 11.3.6 leads to the dialog shown in Figure
11.3.7. This dialog shows the model and allows the user to view the contact surfaces, the
edge of contact, the fretting nucleation cycles and the fretting parameter values. The
latter two items can be displayed as text or using color contours.
157
Figure 11.3.7 Fretting dialog for displaying fretting nucleation cycles and parameter
values and contours.
Selecting the Save to File button on the dialog shown in Figure 11.3.7 leads to the file
save dialog shown in Figure 11.3.8. The fretting nucleation data is saved to a text file
with the following format:
master surface
node x y z parameter cycles
19222 0.49648972 0.91291108 0.15 25 19283
20917 0.52414545 0.94056681 0.12 29 18453
20881 0.51283174 0.92925310 0.12 24 19898
158
Figure 11.3.8 Fretting dialog for selecting file to save fretting nucleation predictions.
The user can go Back and choose a different fretting nucleation model to compare
predictions. Selecting Finish on the dialog shown in Figure 2.18 closes the dialog.
11.4 Extract Subvolume

FRANC3D is able to extract a subvolume (or portion) of the full model that is positioned
such that it contains the predicted fretting crack nucleation site. The dialog shown in
Figure 11.4.1 is displayed when the user selects the Extract Subvolume menu item. The
user can choose the size, shape, location and orientation of the cutting-region (the
magenta region in Figure 11.4.1) as well as specifying the material region from which to
extract the subvolume. Selecting Next on this dialog leads to the dialog shown in Figure
11.4.2. The global and local portions of the model should be saved. The initial crack can
also be saved to a file (if it is oriented correctly). Note that some fretting models do not
predict the initial crack orientation; in this case, the predicted orientation is based on the
maximum principal stress direction. Selecting Finish on the dialog shown in Figure
11.4.2 closes the dialog. The full fretting model remains active if the user wishes to re-
evaluate the fretting nucleation using a different model or with different parameters.
Discrete crack growth simulations can be conducted using the saved files.
159
Figure 11.4.1 Fretting dialog for extracting a subvolume.
160
Figure 11.4.2 Fretting dialog for saving a subvolume and its corresponding ‘global’
model counterpart.
11.5 Turn Off Region Color

FRANC3D will display material regions with different colors. The Turn Off Region
Color menu item allows the user to select the material regions to be colored using the
dialog shown in Figure 11.5.1. The regions that are checked are drawn in solid colors
while the unchecked regions are drawn as wireframes. Selecting Accept will draw
colored regions while selecting Cancel will convert all regions to the default (grey)
model color. This option is purely for display purposes so that interior regions can be
viewed in complex multi-region models.
161
Figure 11.5.1 Fretting dialog for turning off/on colored regions.
12. Advanced Menu Wizards and Dialog Boxes

The wizards and dialog boxes for the Advanced menu options are described in this
section.
12.1 Edges Wizard

The Edge Extraction dialog, Figure 12.1.1, allows the user to control the geometry that
is extracted from the finite element facets. The angle threshold can be adjusted to
increase or decrease the number of surfaces by blending facets together.
162
Figure 12.1.1 Edge extraction dialog.
For cylindrical surfaces such as a hole in a plate, the user should add edges to break the
surface into at least two surfaces. By selecting the Add button for Edge Lines in Figure
12.1.1, the dialog in Figure 12.1.2 is displayed to allow the user to define edges.
Figure 12.1.2 Add edge dialog.
12.2 No Crack Regions

The no crack regions dialog box, Figure 12.2.1, allows the user to insert a crack into a
single region in a multi-region model. Each of the regions can be displayed using the
Displayed Region selection; the selected region is colored while the other regions are
shown as wireframes. The user selects the region that will not be cracked by checking
the appropriate region id in the No Crack Regions pane.
163
When a crack is inserted that crosses the material boundary, Figure 12.2.2, the crack
geometry is trimmed so that the final meshed crack model does not have any crack
surface in the selected region, Figure 12.2.3.
Figure 12.2.1 No crack regions dialog.
Figure 12.2.2 Inserting a crack into a two-region model where the second region is
designated as a no-crack region.
164
Figure 12.2.3 Crack inserted into one region of a two-region model.
12.3 Write Crack Front Data

The Save File As dialog, Figure 12.3.1, is presented so that crack front data can be saved
to a file. The saved file is an ASCII text file with extension is .fcg. The content of the
file consists of the SIF data for each crack front for each step of crack growth.
Figure 12.3.1 Write crack front data - Save File As dialog.
The .fcg file format is briefly described here. This file can be imported into the SIF
history dialog.
StepData: 4 # number of crack growth steps

LoadFactors: 1 # load factors for each load case
111
FrtData: 1 # number of crack fronts in current step
Start: -0.5 0.0 10 # start of crack front
Stop: 0.5 0 10 # end of crack front
165
FitFrt: -0.5407 -0.00021 10.045 ….. 0.556 -0.00022 10.045 # list of fit new points
FitOld: -0.498 0.0 9.967 …… 0.490 0.0 9.906 # list of current front points
FitExt: 0.089 …… 0.15387 # list of extensions at each point
FitParams: FIXED_ORDER_POLY 3 0 0 3 3 # fitting parameters
FrtPts: 24 # number of front points
NPos: 0.02090 # parametric location of first point
Ks: 0.9082 0.00074 -0.00083 # SIFs at point
Js: 7.4872e-005 # J-integral at point
Ts: -0.6669 # T-stress at point
Coord: -0.49788262 1.0932882e-016 9.9672525 # coordinate of point
Axes: -0.9979 0.0 -0.0645 0.0 1.0 0. 0 0.0645 0.0 -0.9979 # local axes
KAng: -0.00163 # kink angle at point
Ext: 0.0481 # extension at point
DKEE: 0.9082 # delta K1 effective
REff: 0 # effective R ration
NodeId: 13371 # node id
ENDFP # end of data for first point
……. # repeat from NPos to ENDFP for each point on crack front
NPos: 0.97917452 # end parametric position on crack front

Ks: 0.9084 0.000642 0.0008515 # same data as for each front point
Js: 7.4896e-005
Ts: -0.6654
Coord: 0.4979 1.249e-017 9.967
Axes: 0.9979 0.0 -0.064 0.0 1.0 0.0 0.06425 0.0 0.9979
KAng: -0.001414
Ext: 0.060896
DKEE: 0.90844
REff: 0
NodeId: 7272
ENDCF # end of current crack front
ENDCS # end of current crack growth step
……. # repeat from FrtData to ENDCS for each crack growth step
ENDFCGD # end of file
12.4 Write COD Data

The Write COD Data menu item allows the user to save crack displacement data to a
file. The first dialog that is displayed, Figure 12.4.1, prompts the user to enter a distance
back from the crack front where crack displacements will be computed. The default is to
compute the values at the entered distance from crack front nodes. If the user turns this
option off, values are computed at geometric points along the crack front.
166
Figure 12.4.1 Write crack front data - Save File As dialog.
Select Accept on the dialog in Figure 12.4.1, and the dialog shown in Figure 12.4.2 is
displayed. This dialog allows the user to choose which data will be written to the file.
The file is saved by selecting the Create File button, which invokes the usual Save As
File dialog. The file is an ASCII text file.
Figure 12.4.2 Write COD data – create file dialog.
12.5 Write Template Data

The Save File As dialog, Figure 12.5.1, is presented so that template data can be saved to
a file. The data is saved to an ASCII text file with .std extension.
167
Figure 12.5.1 Write template data - Save File As dialog.
The file format for this file is briefly described here.
STD_TEMPLATE_DATA
{
VERSION: 1
NUM_FRONTS: 1
CRACK_FRONT: 0 49 25 OPEN
CORNER_SET: 0 # corner node ids of template element ring
11978 12907 11421 12440 11888 6756 7686 7222 8147 5762
6227 10350 10816 973 1436 4673 5142 8373 8835
….
SIDE_SET: 0 # side node ids
6938 3386 6470 14975 6003 2013 616 1081 3384
2479 2916 6383 2450 7784 6385 6854 9277 8246
8815 4877 8353 3061 1198 1662 7643 3527 7180
13551 6713 14015 14362 6338 13898 4288
…..
NODE_COORDS: 1781 # list of all node ids and coordinates
7321 -0.52397588 -0.01178516 9.9308077
11252 -0.47625961 1.0479856e-014 9.7249057
….
NODE_DISP: 1781 # list of all node ids and displacements
7321 2.34113830186791e-005 0.000939063262674639 -0.000290174323814175
11252 2.24602369565477e-005 0.000940419013229567 -0.0002799458448084
….
}
12.6 View Response

The View Response menu item allows one to view the deformed shape of the current
model. Analysis results are required to activate this menu item. The dialog shown in
168
Figure 12.6.1 is displayed. The Display Mesh Overlay can be turned off to remove the
surface mesh facets from the model view. The deformed shape can be displayed by
turning the Display on Deformed Geometry option and entering a non-zero magnification
factor, Figure 12.6.2.
Figure 12.6.1 View Response dialog showing undeformed mesh.
Figure 12.6.2 View Response dialog showing the deformed shaded solid and the original
wireframe outline.
169
12.7 Create Growth History
The Create Growth History dialog, Figure 12.7.1, allows a user to create and edit the
SIF history data. A list of the crack growth steps is provided, and then for each step the
crack front data for each crack front is given. The data was briefly described in Section
12.3. The dialog has three menu items: File, Edit and Plot. The File menu has four
options, Figure 12.7.2. The Open History menu item invokes the usual File Open
dialog with the .fcg file filter. The Add Step menu item invokes the usual File Open
dialog with the .sif file filter. The Add List menu item invokes the usual File Open
dialog with the .txt file filter; the .txt file should contain a list of .sif files. The last menu
item, Save History invokes the usual File Save As dialog for saving the data to a new
.fcg file.
Figure 12.7.1 Create Growth History dialog.
Figure 12.7.2 File menu for Create Growth History dialog.
170
The Edit menu option has one item: Set Start Condition, which invokes the dialog
shown in Figure 12.7.3. This dialog allows the user to set the start condition for the SIF
history be either setting a location or providing an initial length. This initial length
should be the initial crack length, but this length is somewhat ill-defined for a general 3D
crack.
Figure 12.7.3 Crack Start Condition dialog from Growth History dialog.
The Plot menu option has one item: Plot Crack Fronts, which invokes the dialog shown
in Figure 12.7.4. This dialog allows the user to view the crack front boundaries for all of
the crack fronts for all of the crack growth steps.
Figure 12.7.4 Plot crack fronts dialog from Growth History dialog.
171
12.8 Crack Growth Sequence
The Crack Growth Sequence menu item invokes the dialog boxes shown in Figure 12.8.1
and 12.8.2. The first dialog shows the model using the camera position for the current
model in FRANC3D. The second dialog allows the user to cycle through the crack steps
using the Next, Prev, First, and Last buttons. The user can snap images from this
window to create a crack growth sequence or animation or movie clip of the crack
advance. Select Close when done.
Figure 12.8.1 Crack Growth Sequence dialog showing the ‘first’ crack step.
Figure 12.8.2 Crack growth sequence dialog lets the user cycle through the crack steps
shown in Figure 12.8.1.
172
13. FRANC3D Command Language and Session Files
The FRANC3D command language is described here. These commands are written to
session##.log file by FRANC3D as GUI operations are completed. The session files can
be played back as described in Section 4.5.
A complete description of the command language is provided in a separate document:

FRANC3D Command Language Version 6.
14. FRANC3D Python Extensions

The FRANC3D command language is replicated in the Python module. Each command
has a Python counterpart. The Python module is named PyF3D.dll or .pyd. A separate
executable called Fcl2Py.exe is available that converts the session .log files containing
FRANC3D Commands into equivalent Python commands. A user can then modify this
script or write their own.
A complete description of the command language is provided in the FRANC3D

Command Language Version 6 document.
173

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Fracture Analysis Consultants, Inc

Revised: November 2011

2. General and 3D View Manipulation

2.1 View Controls

Figure 2.1.1 View control panel.

Axes Toggle: This turns the axes display on or off.

Mesh Toggle: This toggles the surface mesh on and off.

Figure 3.1.2 FRANC3D documentation file location dialog.

3.1.1 About Dialog

Figure 3.2.1 File Menu.

Quit - Closes the model and exits the program.

Figure 3.3.1 Edit Menu.

Figure 3.5.1 Materials Menu.

Figure 3.6.1 Loads Menu.

Figure 3.7.1 Analysis Menu.

Figure 3.8.1 Fatigue Menu.

Figure 3.9.1 Fretting Menu.

Figure 3.10.1 Advanced Menu.

Figure 4.1.1 Model File dialog box.

4.1.1 FRANC3D Restart Files

4.1.2 FEM Input Wizard

4.1.3 Retain Model Panel

Figure 4.1.3.2 View ANSYS cdb file dialog.

4.1.4 Select Items to Retain Panel

4.1.5 Materials to Retain Panel

4.1.6 Coordinate Systems to Retain Panel

4.1.7 Boundary Conditions to Retain Panel

4.1.8 Components/Nsets to Retain as Mesh Facets Panel

Figure 4.1.8.1 Components/Nsets to retain as mesh facets panel.

Figure 4.1.9.1 Surfaces to retain for contact/constraint panel.

4.1.10 Components/Nsets for Residual Stress Panel

Figure 4.2.1 Save Model Warning dialog.

4.3 Save As…

4.4 Read Results

Figure 4.5.1 Playback session file selection dialog.

4.6 Quit - Ctrl-Q

5. Edit Menu Wizards and Dialog Boxes

5.1 Undo - Ctrl-Z

5.3.1 Folders Tab

Figure 5.3.1.1 Folders tab of Preferences dialog.

The Defaults button restores all values to default settings.

Figure 5.3.2.1 Window tab of Preferences dialog.

Figure 5.3.2.2 Font selection dialog.

5.3.3 3D View Tab

The Defaults button restores all values to default settings.

Figure 5.3.1.1 3D View tab of Preferences dialog.

5.3.4 Display Tab

The Defaults button restores all values to default settings.

Figure 5.3.4.1 Display tab of Preferences dialog.

5.3.5 ANSYS Tab

License Type stores the ANSYS license type.

Solver allows one to specify the ANSYS equation solver.

Number of Processors is self-explanatory.

5.3.6 ABAQUS Tab

Figure 5.8 ABAQUS tab of Preferences dialog.

Figure 5.3.7.1 NASTRAN tab of Preferences dialog.

5.3.8 FEAWD Tab

5.3.9 Meshing Tab

Figure 5.3.9.1 Meshing tab of Preferences dialog.

6. Cracks Menu Wizards and Dialog Boxes

6.1 New Flaw Wizard

The individual wizard panels are described below.

6.1.1 Flaw type panel