PROBLEM STATEMENT AND OBJECTIVES

Crack initiation and pre-existing fractures are inextricably linked to the brittle fracture
characteristics of costly and heavy engineered projects. Some technical materials are even
susceptible to crack occurrences. Avoiding crack propagation can prevent materials from
failing to withstand stress. Finding the stress intensity factor is one of the finest ways to
analyse crack propagation at the tip. Experimental measurement of the stress intensity factor
is thought to be the most accurate. However, the range of experiments is constrained by the
compatibility of laboratory apparatus and mostly by human error. However, it can be difficult
and time-consuming. On the other hand, the stress intensity factor can also be determined
using empirical calculation and numerical approach. This is as a result of the various
parameters that are taken into account and considered during calculations. Some of the key
factors used to determine how flexible a component with a fault is to resist fracture are crack
size, component shape, applied force, and the material quality known as fracture toughness.
The main objectives of this report are described as below:

1. To study the test method for the plain-strain fracture toughness of metallic materials.
2. To determine the ability of materials to withstand the load in the presence of a sharp
crack before failure.
3. To model, analyses and determine stress intensity factor for compact tension
specimen by using empirical calculation and numerical method (ANSYS).
4. To compare stress intensity factor valued obtain by empirical calculation and
numerical method.
INTRODUCTION

When a crack suddenly starts to spread quickly and uncontrollably, fracture toughness is the
essential stress intensity element. With thin components having plane stress circumstances
and thick components having plane strain conditions, a component's thickness impacts the
constraint conditions at the fracture tip. The lowest value of fracture toughness, a material
attribute, is produced under conditions of plane strain. The term "plane strain fracture
toughness," designated by the symbol K Ic, refers to the critical value of the stress intensity
factor in mode I loading when evaluated under circumstances of plane strain. The fracture
toughness value obtained is labelled K c when a test fails to satisfy the thickness and other test
parameters that are in place to assure plane strain conditions.

Figure 1: Impact of specimen thickness on fracture toughness

According to the ASTM E399 standard, a pre-existing fracture is introduced to the specimen
in this experiment by the use of machining. In order to start the crack from spreading, loads
are applied cyclically to both sides of cracks during testing. Application of load continues
until sample cracks get worse. Additionally, the number of fracture cycles was counted and
studied to help determine the crack development features.
Body cracks are primarily categorised into three types (1, 2 &3). The major load is delivered
normal to the fracture plane and tends to open the crack, while the displacements of the crack
surfaces are perpendicular to the crack plane. This is known as mode 1 loading. Given that
the loading situation is significant and adds to the ease with which cracks spread, Mode 1
cracking phenomena is also regarded as the most crucial to be studied.

Figure 2: Example of Mode 1 cracking.

Fracture toughness, which is represented by the value of KIC, is determined by a material's

capacity to sustain load in the presence of sharp fractures. According to the ASTM E399
standard, Standard Test Method for Plane-Strain Fracture Toughness of Metallic Materials,
four factors must be taken into account in order to estimate KIC. The following are the
factors.

1. Specimen preparation.
2. Testing machine/procedure.
3. Calculation of 𝐾𝐼𝐶 value.
4. Validation of 𝐾𝐼𝐶 value.

Specimen preparation considerations

There are 2 specimen samples prepared for this experiment which are Notched Bend
Specimen (SENB) and Compact Tension Specimen (CT). Both standards of specimen
preparation are shown in figure 3 and figure 4.
 Figure 3: SENB specimen preparation standard.

Figure 4: CT specimen preparation standard.

For the purpose of ensuring high stress distribution ahead of the crack tip, the specimen is
prepared by applying fatigue load under controlled conditions of modest load and amplitude
to produce a sharp fatigue pre-crack.
Calculation of KIC Value

KIC value is calculated using the formula in figure 5 with some parameters are available in
ASTM E399 standard, shown in figure 6.

Figure 5: KIC Calculation Formula

Figure 6: Availability of some important parameter values in ASTM E399 standard.

Validation of KIC Value

To validate the value of KIC due to criterion for brittle structure in the presence of the notch
in the plain strain condition, the following criteria must be met:

When the requisite of the criteria is fulfilled, then only KIQ can be considered as KIC.