ME-350 Mechanical Behavior

of Materials

Col (ret) Rob Fredell, Ph.D.

Office: 6L-165
robert.fredell@afacademy.af.edu
 Block 1 Lessons 1-16 Reading Suggested HW Assignments Due
Day/Date Lesson Topic
(before class) (after class) (Beginning of Class)

10/11 Aug M/T 1 Course Introduction 1.1-1.6, 6.1-6.2 6.1(a)

14/15 Aug M/T 2 Matl Sci - Structure & Deformation I 2.1-2.4 2.3

16/17 Aug M/T 3 Mat Sci - Structure & Deformation II 2.5-2.7 2.13

18/21 Aug M/T 4 Matl Sci - Strengthening Methods I Appendix C.1 -C.2 2.12 Skills Review

22/23 Aug M/T 5 Matl Sci - Strengthening Methods II Appendix C.3-C.4

24/25 Aug M/T 6 Mechanical Testing I 3.1-3.3.4, 3.3.6, 3.43.6 3.19(a),

28/29 Aug M/T 7 Mechanical Testing II 4.1-4.4, Appendix B.1B.6 4.5, 4.7

30/31 Aug M/T 8 Tensile Test Lab Tensile Test Lab Instructions B-47 Homework

1/5 Sep M/T 9 3-D States of Stress 6.2-6.4 6.6, 6.20, 6.22 Parents Weekend

6/7 Sep M/T 10 3-D States of Strain 5.3, 6.6 - 6.7 5.13, 5.17, 5.23, 6.53

8/11 Sep M/T 11 Failure Criteria Review 7.1-7.6.3, 7.9-7.10 7.1, 7.5, 7.14, 7.26, PP#2 Tensile Lab Report

Appendix A.6 & Residual Stress Reading on

12/13 Sep M/T 12 Stress Concentrations & Residual Stresses Teams

14/15 Sep M/T 13 Fracture Mechanics: Introduction 8.1 - 8.2 8.1 Homework #1

18/19 Sep M/T 14 Fracture Mechanics: The Math 8.3

20/21 Sep M/T 15 Fracture Mechanics: Applications 8.4 - 8.5.3, 8.5.5, A.7 8.7, 8.8, 8.10, 8.24 Design Project Part 1

22/25 Sep M/T 16 Fracture Mechanics: Applications 8.4 - 8.5.3, 8.5.5, A.7 PP#4

26/28 Sep M/T 17 Fracture Toughness Testing 8.6, 8.8 8.42 (a), 8.44 (a & b), 8.45
27 Sep Commandants Trng

29-Sep M 18 GR #1
Fracture Mechanics – The Math
Lesson 14
EM350
Fall 2023
 Lesson 14 - Overview

• Review Lesson 13
• General equation for LEFM
• Stress State at the Crack Tip for Mode I Loading
• Plane Stress and Plane Strain
• Crack tip behavior in real engineering materials
• Effects of triaxial stress state at crack tip on
material behavior
• Sample equations/charts for geometry factors

• GR 1: Lesson 18, covers lessons 1 - 16

 Last time: Stress Intensity Factor (K)
• The stress conc. factor (Kt): ratio of peak stress to nominal (________)
• The _______ ___________ factor (K) is a measure of the severity of a
crack as affected by crack size, stress, and geometry
• The equation used to relate the four variables is: 𝐾 = 𝐹𝑆 𝜋𝑎 𝑤ℎ𝑒𝑟𝑒
– 𝐾 = 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛𝑡𝑒𝑛𝑠𝑖𝑡𝑦
– 𝑆 = 𝑟𝑒𝑚𝑜𝑡𝑒𝑙𝑦 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑠𝑡𝑟𝑒𝑠𝑠 𝑢𝑠𝑢𝑎𝑙𝑙𝑦 𝑔𝑟𝑜𝑠𝑠 𝑠𝑡𝑟𝑒𝑠𝑠
– 𝑎 = 𝑐𝑟𝑎𝑐𝑘 𝑙𝑒𝑛𝑔𝑡ℎ
– 𝐹 = 𝑎 𝑓𝑎𝑐𝑡𝑜𝑟 𝑛𝑒𝑒𝑑𝑒𝑑 𝑡𝑜 𝑎𝑐𝑐𝑜𝑢𝑛𝑡 𝑓𝑜𝑟 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑡 𝑔𝑒𝑜𝑚𝑒𝑡𝑟𝑖𝑒𝑠
• KC is the critical material property of K at which _______ __________
occurs in a cracked material
– In contrast, su is the stress at which fracture occurs in an uncracked material.
– KC is a function of material, temperature, loading rate, and member thickness
– KIC the worst case value of KC for thick members (called plane strain fracture
toughness)
– KC is called the material fracture toughness
Last time: Transition crack length, Fracture toughness Kc
Figure 8.6 Transition crack length at for a low-strength, high-toughness material
(a), and for a high-strength, low-toughness material (b). If (b) contains internal
flaws ai, its strength in tension σut is controlled by brittle fracture.

Type equation here.

2
1 𝐾𝑐
𝑎𝑡 =
𝜋 𝜎𝑜
When a < at failure occurs by _________
Predicted behavior
When a > at failure occurs by _______ ______

Mechanical Behavior of Materials, Fourth Edition Copyright ©2013 by Pearson Education, Inc.
Norman E. Dowling All rights reserved.
Figure 8.8 The basic modes of crack surface displacement.
(Adapted from [Tada 85]; used with permission.)

Sliding Mode

Opening Mode Tearing Mode

Mode I is caused by tension loading Modes II and III are caused by shear

Most cracking problems of interest are Mode I.

Discussion will be limited to this case.
Mechanical Behavior of Materials, Fourth Edition Copyright ©2013 by Pearson Education, Inc.
Norman E. Dowling All rights reserved.
 Equations describing stress field near crack tip
KI   3 
sx  cos 1  sin sin 
2r 2 2 2
KI   3 
sy  cos 1  sin sin 
2r 2 2 2
KI   3
 xy  cos sin cos
2r 2 2 2
s z  0 plane stress (thin members)
s z   s x  s y  plane strain
 yz   zx  0 (thick members)

As r → 0, non-zero stresses → ∞.
All non-zero stresses are proportional to KI. Thus, the magnitude of the stress
field is characterized by setting the value of KI.
The terms r and  describe the stress variation as a function of distance from the
crack tip and the angle with respect to the crack plane.
KI is most _________ immediately ahead of the crack tip ( = 0).
Mechanical Behavior of Materials, Fourth Edition Copyright ©2013 by Pearson Education, Inc.
Norman E. Dowling All rights reserved.
 Mohr’s Circle at   0 for Plane Stress and Plane Strain
𝐾𝐼
𝜎1 = 𝜎2 =
Plane Stress 2𝜋𝑟 Plane Strain
2𝜈𝐾𝐼
𝜎3 = 0 𝜎3 =
2𝜋𝑟

𝐾𝐼 𝐾𝐼 1 − 2𝜈
𝜏𝑚𝑎𝑥 = 𝜏𝑚𝑎𝑥 =
2 2𝜋𝑟 2 2𝜋𝑟
The 3-D plane strain stress state near a crack tip suppresses yielding
and may cause a ductile material to act in a brittle fashion
Example:
A thick 2024-T351 aluminum plate has a crack in it such that the stress
state is plane strain.

Calculate: factors of safety for uncracked brittle fracture, XN, and yielding,
X0 on the crack plane =0).
Based on these factors of safety, is failure more likely to occur by brittle
fracture or yielding?

Use: so= 325 MPa, su = 470 MPa,  = 0.3, r = 1.0 mm, KIC = 20 MPa-m1/2
KI    3 
sx  cos 1  sin sin
2r 2 2 2 
KI    3 
sy  cos 1  sin sin
2r 2 2 2 
KI   3
 xy  cos sin cos
2r 2 2 2
s z  0 plane stress
s z   s x  s y  plane strain
 yz   zx  0
Mechanical Behavior of Materials, Fourth Edition Copyright ©2013 by Pearson Education, Inc.
Norman E. Dowling All rights reserved.
 Solution:
𝐾𝐼
𝜎𝑥 = 𝜎𝑦 = = = 252.3 𝑀𝑃𝑎
2𝜋𝑟
𝜎𝑧 = 𝜐 𝜎𝑥 + 𝜎𝑦 = = 151.4 𝑀𝑃𝑎

1 2 2 2
𝜎𝐻 = 252.3 − 252.3 + 252.3 − 151.4 + 252.3 − 151.4 = 100.9 M𝑃a
2
𝜎𝑜 325 𝑀𝑃𝑎
𝑋𝐻 = = =
𝜎𝐻 100.9 𝑀𝑃𝑎

𝜎𝑢
𝑋𝑁 = = =
𝜎𝑦

Therefore, Fracture is ______ likely than yield.

Further increases in K will result in su being reached prior sH reaching so.

The 3-D plane strain stress state near a crack tip suppresses yielding and may
cause a ductile material to act in a brittle fashion.
Figure 8.12 Stress intensity factors for three cases of cracked plates under tension.
Geometries, curves, and equations labeled (a) all correspond to the same case, and
similarly for (b) and (c). (Equations as collected by [Tada 85] pp. 2.2, 2.7, and 2.11.)

Different crack geometries have different values of F, Sg and K

Mechanical Behavior of Materials, Fourth Edition Copyright ©2013 by Pearson Education, Inc.
Norman E. Dowling All rights reserved.
 Lesson 14 Summary
• Stress intensity factor solutions (K) exist and have been
derived for all three crack modes:
 Mode I (crack opening, most common)
 Mode II (crack sliding)
 Mode III (tearing)

• _______ _______ applies when sz = 0 (thin sheets) and

material fracture toughness K𝜎c 𝑜is highest, but shear stress is
higher (yielding more likely) 𝜎𝐻

• _______ _______ applies when sz = (sx + sy) and fracture

toughness KIC is lowest; triaxial tension results in lower shear
stress that is more likely to result in brittle fracture

• Equations and charts are available to determine values of F

and S for fracture mechanics calculations.

Mechanical Behavior of Materials, Fourth Edition Copyright ©2013 by Pearson Education, Inc.
Norman E. Dowling All rights reserved.
Mohr’s Circle at   0 for Plane Stress, Plane Strain
this is perhaps the most important concept in ME 350
𝐾
𝐾𝐼𝐼
𝜎𝜎1 = 𝜎 =
1 = 𝜎22 = 2𝜋𝑟
Plane Stress
Plane Stress
2𝜋𝑟 Plane Strain
Plane Strain 2𝜈𝐾𝐼
𝜎3𝜎3==00 𝜎3𝜎 == 2𝜈𝐾𝐼
3 2𝜋𝑟 2𝜋𝑟

𝐾𝐼 1 − 2𝜈
𝐾𝐼𝐼 𝜏𝑚𝑎𝑥 =𝐾𝐼 1 − 2𝜈
𝜏𝑚𝑎𝑥
𝑚𝑎𝑥 =
𝜏𝑚𝑎𝑥 = 2 2𝜋𝑟
2 2𝜋𝑟 2 2𝜋𝑟
3-D plane strain stress state near a crack tip reduces shear stress,
suppresses yielding and may cause a ductile material to act in a brittle fashion

Mechanical Behavior of Materials, Fourth Edition Copyright ©2013 by Pearson Education, Inc.
Norman E. Dowling All rights reserved.