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doi: 10.1680/jemmr.20.00269
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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Submitted: 23 September 2020

Published online in ‘accepted manuscript’ format: 18 November 2020

Manuscript title: Experimental and Numerical Investigations of Crack Growth under Mixed

Mode Loading

Author: Sedat Iriç

Affiliation: Sakarya University, Sakarya, Turkey.

Corresponding author: Sedat Iriç, Mechanical Engineering Faculty, Sakarya University,

Sakarya, Turkey. Tel.: +90 264 295 55 76

E-mail: siric@sakarya.edu.tr

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Abstract

Fatigue fracture is the one of the most common failures of mechanical components. This is

caused by the initiation and growth of cracks. In this study, mixed mode-I/III fatigue crack

growth is studied experimentally and numerically for cylindrical specimen with a stress ratio R

= 0.1 for both loading. Digital camera was used to monitoring the crack growth path in the

experimental studies. The crack growth path, crack tip profiles, variations of stress intensity

factors (SIF) and equivalent SIF were calculated by Ansys, FCPAS and Solidworks software

and results were compared with experimental data. Modeling, meshing and problem solving

were performed using Ansys, and the resulting SIF and equivalent SIF along the crack front

were calculated using FCPAS that is employed with enriched elements. It is seen that the

criteria from literature (Richard, Tanaka, Pook and Ayhan-Demir) can be successfully applied

to the problem. The results show that very good agreements are obtained between the results of

the simulation and experiment in terms of both evolving the crack growth paths and crack tips.

The presented methodology can be used to predict the both surface and interior the crack path

for various loading conditions and applications.

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Notation
E Young’s modulus

y Yield strength

 Poisson's ratio

C Paris constants

m Paris constants

KIC Fracture toughness

a Crack length

N Load cycle

Keq Equivalent stress intensity factor

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
1. Introduction

The applications of fracture mechanics have concentrated to predict the fatigue crack growth of

flawed structures under mode I loading condition. But in industry, many service failures occurs

due to the crack is not perpendicular to the mode I loading direction or the structure is

subjected to multiaxial (mixed mode) loadings. Under such mixed-mode (mode I/III) loading

conditions, out of plane (Mode III) loading can accelerate crack growth and the crack may

deviate from the original crack path. Thus, thorough understanding and knowledge of

mechanisms driving mixed mode fracture and crack growth conditions are necessary for

accurate assessment of such conditions computationally and experimentally. Linear elastic

fracture mechanics (LEFM) approach has been widely used in analyzing the fatigue crack

behavior where elastic stress-strain field in the vicinity of crack tip are usually evaluated by

calculating the SIF.1 To investigate the SIF under mixed mode-I/III loading conditions some

studies were performed experimentally and numerically using different criteria, materials and

specimen types. Jiang2 has proposed a multiaxial fatigue criterion to predicting general crack

growth. J.Qian and A.Fatemi3 has prepared a reviews the various criteria and parameters for

predictions of mixed mode crack growth directions and rates. Nikitin at al.4has focused on the

analysis of fatigue crack initiation and growth mechanisms in defect free cylindrical specimen

made from VT3-1 titanium alloy in VHCF regime under tensile and torsion loadings. Tanaka,

Tong et al., Richard, Rhee et al., Forth et al., Hänsel et al., Liu and Mahadevan have proposed

various criteria for the calculation of effective mixed-mode SIF.5 Pook6, Richard et al.7 and

Schollmann et al.8 have developed three-dimensional (3D) criteria for the prediction of crack
5

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
propagation crack front profile and equivalent SIF. Demir et al.9 have proposed an improved

empirical mixed mode-I/II/III fracture criterion using all data obtained from numerical and

experimental analyses. Erdogan et al.10 have proposed the maximum tangential stress criterion.

Seifi el al.11 has studied numerically and experimentally by using modified CT specimen under

mixed mode I-III fatigue crack growth. Citarella et al.12 has investigated fatigue surface crack

growth in cylindrical specimen under combined loading. Kurt et al.13 have made several 3D

mixed mode fatigue crack growth simulation using FCPAS software. In this study, a numerical

and experimental analyses were performed using round bar specimens with V-shaped notch

made of Al 7075-T651 to compare crack paths and life under tensile and torsion loadings.

2. Experimental investigations

The extruded bar of aluminum alloy 7075-T651 with 30 mm diameter were used in this study.

The mechanical properties of the alloy and the constants of the Paris equation (Equation 1) for

this material are listed in Table 1. where E is the Young’s modulus, y is the yield tensile

strength, C and m are the Paris constants. The fracture toughness (K IC) and The Paris

constants were determined using standard notched and pre-cracked specimens.14,15

da
 C K eqm (1)
dN
The specimen geometry and test section dimensions are shown in figure 1. A milling

cutter was used to prepare a V-shaped notch on one side of the specimen.

The axial/torsional test system (MTS 809) was used for mixed mode fatigue and fracture

testing of the specimens. This system was equipped with fatigue rated axial–torsional dynamic

load cell with axial capacity 100 kN and torsional capacity 1100 Nm. Two independent 800x
6

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
usb digital microscopes were used for the monitoring of the cracks (Figure 2). This system has

enabled simultaneous observation of two sides of the specimen during the fatigue test. Before

fatigue crack growth tests, pre-crack was prepared at the notch tip by applying the cyclic mode

I loading. The limit load for fatigue pre-cracking has to be selected such that maximum stress

intensity factor (Kmax) would not exceed 80% of minimum expected fracture toughness

according to ASTM E-399. The fatigue pre-crack was done at a maximum tensile load of 17.5

kN and with a stress ratio R = 0.1. When the surface crack length (a) in Figure 3 was

approximately equal to 1.3 mm, the test was stopped.

After generated the fatigue pre-crack, the specimen was tested such that tension and

torsion loadings were 12.75-1.275 kN and 67.5-6.75 Nm (R = 0.1 for both loading)

respectively, until the specimen was fractured (Figure 3). The pre-crack and the fatigue crack

growth tests were done at frequency f=3 Hz.

Digital image observations of the specimen fracture surfaces were carried out in order to

find geometry of the pre-crack tip. Obtained images was converted to 3D curve using curve

fitting tool that is inside the Solidworks software. The curve was used to define the tip of the

crack for the fatigue crack growth simulation under mixed mode loading.

3. Numerical modeling and analysis

In this section, ANSYS, Solidworks and FCPAS software were used for modeling and

analyzing the mixed mode fatigue crack growth. The process steps of the analysis procedure

are shown in Figure 4.

The finite element model of the specimen was modeled as shown in Fig 1 and applied
7

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
12.75 kN tension and 67.5 Nm torsion loadings with as in the experimental test. Hexahedral

enriched and transition elements were used along and near the crack front, while remaining

regions are meshed using tetrahedral elements (Figure 5).

The FEM model was used to calculate some inputs for FCPAS and FRAC3D as show in

Figure 4. FRAC3D solver, which is part of Fracture and Crack Propagation Analysis System

(FCPAS) was used to compute three-dimensional mixed mode SIFs. FRAC3D is a

general-purpose standalone finite element-based program16,17 employing enriched crack tip

elements to compute SIFs. Enriched finite elements do not require special mesh near crack

front and SIFs are directly solved for at the same time as nodal displacements without any

post-processing effort. The predicted crack growth directions were determined by maximum

tangential stress (MTS) criterion using calculated SIF. In Figure 6, distributions of mixed

mode SIFs along the crack tip obtained from each propagation step using FCPAS were

presented. The SIF were shown a good agreement with Citarella's results.

The equivalent SIF was calculated using different criteria defined in FCPAS to compare

results. When the stress intensity factor reaches the KIC value, unstable fracture occurs. Crack

growth model of Paris-Erdogan law as shown in equation 1 was used for prediction of nodal

crack growth increments using the calculated equivalent SIF. The generated curve by FCPAS

was converted to an elliptical and smooth form using Solidworks software and then the curve

was added to FEM model to growth of the crack. This process was repeated until the

equivalent SIF was reached to the fracture toughness (KIC) of the material. The SIF of the 1st

step (pre-crack) and 6th step were shown in Figure 6 a,b. Richard, Tanaka, Pook and

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Ayhan-Demir 3D criteria were used to calculate the equivalent SIF by FCPAS. The calculated

equivalent SIF value of 6th step was 29.8, 29.6, 30.4 and 33.2 MPa.m1/2 respectively. At the

6th step, the equivalent SIF has reached the fracture toughness of the material as shown in Fig

6c, therefore the numerical analysis process for fatigue crack growth was completed.

4. Result and discussion

Digital image examination of the specimen fracture surfaces were carried out in order to find

the beginning of the stable and unstable crack growth zones as shown in Figure 8.

Using the examination in Figure 8, the stable and unstable crack growth path was also

determined.

In figure 9 both the experimental and numerical results images were overlapped to

compare results. The dashed yellow line indicates the predicted the ith crack tip. The

simulation was begun with the pre-crack tip determined by digital image and propagate with

the calculated next crack tip by FCPAS, until equivalent SIF was reach the fracture toughness.

The calculated equivalent SIF for the 6th crack tip was equal to the fracture toughness of the

material. This mean, unstable crack growth or fast fracture will occurs. Very good agreements

are obtained between the results of the simulation and experiment in terms of both evolving the

crack growth paths and crack tips shown in Figure 9. The SIF were shown a good agreement

with Citarella's results and the crack growth path prediction also very good agreement with

Sajith’s18,19,20 results.

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
5. Conclusion

In this study, numerical and experimental studies for the surface crack growth in cylindrical bar

under combined cyclic tension-torsion loads were performed. When the above results are taken

into consideration, this study has primarily yielded the following conclusions.

- Finite element modeling can be used accurately for study of mixed mode (I/III) fatigue

crack growth.

- The MTS criterion for determination of crack growth direction can be used

successfully for mixed mode I/III fatigue crack growth.

- Along crack tip, KI values in outer points are larger than interior points at initial steps

of crack growth but with further growth of the crack the differences decrease.

- KII values are small and negligible in comparison with other modes.

- KIII values in outer points are larger than interior points such as KI

- The all used criteria in FCPAS for calculate the equivalent stress intensity factor under

mixed mode conditions are in very good agreement with the experimental

measurement.

- There are no a significant difference between the results of the simulation and

experiment in terms of both evolving the crack growth paths and crack tips.

- The presented methodology can be used to predict the life of the specific component

using a camera which is used to observe the surface crack path.

10

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Acknowledgments

The financial support by The Scientific and Technological Research Council of Turkey

(TUBITAK) under Project Number: 217M690 for this study is gratefully acknowledged. I

would also like to thank Strategic Products Research and Development Center (SARGEM) for

the use of the facilities.

11

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
References
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2. Jiang, (2000) A fatigue criterion for general multiaxial loading, Fatigue & Fracture of

Engineering Materials and Structures, 23(1): 19-32.

3. J. Qian, A. Fatemi (1996) Mixed mode fatigue crack growth: A literature survey,

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4. A. Nikitin, T. Palin-Luc, A. Shanyavskiy (2016) Fatigue crack initiation and growth on an

extruded titanium alloy in gigacycle regime: comparison between tension and torsion

loadings, Procedia Structural Integrity 2: 1125-1132.

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7. H. A. Richard, M. Schollmann, M. Fulland, M. Sander (2001) Experimental and numerical

simulation of mixed mode crack growth, Proc. of 6th Int. Conf. of Biaxial/Multiaxial

Fatigue and Fracture: 623-630.

8. M. Schollmann, G. Kullmer, H. A. Richard (2001) A new criterion for 3d crack growth

under mixed mode (I+II+III) loading, Proc. of 6th Int. Conf. of Biaxial/Multiaxial Fatigue

and Fracture: 589-596.

9. O. Demir, A. O. Ayhan, S. İriç (2019) A novel test system for mixed mode-I/II/III fracture

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tests – Part 2: Experiments and criterion development, Engineering Fracture Mechanics,

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in cylindrical specimen under combined loading, Engineering Fracture Mechanics 131:

439-453.

13. E. Kurt, O. Demir, A. O. Ayhan (2019) Applications on three-dimensional mixed mode

fatigue crack propagation using fracture and crack propagation analysis system (FCPAS),

Procedia Structural Integrity 21: 32-30.

14. Altuncu E. , İriç S. (2017) Evaluation of Fracture Toughness of Thermal Sprayed and Hard

Chrome Coated Aluminium-Zinc Alloy, Acta Physica Polonica A 132(3): 926-929.

15. İriç S. , Ayhan A. (2017) Dependence of Fracture Toughness on Rolling Direction in

Aluminium 7075 Alloys, Acta Physica Polonica A 132(3): 892-895.

16. A. O. Ayhan, H. F. Nied (2002) Stress intensity factors for three‐dimensional surface

cracks using enriched finite elements, International Journal of Numerical Methods in

Engineering 54: 899-921.

17. A. O. Ayhan, H. F. Nied (1998) Finite Element Analysis of Interface Cracking in

Semiconductor Packages 22(4): 503-511.

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
18. S. Sajith, K.S.R.K. Murthy, P.S. Robi (2020) Experimental and numerical investigation of

mixed mode fatigue crack growth models in aluminum 6061-T6, International Journal of

Fatigue, doi: 10.1016/j.ijfatigue.2019.105285.

19. P. Zhanga, L. Xiea, C. Zhoua, X. Hea (2020) Experimental and numerical investigation on

fatigue crack growth behavior of commercial pure titanium under I-II mixed mode loading

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20. Y. Yang, M. Vormwald (2017) Fatigue crack growth simulation under cyclic

non-proportional mixed mode loading, International Journal of Fatigue (102): 37-47.

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Table 1. Main mechanical properties of Aluminum alloy 7075-6519

E (GPa) y (MPa)  KIC (MPa√m) C m

70 500 0.33 29.6 2.28 x 10-7 3.11

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Figure 1. Details of specimen geometry

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Figure 2. (a) Test setup (b) camera views

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Figure 3. (a) Fractured specimen (b) Perspective view (c) Front view (d) Top view (e)
Schematic representation of the fractured section

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Figure 4. The process steps of the analysis procedure

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Figure 5. The overall and close-up views of crack front including enriched elements and
adjacent transition elements in the specimen model

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 Accepted manuscript
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Figure 6. Variation of SIF values along the crack tip for each propagation step (a) KI variation,
(b) KII variation, (c) KIII variation

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 Accepted manuscript
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Figure 7. Variation of SIF values along the crack tip (a) 1st step (b) 6th step, (c) Equivalent
SIF at the 6th step

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 Accepted manuscript
doi: 10.1680/jemmr.20.00269
Figure 8. Digital images of the fractured surface of the specimen (a) Front & Top view, (b)
Surface crack growth paths, (c) Crack growth zone boundaries

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doi: 10.1680/jemmr.20.00269
Figure 9. Overlapped views of the experimental and numerical simulation results (a) Front
view, (b) Top view

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