Fracture Mechanics Analysis In: MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
Fracture Mechanics Analysis in

Structural Design
MAE4301/AE5339/ME5339 Spring 2015

Department of Mechanical & Aerospace Engineering
Chapter 11
OUTLINE
11.1 Background.
11.2 Fracture Process.
11.3 Fundamental Fracture Modes.
11.4 Stress Field in a Crack.
11.4.1 Stress and Displacement Field at The Crack
Tip.
11.5 Meaning of Stress Intensity Factor (SIF).
11.6 Finite Width Effect of SIF.
11.6.1 Center Crack.
11.6.2 Double Edge Crack.
11.6.3 Single Edge Crack.
11.6.4 Surface Crack.
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
OUTLINE (Contd)
11.7 Energy Rate Analysis of Crack Extension and Its
Measurement.
11.8 Equivalence of Strain Energy Release Rate and
SIF Approaches.
11.9 Fracture Toughness (Critical Stress Intensity
Factor).
11.10 Fatigue Crack Propagation.
11.11 Crack Growth Models.
11.12 Factors That Affect The Fatigue Crack Growth.
11.13 Plastic Zone Size.
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
11.1 Background
Structural failure often occurs at a strength well
below the yielding point. This led to reveal that
failures occur due to a flaw or crack in
structures and the stress gradients around a
crack were responsible for failure.
Cracks existence in structure may be due to
fabrication or in service.
Fracture mechanics is used to study the
behavior of crack. The following questions are
often considered to designers:
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
Background (Contd)
1)
What is the residual strength as a function of

crack size?
2)
What is the maximum permissible size of a

crack before catastrophic failure?
3)
How long does it take from the maximum

detectable crack size to maximum
permissible size?
4)
During the period available for crack

detection how often should the structure be
inspected for cracks?
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
Background Contd)
a
a
detectable
crack size
max. permissible
crack size
a0
time
time available
for crack detection
design strength
stress level
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
11.2 Fracture Process

Three stages are often considered in the study of
crack:
1)
Crack Initiation micromechanics, dislocation

theory
2)
Crack Extension (slow crack growth) preexistence of a crack size is required.
3)
Crack Propagation (fast crack propagation)

dynamic crack behavior.
In the scope of Fracture Mechanics, (2) and
(3) are included. In this chapter, only (2) will be
discussed.
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
11.3 Fundamental Fracture Modes

Mode 1. Opening Mode
y
x
growth
direction
Stress in perpendicular to growth direction.

Stress is perpendicular to crack surface plane
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
Fundamental Fracture Modes (Contd)

Mode 2. Shearing Mode
y
xy
Stress is parallel
to growth direction.
Mode 3. Tearing Mode

y
xz
Stress is perpendicular
to growth direction.
Stress is on the
crack plane.
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
Fundamental Fracture Modes (Contd)

Examples:
Mode I
Mode III
Mode I
Mode II
Mode I II (Mixed Mode)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
10
11.4 Stress Field in a Crack

The elastic stress analysis
shows that the stress at the
crack tip is singular, i.e. stress
at r = 0 is undefined (infinite).
design
2a
The stress near a crack is

found to be inversely
proportional to the square
root of half of the crack
length.
1
(11-1)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
11
Stress Field in a Crack (Contd)

Experience indicates that the conditions of
crack growth are controlled by the magnitude
of elastic stress field near a crack.
The term used to characterize the intensity of
singular stress field is so-called Stress
Intensity Factor (SIF).
K 0 a
(11-2)
K Stress Intensity Factor.
0 Applied Load.
a Half of Crack Length.
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
12
Stress Field in a Crack (Contd)

K is dependent on the Mode of Fracture.
K I y a
K II xy a
K III xz a
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
13
11.4.1 Stress and Displacement Field at The Crack Tip

Consider the following plate with an elliptical
cutout. The stress, at point A can be in term of
y
0
2b
A
2a
y
a
SCF 1 2
0
b
For a hole, a b SCF 3
y
The cutout becomes a line crack.
if b 0
the state of stresses near the crack tip is given

below, without a detail derivation.
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
14
Stress and Displacement Field at The Crack Tip (Contd)

a) Mode I:
0 a
3
x
cos 1 sin sin
2
2
2
2r
0
y
r
2a
0 a
3
y
cos 1 sin sin
2
2
2
2r
(11-3)
0 a
3
xy
cos sin cos
2
2
2
2r
z x y
xz yz 0
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
15

The stress intensity factor of Mode-I Fracture is
defined as: K lim
I
y 0 2r 0 a
(11-4)
r 0
The stress field of equation (11-3) can be
rewritten as:
KI
3
x
cos 1 sin sin
2
2
2
2 r
KI
3
y
cos 1 sin sin
2
2
2
2 r
(11-5)
KI

3
xy
cos sin cos
2
2
2
2 r
z x y
xz yz 0
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
16

The corresponding displacement field can be
obtained from the theory of elasticity.
K I 2r
3
[(2k 1)cos cos ]
8
2
2
ux
uy
K I 2r
3
[(2 1)sin sin ]
8
2
2
3 4v Plane Strain
E
k 3 v
2(1 )
1 v Plane Stress
uz 0
Note:
ux
uy
(11-6)
for plane strain.
is a symmetric function of
2
is an unsymmetric function of
2
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
17

b) Mode II:
K II
3
x
sin 2 cos cos
2
2
2
2 r
0
y r
2a
K II
3
y
cos sin cos
2
2
2
2 r
xy
(11-7)
K II
3
cos 1 sin sin
2
2
2
2 r
z x y
xz yz 0
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
18

K II lim xy
r 0
ux
2 r 0 a
K II 2r
3
[(2 3)sin sin ]
8
2
2
(11-8)
K II 2r
3
uy
[(2 3)cos cos ]
8
2
2
uz 0
Note: u x
uy
(11-9)
for plane strain.
is an unsymmetric function of
2
is a symmetric function of
2
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
19

c) Mode III:
K III
xz
sin
2
2 r
yz
y
yz
K III
cos
2
2 r
(11-10)
xy x y z 0
K III yz
(11-11)
2r 0 a
K III
uz w
2r
sin
ux u y 0
E
2(1 )
(11-12)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
20
11.5 Meaning of Stress Intensity Factor (SIF)

The SIFs defined as in equation (11-4), (11-8)
and (11-11) are the measurement of the
intensity or magnitude of the singular stress
field. The SIF is a primary parameter in
Fracture
Mechanics.
Unlike
stress
concentration factor (SCF), the SIF is a square
root function of a half crack size and applied
load. The SCF is independent of hole size.
The unit of SIF is
psi - in
1
2
or ksi - in
Stress (Lengh)
1
2
1
2
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
21
Meaning of Stress Intensity Factor (Contd)

It should be noted here that there exists another
definition of SIF(K) call it K* -- which defers from
the present definition by the factor . That is, K . K *
When K* is used then the singular stress fields
are written in the form 1 rather that 1 .
2r
2r
To avoid an error of
when using SIF
solutions from literature, you must be careful to
determine which definition the another used.
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
22
11.6 Finite Width Effect of SIF

The solution for the SIF in the previous section is
strictly valid only for an infinite plate. The geometry of
finite size has an effect on the crack tip stress field
and so expressions for stress intensity factors have to
be modified by the addition of correction factors to
enable their use in practical problems.
A general form for such a correction factor is
a
K I c a f
(11-13)
w
a
Where c and f( ) have to be determined by stress
w
analysis. There are few closed form solutions

available. Most solutions are obtained by numerical
approximation methods.
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
23
11.6.1 Center Crack

2b
a
a
KI a
tan
a f
b
a 2b
0
2b
2a
a
b
0.074
0.207
0.275
0.337
0.410
0.466
0.535
0.592
(11-13)
a
b
1.00
1.02
1.03
1.05
1.08
1.11
1.15
1.2
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
24
11.6.2 Double Edge Crack

a
K I 1.12 a f
b
(11-14)
2b
a
The table shown in

section (11.6.1) can be
also applied.
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
25
11.6.3 Single Edge Crack

0
2b
a
KI a f
b
a
b
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
(11-15)
b
1.15
1.20
1.29
1.37
1.51
1.68
1.89
2.14
2.46
2.86
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
26
11.6.4 Surface Crack
/2
2c
a
K I 1.12
Q
(11-16)
c2 a2
2
sin
1
2
1/2
(11-17)
For circular cracks, a=c

a
a
K I 1.12
1.12 2
2
/4
(11-18)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
27
11.7 Energy Rate Analysis of Center Crack and its Measurement

P
a a
Strain energy release rate
= energy per unit of new

crack
area
generated
available for an increment
of crack extension.
= work done by external
force strain energy in the
body.
dW
dU
G
dA
dA
(11-19)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
28
Energy Rate Ana. of Center Crack and its Measurement (Contd)

(I) For a constant load,
dW Pd
(11-20)
1
1 2
U P P
2
2
Measurement of G is
accomplished by the
definition of compliance,
inverse of spring constant

P
1
dU P d
2
dW
dU
2
dA
dA
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
29

B is the thickness
of the plate
dU dU
1 P
P
dA Bda B a
2 a
P
dW 1 dW 1 Pd
(P )
dA B da B da
d P
P
da a
a
2
dW dU 1
G

dA dA B
1 P
P
P2
B a
Pd dU
da
da
P
P 2
1 P 2
P

a
a
2 a
B 2 a
(11-21)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
30

(II) For a constant displacement
dW
0
dA
2
1
1
d 0U P
2
2
1 dU
1 2
P 2
G

2
B da
2
a
2 B a
(11-22)
Equation (11-21) and (11-22) are identical.

This concludes that
1 P 2 is independent of the
G
B 2 a type of test fixture.
(11-23)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
31

In experiment,
P
a0
a 1
P a2
a can be
determined
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
32
11.8 Equivalence of Strain Energy Release Rate

and SIF Approaches
In section (11-7), we have shown that the strain
energy release rate, G is independent of the
load type and/or grip condition. Thus, for
convenience, in the following discussions, the
fixed grip condition will be used with no loss in
generality of the results.
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
33
Equivalence of S. Energy Release Rate and SIF Approaches
Consider an elastic body be loaded and the grips

be fixed, the G can be written as
dW dU
dU
G
dA dA
dA
2a
fixed
energy
a x
grip
release
x Displacements
forces
along a
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
34
The work required to close a small segment

of the crack, from the opened position to the
closed position is identical to the strain
energy released upon its opening.
dU
2 yyu y xyu x yz uz
G
lim
dx
da a0 a 0 2
2
2
a
(11-24)
The negative sign is removed because the

crack closing displacements are negative.
The factor of 2 preceding the integral is
necessary because displacements occur on
both sides of the crack planes.
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
35
Equation (11-5) 0, r x
Equation (11-7)
0, r x
Equation (11-10)
0, r x
KI
y
2x
K II
xy
2x
K
yz III
2x
(11-25)
KI
2(1 )
a x
2(1 )
E
2
K
2(1 )
2(1 )
Equation (11-9) , r a x, u x II a x
E
2
K III
2(1 )
Equation (11-12) , r a x, u z
2(a x)
E
Equation (11-6) , r a x, u y
(11-26)
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
36
Substituting equation (11-25) and (11-26) into

(11-24), we have
1 K I2 a 4(1 2 ) K II2 a 4(1 2 ) K III2 a 2(1 )
G lim
1
1
dx
a0 a
2 x
E
2 x
E
2 x
E
0
a
1 K I2 4(1 2 ) K II2 4(1 2 ) K III2 2(1 )

lim
a
a0 a 2
2
E
2
2
E
2
2
E
1 2 2 1 2
1
2
2
KI
K II
K III
E
E
E
(11-27)
GI GII GIII
(11-28)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
37
Where
1 2 2
GI
KI
E 2
1
2
GII
K II
E
1
2
2
2
GIII
K III K III
E
G
For plane stress,
K
GI I
E2
K
GII II
E
GIII
(11-29)
2
2
K III
G
(11-30)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
38
Example
Consider an equally split beam loaded as
shown in the figure. Determine GI
P
3
2h
The beam is divided into three parts. Beam 1

and beam 2 are cantilevered at the crack tip
area. Beam 3 is not loaded.
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
39
Example (continued)
P
1
2h
Mx Px
a
x
For constant load,

we have
dW dU dU
(11-19)
G
dA
dA
dA
a
M x2
p a
dx
Strain energy for Beam 1 U1
2 EI
6 EI
0
Strain energy for Beam 2 U 2 U1
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
40
Example (continued)
P
1
2h
Strain energy for Beam 3
dW
dU
dU
G
dA
dA
dA
U3 0
Total strain energy

U T U1 U 2 U 3 2U1
p2a3
U1
6EI
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
41
Example (continued)
P
1
2h
dA t da
Total strain energy

p 2a3
UT
3EI
dW dU dUT
G
dA dA
dA
1 3
I th
12
pa
G
t EI
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
42
11.9 Fracture Toughness (Critical SIF)

Fracture toughness is the critical value of
stress intensity factor. Fracture toughness is a
material parameter, but it depends on both
temperature and the specimen thickness.
K IC a f atcriticalstage.
K IC c
orK IC
K IC
a f c
a f
K IC
ac f ac
f
(11-31)
1
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
43
11.10 Fatigue Crack Propagation

Typical constant amplitude crack propagation
data is shown as:
a
3 2 1
3 2 1
Crack growth rate is defined as

N
da
Crack extension per cycle,
dN
The growth rate is a function

of stress intensity factor
N
max min
da
f (K )
dN
(11-32)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
44
Fatigue Crack Propagation (Contd)

Experimental data plot of da Vs. K is shown as:
da
dN
K th
K c
dN
Region I: crack behavior is

associated with K th (threshold
value) below which the crack
growth is negligible.
da
10 8 in / cycle
dN
da
Region II: log Vs. log K is a linear relationship.
dN
da
10 3 ~ 10 6 in / cycle
dN
Region III: Crack growth rate is extremely high

and little fatigue life is involved.
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
45
Example: Fatigue Crack Propagation for a Central

Crack in a Plate.
Assumption: There exists a crack in the material.

Growth rate,
2a
da
crack extension per cycle.
dN
fatigue loading f (K )
Pairs and Erdogan

da
C (K ) m
dN
K K atmax. K atmin.
( m min ) a a
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
46
Example: Fatigue Crack Propagation for a Central

Crack in a Plate (Contd)
ln
da
dN
da
ln
ln C m ln(K )
dN
ln(K )
ln C
Fatigue life prediction for constant loading:

da
C(K )m
dN
K a
da
dN
C( )4 ( a)2
1
Nf
C 2 ( ) 4
Nf
N0 0
dN
1
1

a0 a f
af
a0
da
C 2 ( )4 a 2
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
47
11.11 Crack Growth Models

Region I:
3 Ksi in
K th 4 Ksi in
5 Ksi in
Al - Alloy
Ti - Alloy
Steel
Designing a component such that K for

service condition K K th would be highly
desirable. However, to satisfy the above
equation, we either have a very low applied
stress or allow a very small crack. This is
impractical for both of the above mentioned
conditions.
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
48
Crack Growth Models (Contd)

Region II:
Pairs and Erdogan Proposed da c(K ) m (11-33)
dN
Where c and m are material constants.

da
log
dN
da
log
log c m log K
dN
log c
K 1
log K
K K max K min max a min a a

MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
49

Fatigue life can be predicted by
da
f (K )
dN
da
a f finalcracksize
dN
N0
a0 f ( K )
af
af
da
da
Nf
a0 f ( K )
a0 c ( K ) m
Nf
af
can be specified or maximum permissible

crack size. For the maximum crack size, can
be determined by
af
0 a f f K IC
1 K IC
af
0 f
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
50

Region III:
In most of engineering analysis, this region is
ignored since it contributes a little crack
propagation life. In this region, plastic zone
size becomes large compare to the
dimension of the crack. Therefore, the
problem should be analyzed by elastic-plastic
approach.
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
51
11.12 Factors That Affect the Fatigue Crack Growth

Stress Ratio Effect:
For a constant K, the more positive R, the
higher the crack growth rates.
Two crack growth models accounting for
stress ratio effect.
1. Forman's Crack Growth Model:
da
cK m
dN (1 R)K C K
(11-34)
2. Walker's Crack Growth Model:

da
c (1 R)m K max
dN
(11-35)
da
For R 0,
increases as R increases.
dN
MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
52
Factors That Affect the Fatigue Crack Growth (Contd)

Frequency Effect:
In a normal environmental condition, frequency
has little effect on fatigue life for metallic
structure. However, growth rate will be
significantly affected if under an adverse
environment.
Temperature Effect:
Fatigue life will be reduced
if temperature is increased.
da
dN
R
K
Higher R gives higher growth rate

MAE4301/AE5339/ME5339 Spring 2015
Chapter 11
53
11.13 Plastic Zone Size

For plane stress problem, yielding can occur
when stress reaches the yielding strength.
y
ys
x
1
ry
2
1
ry
6
KI

ys
KI

ys
KI
3
cos 1 sin sin
2
2
2
2r
at y ys 0
ys
KI
2ry
Plane Stress.
(11-36)
Plane Strain.
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
54
Plastic Zone Size (Contd)

Note: Plastic zone size for plane strain is
smaller than the size for plane stress.
For cyclic plastic zone size, the change in
stress at the crack tip due to the reversed
loading is twice the value of the yield stress.
1
ry
2
1
ry
6
KI
2
ys
KI
2
ys
KI

ys
24
KI

ys
Plane Stress.
Plane Strain.
(11-37)
MAE4301/AE5339/ME5339 Spring 2015

Chapter 11
55

Fracture Mechanics Analysis In: MAE4301/AE5339/ME5339 Spring 2015

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Chapter 11

Fracture Mechanics Analysis in

MAE4301/AE5339/ME5339 Spring 2015

MAE4301/AE5339/ME5339 Spring 2015

What is the residual strength as a function of

What is the maximum permissible size of a

How long does it take from the maximum

During the period available for crack

Department of Mechanical & Aerospace Engineering

MAE4301/AE5339/ME5339 Spring 2015

11.2 Fracture Process

Crack Initiation micromechanics, dislocation

Crack Extension (slow crack growth) preexistence of a crack size is required.

Crack Propagation (fast crack propagation)

11.3 Fundamental Fracture Modes

Stress in perpendicular to growth direction.

MAE4301/AE5339/ME5339 Spring 2015

Fundamental Fracture Modes (Contd)

Mode 3. Tearing Mode

MAE4301/AE5339/ME5339 Spring 2015

Fundamental Fracture Modes (Contd)

Mode I II (Mixed Mode)

MAE4301/AE5339/ME5339 Spring 2015

11.4 Stress Field in a Crack

The stress near a crack is

MAE4301/AE5339/ME5339 Spring 2015

Stress Field in a Crack (Contd)

K Stress Intensity Factor.

Stress Field in a Crack (Contd)

MAE4301/AE5339/ME5339 Spring 2015

11.4.1 Stress and Displacement Field at The Crack Tip

the state of stresses near the crack tip is given

Stress and Displacement Field at The Crack Tip (Contd)

Stress and Displacement Field at The Crack Tip (Contd)

MAE4301/AE5339/ME5339 Spring 2015

Stress and Displacement Field at The Crack Tip (Contd)

for plane strain.

MAE4301/AE5339/ME5339 Spring 2015

Stress and Displacement Field at The Crack Tip (Contd)

Stress and Displacement Field at The Crack Tip (Contd)

for plane strain.

MAE4301/AE5339/ME5339 Spring 2015

Stress and Displacement Field at The Crack Tip (Contd)

MAE4301/AE5339/ME5339 Spring 2015

11.5 Meaning of Stress Intensity Factor (SIF)

MAE4301/AE5339/ME5339 Spring 2015

Meaning of Stress Intensity Factor (Contd)

MAE4301/AE5339/ME5339 Spring 2015

11.6 Finite Width Effect of SIF

analysis. There are few closed form solutions

11.6.1 Center Crack

MAE4301/AE5339/ME5339 Spring 2015

11.6.2 Double Edge Crack

The table shown in

MAE4301/AE5339/ME5339 Spring 2015

11.6.3 Single Edge Crack

MAE4301/AE5339/ME5339 Spring 2015

11.6.4 Surface Crack

For circular cracks, a=c

MAE4301/AE5339/ME5339 Spring 2015

11.7 Energy Rate Analysis of Center Crack and its Measurement

Strain energy release rate