Modeling and Analysis of Three Dimensional Cracks

Modeling and Analysis of Three-Dimensional
Cracks Using Unstructured Finite Elements
E. Nart, A. O. Ayhan*
Department of Mechanical Engineering
Sakarya University
54187 Sakarya, TURKEY
*E-mail: ayhan@sakarya.edu.tr 1
Agenda
Fracture Mechanics Motivation and Needs
3D Fracture Mechanics Available Methods/Tools
Enriched Finite Elements for 3D Fracture Mechanics
FCPAS Fracture and Crack Propagation Analysis System
Fracture finite element models developed using ANSYS
Fracture finite element models developed by crack insertion into an uncracked model
Fracture analysis by three-dimensional enriched finite elements
Applications:
Mode-I surface crack insertion into an uncracked finite-thickness plate
Inclined and deflected surface crack insertion into an uncracked finite-thickness plate
Fracture solutions by enriched finite elements
Fatigue crack growth analysis of Mode-I surface crack in a plate under cyclic bending load
Summary/Conclusions
2
Why Fracture Mechanics?
Schenectady T2 Tanker, January 16, 1943
152m long T2 tanker, 'Schenectady'
16 January 1943 (A few days after the
sea trials)
Breaks into two parts while lying at the
harbor (Portland, Oregon)
Still harbor water and about 4C
Light winds and air temperature about -
3C
Sudden failure heard a mile away
Fracture extended through the deck, the
sides of the hull, the longitudinal
bulkheads and the bottom girders.
Central part of the ship rose clear of the
water
Poor welding in highly stressed region
Ref: http://www.twi.co.uk/j32k/protected/band_13/oilgas_caseup31.html 3
Why Fracture Mechanics?
Aloha Airlines Flight 243, April 28, 1988
April 28, 1988, 1:25 pm Hilo to Honolulu

Rupture of fuselage at the top of its climb
Senior flight attendant blown from the aircraft to her death
The cockpit door and roof blown away
Most passengers were injured, seven seriously
Undetected fatigue damage

Ref: http://www.volpe.dot.gov/infosrc/journal/30th/safety.html 4
Mechanical Life of A Part
LCF, HCF, Creep, Fatigue & Creep
Oxidation CP, Fracture
Crack Crack
Initiation + Propagation = Total Life
Fracture Mech.,
S-N, Goodman,
da/DN, da/dt
Creep Curves
Curves, KIC
5
3D Fracture Mechanics Motivation and Needs
Aluminum Plate
A Machine Part
(Takashi et al, 2000)
(Dowling, 2002)
Fatigue Crack Propagation
Turbine Bucket Dovetail

Electronic Package (D.
(Dumas et al, 2006)
Peterson, 1998)
Though many problems can be approximated by 2D methods, most real problems are 3D 6
Agenda
Applications:
Summary/Conclusions
7
3D Fracture Mechanics
The Most Common Types of Cracks are Surface & Corner Cracks
Deflected Surface Crack Inclined Surface Crack

0 0
H H
2W 2W
t t
xy y x
z
a a
z
2c H 2c H
Y Y
X X
Z 0 Z 0
8
Disadvantages Advantages
Alternating methods
Limited geometry Quicker to solve,
or loading Boundary element methods simple models and
geometries
Virtual Crack Extension Method
Line-Spring Method
Finite Element Methods
Quarter-point elements Accurate
representation of
Model and mesh actual geometry and
generation can be
J & Interaction Integral local loads near crack
time consuming region
Domain Integral Multi-loading and
material model
Enriched Finite Elements capabilities
(Topic of This Presentation)
9
Agenda
Applications:
Summary/Conclusions
10
Enriched Finite Elements for 3D Fracture Analysis
nodel ntip
nodel
u ( , , ) = N j ( , , )u j + Z 0 ( , , ) N i ( ) K f1 ( , , ) N j ( , , ) f 1 j
i
I
j =1 i =1 j =1
ntip
nodel
+ Z 0 ( , , ) N i ( ) K g1 ( , , ) N j ( , , ) g 1 j
i
II
i =1 j =1
nodel ntip
nodel
v( , , ) = N j ( , , ) v j +Z 0 ( , , ) N i ( ) K i

I 2f ( , , ) N j ( , , ) f 2 j
j =1 i =1 j =1
ntip
nodel
+ Z 0 ( , , ) N i ( ) K g 2 ( , , ) N j ( , , ) g 2 j
i
II
i =1 j =1
nodel ntip
nodel
w( , , ) = N j ( , , ) w j +Z 0 ( , , ) N i ( ) K h( , , ) N j ( , , )h j
i
III
j =1 i =1 j =1
Unknown Stress Intensity Factors Are Included in the FE Formulation & Solved for Directly 11
Agenda
Applications:
Summary/Conclusions
12
Fracture and Crack Propagation Analysis System (FCPAS)
Uncracked
FCPAS GUI
Model
Insert Crack
and Re-mesh
Model
FCPAS GUI
FCPAS GUI
Re-mesh New
Apply B.C.s
Cracked Model
STOP
CALCULATE LIFE
Analyze
Cracked Model
(FRAC3D)
Y
Post-Process, N Predict Next Insert/Grow
Failed?
Check Failure Crack Profile New Crack
13
FCPAS GUI
FRAC3D FCPAS Solver for 3D Fracture Analysis
Supported Element Types

32-Node Hexahedron 26-Node Pentahedron

10-Node Tetrahedron

20-Node Hexahedron 15-Node Pentahedron
14
Boundary Conditions
Load Types Constraints
Pressure Loading on Displacement Constraints on
Surfaces Nodes
Concentrated Forces on Constraints on Node Sets (Tied
Nodes Nodes)
Thermal Loading Displacements on Skew Edges
Inertia Loading
Sub-model BCs from ANSYS
Centrifugal Loading
15
Analysis Types & Material Systems Supported
Analysis Types Material Systems
Elastic Stress Analysis Homogeneous Isotropic
Elastic/Plastic Stress Analysis Bi-material Isotropic
Linear Elastic Fracture
Mechanics w/ & w/o plasticity Homogeneous Orthotropic
on uncracked material FGM Isotropic
Submodeling of ANSYS models Elastic/plastic Isotropic
16
Agenda
Applications:
Summary/Conclusions
17
Applications: Crack Insertion (Mode-I Surface Crack)
Uncracked Plate Finite An Elliptical Crack Shape to

Element Model be Inserted into Plate Model
2W
2H
Info for
Location, Size and Orientation
of the crack are needed !
18
Select A Chunk Region
Separate Chunk Exterior

Mesh Facets
Chunk Outer Free Chunk outer

Surface shared-surface
19
Combination of the crack mouth line and crack front line
2D meshing by Triangle,1
Combine the modified chunk exterior facets
,1 Shewchuk, J.R., 1996. Triangle: engineering a 2D quality mesh generator and Delaunay triangulator. In: Ming C., Dinesh
M, editors. Applied computational geometry: towards geometric engineering. Springer-Verlag. 1148, pp. 203-222. 20
3D meshing of Chunk Domain by Tetgen,2
Constrained volume meshing for keeping,
chunk outer surface facets,

crack surfaces meshing by Triangle , and
crack mouth-line nodal points
unchanged.
21
,2 Tetgen software website, http://tetgen.berlios.de/
Consolidation of chunk volume mesh by Tetgen with plate without the chunk
Consolidation of chunk mesh with plate,
node numbers on the shared surfaces kept the same,

displacement and load boundary conditions outside
chunk zone book kept,
nodes on the crack surfaces duplicated and surface split,
nodes and elements along crack front book kept to
define the local crack front geometry.
The fully-unstructured finite element mesh w/ crack included (a/t=0.2, a/c=0.2)
(Next step Fracture Analysis by 3D Enriched Elements) 22
a/c=0.2
a/t=0.2 a/t=0.5
a/t=0.8
23
a/c=1.0
a/t=0.2 a/t=0.5
a/t=0.8
24
a/c=2.0
a/t=0.2 a/t=0.5
a/t=0.8
25
a/c=0.2
Deformed shapes as a first-step validation of the mesh 26

Applications: Fracture Analysis (Mode-I Surface Crack)
a/c=0.2
3.50
Enriched elements
3.00 Raju and Newman (1986)
Normalized Mode I SIF (K1_N)
2.50
2.00
1.50
1.00 a/t = 0.8

a
a/t = 0.5
0.50
a/t = 0.2
2c
0.00
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0
Parametric Ange ( ) 27
a/c=1.0
0.80
Enriched elements
0.75 Raju and Newman (1986)
0.70
a

0.65 2c
a/t = 0.8
0.60
a/t = 0.5
a/t = 0.2
0.55
0.50
0.45
0.40
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0
a/c=2.0
1.00
Enriched elements
Raju and Newman (1986)
0.90
a
0.80

2c
0.70 a/t = 0.8
a/t = 0.5
a/t = 0.2
0.60
0.50
0.40
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0
Applications: Crack Insertion (Inclined Surface Crack)
0
H
2W
t y x
z
a

2c H
Y
X
Z 0
1.00
0.80
KI
0.60
Normalized Mode I SIF (K_N)
0.40
0.20 KIII
0.00
a
-0.20
-0.40 2c KII
Tetrahedral enriched elements (2010)

-0.60
Hex/wedge enriched elements (2004)
-0.80
-1.00
0 20 40 60 80 100 120 140 160 180
Parametric Ange ( )
Results by Tetrahedral Enriched Elements agree with those of Hexahedral Enriched Elements (2004) 30
Applications: Crack Insertion (Deflected Surface Crack)
0
H
2W
t
xy
a

z
2c H
Y
X
Z 0
0.80
0.60 KI
0.40
Normalized Mode I SIF (K_N)
KII
0.20 a

0.00
2c
-0.20
KIII
-0.40
Tetrahedral enriched elements (2010)

-0.60
Hex/wedge enriched elements (2004)
-0.80
0 10 20 30 40 50 60 70 80 90
Parametric Ange ( )
Results by Tetrahedral Enriched Elements agree with those of Hexahedral Enriched Elements (2004) 31
FCPAS Fatigue Crack Propagation Analysis (FE Models by ANSYSTM)
FCPAS
Surface Crack in a Finite-Thickness
Plate under Bending Load
Crack Length (mm)
Number of Cycles
Experiment
(Reytier, M., 2004)* Crack Profiles by FCPAS
FCPAS Simulation Results Agree Very Well with Experimental Observations

*(The permission by OMMI (Power Plant: Operation Maintenance and Materials Issues) and its publisher European Technology 32
Development Ltd. UK, for reproducing and republishing data by Reytier, M. is gratefully acknowledged.)
Agenda
Applications:
Summary/Conclusions
33
Summary/Conclusions
Crack Insertion into an Uncracked Finite Element Model Using Fully Unstructured Mesh
Successfully Demonstrated,
2D Meshing Triangle , 3D Meshing by Tetgen
Crack insertion procedure presented by in-house code,
Output model with fully tetrahedral finite elements to be analyzed by FCPAS Solver
Finite Element-Based Fracture Analysis Using Tetrahedral Enriched Elements,
Fracture finite element model from crack insertion readily available for fracture analysis (*.geo file),
Three-dimensional enriched finite elements for fracture calculations,
No special mesh requirements other than customary refinement near crack front,
Stress intensity factors along crack front directly calculated at the same time as nodal displacements,
Accurate solutions without any post-processing of finite element solution,
Presented method very efficient as any model can be meshed with tetrahedral elements.
Crack insertion, meshing and fracture analyses of parts with curved outer surfaces next steps.
34
Acknowledgements
Authors are thankful to The Scientific and

Technological Research Council of Turkey (TUBITAK)
for the financial support and to the administration
and personnel of ukurova and Sakarya Universities
for the organizational support.
35

Modeling and Analysis of Three Dimensional Cracks

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Modeling and Analysis of Three Dimensional Cracks

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Modeling and Analysis of Three-Dimensional

Cracks Using Unstructured Finite Elements

Poor welding in highly stressed region

April 28, 1988, 1:25 pm Hilo to Honolulu

Undetected fatigue damage

Fatigue Crack Propagation

Turbine Bucket Dovetail

Deflected Surface Crack Inclined Surface Crack

Supported Element Types

20-Node Hexahedron 15-Node Pentahedron

Uncracked Plate Finite An Elliptical Crack Shape to

Separate Chunk Exterior

Chunk Outer Free Chunk outer

Combine the modified chunk exterior facets

Constrained volume meshing for keeping,

chunk outer surface facets,

Consolidation of chunk mesh with plate,

node numbers on the shared surfaces kept the same,

Deformed shapes as a first-step validation of the mesh 26

1.00 a/t = 0.8

Tetrahedral enriched elements (2010)

Tetrahedral enriched elements (2010)

FCPAS Simulation Results Agree Very Well with Experimental Observations

Authors are thankful to The Scientific and

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