Engineering Failure Analysis 102 (2019) 226–236

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Engineering Failure Analysis

journal homepage: www.elsevier.com/locate/engfailanal

Research of large scale mechanical structure crack growth method

T
based on finite element parametric submodel
Yuantao Sun, Jinjin Zhai*, Qing Zhang, Xianrong Qin
School of Mechanical and Energy Engineering, Tongji University, Shanghai 201804, China

A R T IC LE I N F O ABS TRA CT

Keywords: With the development of mechanical structure in large scale, the dimension difference between
Crack growth whole structure and part damage-crack can be widely further. In order to get a precise analytic
Multi scale result of crack structure the grid of crack structure finite element model should be meshed very
Submodel dense so that the calculation scale is very large and calculation efficiency is lower even the
Parametric
calculation cannot be completed. To solve this multi scale problem of crack structure, presently
Finite element method
the submodel method is used, but in the method crack growth trajectory need to be supposition
and the crack model also need to be built by man-made, which is not satisfied with need of mix-
mode crack growth especially for continuously reconstructing of crack model. In this paper the
parametric submodel will be put forward. The method describes crack coarse model and sub-
model data by parameter way, including meshing, load, boundary condition etc. In the method
dynamic relationship of analytical results between coarse model and submodel is built, so that
crack stress intensity factor and growth angle can be automatically calculated for every crack tip.
According to the dynamic modification of crack coarse model and submodel, the crack growth
trajectory simulation can be calculated through iterative steps instead of the traditional suppo-
sition growth trajectory and crack propagation life calculation can also be finished. The method
gets the accuracy crack growth trajectory and improves analytical efficiency. At last the case of
the crack growth trajectory and life analysis in gantry crane verifies the validity of this method.

1. Introduction

Because of the limits of technological level of mechanical structures and the impacts of long-term mechanical load, temperature
and various kinds of corrosion in their working conditions, crack may appears in different parts, especially for some large-scale ones,
which can cause serious losses of properties and disasters [1]. Recently the mechanical structures are developing into large scale, and
the investigation and research result for the port crane showed that the four major security risks of the port crane are crack, fracture,
deformation and corrosion, among which the percentage of crack is 81.16, and those of fracture, deformation and corrosion are
5.67,11,34 and 1.4 respectively. So crack is the main defect of metal structures of crane. Moreover, crack may exist in all parts of the
gantry crane's structures, and the crack length ranges from dozens of millimeters to hundreds of millimeters. On the other hand, these
large mechanical equipment cannot be replaced at once or frequently stop and maintained when the defects is detected, for the
reasons of large volume, high cost of manufacture, long maintenance cycle and huge economic losses caused by the stagnation of
production. So the research and application of the crack diagnosis technology have significance in proper maintenance, production
safety and reducing the economic losses.

⁎
Corresponding author.
E-mail address: zhaijinjin5200@sina.com (J. Zhai).

https://doi.org/10.1016/j.engfailanal.2019.04.012
Received 23 November 2018; Received in revised form 4 April 2019; Accepted 8 April 2019
Available online 15 April 2019
1350-6307/ © 2019 Elsevier Ltd. All rights reserved.
Y. Sun, et al. Engineering Failure Analysis 102 (2019) 226–236

In generally, analytic method only can be used in simple components which have simple crack type. Actually the shape and load
or stress distribution of the mechanical structure are very complex, so the finite element method is often applied in researching and
analyzing the crack growth of these structures [2]. Even though many advanced numerical methods such as XFEM and adaptive FEM
are used [3,4], the dimension difference between whole structure and part damage-crack may result in further error. To avoid the
error the grid of crack structure finite element model should be meshed very dense or fine so that the calculation scale is very large
and calculation efficiency is lower even the calculation cannot be completed. To deal with the multi scale simulation of large
structure containing crack, the submodel method is used. Reference [5] calculated the stress intensity factors of surface cracks in a
box structure by sub-modeling technology; Reference [6,7] built several submodels to calculate the stress intensity factors and then
analyzed the rate of crack propagation, for the assumption that the direction of crack growth is constant.
As can be seen that the crack submodel method is a prevalent static analysis method, but the mix-mode crack propagation's
direction will change frequently according to the previous stress state. Therefore the method has a low efficiency of modeling and
calculating, and the result does not match the propagation rules of mix-mode crack, and the analytical precision is affected.
This paper presents the dynamic submodel method for large mechanical structure mix-mode crack based on the research of mix-
mode crack's analytic process and submodel principle, which is introduced in Section 2 and Section 3. In Section 4 the dynamic
submodel analysis method for mix-mode crack is proposed. Finally, a mix-mode crack analysis for gantry crane is explained in Section
5.

2. The analysis procedure of mix-mode crack propagation

The basic types of crack is usually divided into open type (type I crack), in-plane shear type (type II cracks) or antiplane shear type
(type III cracks) according to its stress forms, and the mix-mode crack in complex stress state can be regarded as compounded by the
three types of basic crack above. The difference between the mix-mode crack propagation and simply open type crack propagation is
that mix-mode crack propagation direction is usually not along the original crack surface, but along the direction which has a certain
angle with the original crack surface. Mix-mode cracks containing type II crack tend to change the direction of the original crack, and
those containing type III crack often have torsion on the surface of the crack [8]. Currently the theoretical and experimental research
of I-II mix-mode crack is more mature [9], so this paper mainly study the application of the I-II complex crack theory in mechanical
structure.
When the residual life of the crack is analyzed, the whole propagation length is defined as Δa, the load cycles N can be got as
shown Eq. (1) according to the Paris Formula
af da
N= ∫a0 C (∆KI )m (1)

And Δa divided it into finite length increment Δa1, Δa2, …, Δai, …, Δan, among them Δai means the propagation length increment of
crack from ai to ai+1,and the corresponding amplitudes of stress intensity factors are ΔKi and ΔKi+1. Generally the length increment of
each crack Δai is relatively short, so the amplitude of the stress intensity factor within it can be considered as linearly changing. When
the crack's length extends from ai to ax(ax ≤ ai+1) and its variation is x, the stress intensity factor ΔKi at ax can be derived by
interpolation, that is
∆K i + 1 − ∆K i
∆Kx = x + ∆K i
∆a i (2)

According to Eq. (1) and Eq. (2), the load cycles Ni can be got,which is needed by the length of the crack to propagate from ai to
ai+1,that is
∆a i
Ni = [∆K i1+−1m − ∆K i1 − m]
C (1 − m)(∆Ki + 1 − ∆Ki ) (3)

According to fracture mechanics，each time when the mix-mode crack grows, the stress state of crack will change at once. At the
same time, the state also determines the direction of crack growth, the corresponding stress intensity factor will also change. To
calculate the residual life of mix-mode crack, the path of the crack's propagation needs to be simulated, and then the stress intensity
factor amplitude variation function in the whole propagation path is obtained, and eventually the crack propagation life is calculated
according to Eq. (3). In the crack propagation path simulation, we mainly calculate the growth angle of crack and crack growth step

Fig. 1. Simulation diagram of the crack propagation process.

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increment in an iterative way to get the new crack tip until the crack propagation path is obtained. The process is shown in Fig. 1. The
crack growth step increment Δai tends to take a small constant in order to simplify the process [10], so the mix-mode crack pro-
pagation path simulation mainly solves the problem of predicting the crack growth angle. Because the maximum circumferential
tensile stress criterion is often used in the engineering calculation to determine the crack growth angle, this paper selects this criterion
to determine the crack growth angle.
Maximum circumferential tensile stress criterion is obtained by Mr. Erdogan and Sih after they researched the fracture behavior of
large flat made of brittle materials which contained inclined crack, namely crack extends along a plane perpendicular to the max-
imum tensile stress in the radial direction from its tip, so the crack growth angle is determined by Eq. (4) [11], that is

3KII2 + KI KI2 + 8KII2

θ = ± arccos
KI2 + 9KII2 (4)

Experiment shows that the sign of θ is opposite to that of KII [12]. On this basis, by repeated calculation of the crack growth angle
and establishing crack model of the corresponding crack tip position we can get the whole process of crack growth trajectory path and
the crack tip stress intensity factor amplitude of the crack tip in the propagation process and then the crack propagation life is
obtained. So the load cycles N needed by the increment of crack propagation Δa is the sum of each crack increment's load cycles, that
n
isN = ∑i = 1 Ni , and N is the total residual life.

3. Submodel analysis principle

According to the content and method of crack analyzing, the main work is to calculate the fracture parameters on each state such
as stress intensity factors, but for the reason that mechanical structure's size is large, its overall scale is much wider than part damage,
namely flaw, and in actual analysis, the grid density of crack area need to be very dense to obtain satisfactory solutions. According to
the principle that element or grid scale should be similar, the finite element modeling of a structure containing cracks is no longer a
single scale problem. That is to say, if the requirement of the whole structure's precision need be meet, the grid can be so large that
the characteristics of the details of the local damage can not be reflected; but if the characteristics of the details of the crack is
considered, the grid will be very dense so that the calculation cannot be carried on; moreover, if we use the method of local crack grid
refinement, the sizes difference between with adjacent cells may be too wide to cause a large calculation error [13].
And submodel analysis method is based on the analysis of the global coarse model, building a more fine element model at the
crack area to give it a secondary analysis,and obtaining the exact solution, so it can guarantee the precision and not lead to a serious
decrease of calculation efficiency. Submodel method is also called cutting the boundary displacement method or specific boundary
method according to finite element theory, there is an equilibrium function below for any structure,
[K ]{U } = {F } (5)

where K is the global stiffness matrix, U is displacement vector and F is load vector.
Assume that U consists of two parts, the displacement vector of part I and that of part B, namely UI and UB, among which UB is
already known and called specified displacement, then Eq. (5) can be reconstructed as

⎡ KII KIB ⎤ ⎧ UI ⎫ = ⎧ FI ⎫
⎣ KBI KBB ⎦ ⎩
⎨UB ⎬⎭ ⎩ ⎨ FB ⎬
⎭ (6)

where KII and KBB are the stiffness matrixes of part I and part B,KBI and KIB are the stiffness matrixes between the two parts, and
UI,UB,FI,FB are displacement vectors and load vectors of each part. Eq. (6) can be expand as Eq. (7)
[KII ]{UI } + [KIB ]{UB } = {FI }
[KII ]{UI } = {FI } − [KIB ]{UB } (7)

Eq. (7) shows that the specified displacement UB is a part of the load vector to obtain UI, that is to say, for a structure with
stiffness, its specified displacement can produce load effect,which is the theoretical basis of submodel analysis [14].
According to the submodel theory, firstly the coarse model of the whole structure should be build, where coarse model means the
grid of the model is relatively rougher than the grid of the submodel, because for the area where accurate analysis is needed, only if
the coarse element model's grid is dense enough that the reasonable displacement can be got. After solving the coarse model, a
submodel for the crack area should be built, and the calculation results of coarse models on the cutting edge is regarded as the
submodel's boundary conditions, then the results of the areas where accurate analysis can be obtained [15]. The implementation
steps and the data flow are shown in Fig. 2.

4. The dynamic submodel analysis method for mix-mode crack

4.1. Basic idea

Considering that recently the submodel reconstruction for crack propagation analysis still stays in pre-setting the growth tra-
jectory path and artificial modeling, which makes the analyse precision and efficiency limited, so this paper presents a dynamic
submodel method, that its basic idea is to build the coarse model and submodel of crack structure including the data such as finite

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Build and analyse the

coarse model

Result file for Data file for

Build submodel and input coarse model coarse model
boundary node file model.rst model.db

Data file of Node file of

submodel cutting edge
Submodel.db submodel.node
Read the coarse model and
generate cutting edge
interpolation
Freedom constraints of
cutting edge
Submodel cbdo
Read submodel, impose
Exact solution
boundary freedom
of the key area
constraints and analyse it

Fig. 2. The implementation steps and the data flow of submodel analysis.

element grid, load and boundary conditions etc. on the basis of parametric description, and make dynamic connection between the
analysis result data of the coarse model and submodel, which can analyse the direction of crack growth automatically, and ac-
complish the dynamic modification for the coarse model and submodel after the crack propagating; finally finish the simulation of the
whole process of crack propagation by iteration. The termination of the iteration is determined by the criterions of fracture, intensity
and stiffness. The criterion of fracture indicates that when the stress intensity factor is larger than the fracture toughness, the crack
will propagate fast and lead to fracture. And according to the strength criterion and stiffness criterion, the working stress and the
structural deflection cannot exceed the allowable value, for example, in some national industry standards such as Chinese and
European crane design specification, the qualification requirements for calculating the deflection and stress are given. But it is also
possible to embed different failure criterions according to project need, in order to give a comprehensive evaluation to each industry
standard and fracture failure criterion.
In conclusion, the implementation process of the parametric submodel analysis method for the mechanical structure's crack
propagation is shown in Fig. 3, whose detail description is in the Part 5 of the paper.

4.2. Arithmetic implementation

As can be seen from the Fig. 3,the core of the crack dynamic submodel analysis method is the parametric description to the coarse
model and submodel of the crack structure, and dynamic modification to the crack model which has growth, along with the auto-
matic data transmission, calculation process, analysis or judgment to the parameters such as crack growth angle

1. Dynamic modification of the crack submodel

As mentioned earlier, the basis of the dynamic modification to the crack submodel is the parametric description of the crack
structure, the method is as follows:
Firstly remove all grid of the submodel to prepare for meshing new element.
Then translate the keypoint of the crack tip for a propagation step along the extending direction of crack surface to determine the
new position of the crack tip and give the corresponding number;
Next create a keypoint at the original crack tip and set up the parameter array variable for it, they connect with the new crack tips
and form new discontinuous interfaces and crack models;
At last, remesh the grid and store the new finite element model of crack, and obtain the submodel of propagated crack.
It should be pointed out that in order to improve the efficiency of modeling, we adopt a hybrid modeling method containing both
direct modeling(GUI mode) and local command modification(Command mode), that is, building the submodel of the initial crack in
advance through the user interface, and use program to modify the crack area directly after the crack propagates, this method makes
the work difficulty and workload of modeling less than building a parametric model for the global crack area.
Similarly, as the crack propagating, the coarse model itself will change with the crack propagation, the modeling method is same
with the modification process of the submodel.

2. Transfer and extraction of the parameters

To make it convenient for the parameters to extract and transfer, in this paper, such parameters as the position of the crack tip,

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1.Build the coarse model

2.Analyse the coarse model

3.σmax<[σ]
f<[f]

4.Build the submodel and

input boundary conditions

9.Modify the coarse

model
5.Read coarse model data
and generate cutting edge
interpolation

8.Calculate propagation 6.Read submodel, impose

boundary freedom
angle of crack θi
constraints and analyse it

7.Keq<KIC

10.Result

Fig. 3. The analysis process of dynamic submodel.

crack growth angle, maximum stress of the structure, stress intensity factor component and the number of crack propagation steps are
defined in the form of an array, and the parameters required by the dynamic submodel calculation will be extracted, stored,
transferred and calculated through these arrays.
Since submodel method need interpolation of boundary node displacement, as the crack propagate, the shape of the elements, the
amount and number of nodes of the crack submodel will all change, so we need to select the boundary nodes and write into the
boundary node file each time the crack propagate. According to the characteristic that these nodes always distribute on the border,
we select the nodes which are attached to the border and write them into the file, and finish displacement interpolation of boundary
nodes, finally fulfill the transfer of model boundary values.
By using the displacement extrapolation method [16] depending on the stored crack tips and the displacement value at every
point along the crack line, we can extract the stress intensity factor component.

5. Numerical examples

5.1. Cracked beam

In order to verify the accuracy of the submodel method, ANSYS is used to solve the stress intensity factor of cracked beam, and the
results are compared with the analytical solution.

1) Cracked beam with concentrated forces.

As shown in Fig. 4, the specimen with unilateral crack is L = 800 mm in length, b = 100 mm in width, 1 mm in thickness,
a = 10 mm in crack length and a pair of concentrated forces P = 500 N on the crack nozzle.
According to reference [17], the analytical solution of stress intensity factor is as follows:

KI = Y ∙2P / πa (8)

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Fig. 4. Cracked beam with concentrated forces.

Where the shape coefficient Y is:

3.52 4.35 a
Y= 3
− 1
+ 2.13 ⎛1 − ⎞ = 1.45437
⎝ b⎠
(1 − )
a 2
b (1 − )
a 2
b (9)
So the analytic solution of stress intensity factor is KI = 259.55MPa mm .
According to the submodel method mentioned above, the coarse model as shown in Fig. 5(a) is firstly established to carry out
numerical simulation, and a total of 89 finite element meshes were meshed.; then the submodel with 318 elements as shown in
Fig. 5(b) is established and the corresponding data of the coarse model is obtained as boundary conditions, and finally the submodel
is carried out again. Meanwhile, as is shown in Fig. 6, the refined finite element model that contains 4236elemts is calculated. The
results are shown in Table 1.

2) Cracked beam in bending.

As is shown in Fig. 7, except the boundary condition is bending moment M = 120 N·m, the cracked beam in bending is the same as
the beam in Fig. 4. According to reference [17], the analytical solution of stress intensity factor is as follows:
KI = Y ∙6M πa / b2 (10)
Where the shape coefficient Y is:
a a 2 a 3 a 4
Y = 1.122 − 1.40 + 7.33 ⎛ ⎞ − 13.08 ⎛ ⎞ + 14 ⎛ ⎞ = 1.044
b b
⎝ ⎠ b
⎝ ⎠ ⎝b⎠ (11)
So the analytic solution of stress intensity factor is KI = 421.32MPa mm .
The submodel method is used again, and the finite element models are the same as the cracked beam with concentrated forces.
The results are shown in Table 2.
As shown in Table 1 and Table 2, the accuracy of the sub-model method has been proved.

5.2. The mix-mode crack analysis for gantry crane

To verify the effectiveness of this method, in this paper, a 100-milimeter-long crack from a JMQ type gantry crane whose rated
load weight is 36 tons is used as the study example, which is shown in Fig. 8, and its residual life of this crack will be analyzed. To
express clearly, we defined the abscissa of leftmost point of the structure as XP = 0 mm, then the abscissa of the crack is
XP = 26,133 mm. According to the requirement of crack analysis we need to take the grid average size to 50 mm,and that of the crack
tip is 1 mm,and considering the principle that the scale of the grid should be consistent, we give the average size of the main girder

Fig. 5. Submodel method.

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Fig. 6. Refined finite element model.

Table 1
Results of the cracked beam with concentrated forces.
Analytical solution Result of submodel Results of refeined model

KI 259.48 258.37 258.65

error(%) 0.43 0.32

Fig. 7. Cracked beam in bending model.

Table 2
Results of the cracked beam in bending.
Analytical solution Result of submodel Results of refeined model

KI 421.32 419.63 420.44

Error(%) 0.40 0.21

Fig. 8. Structure diagram of a gantry crane

50 mm as well, then the element number of the main girder reaches 530,696, and it takes 36 min to mesh them, the calculation scale
is so large that it is difficult to solve it by computer. It will be much more cost if the crack propagation path need be got, and
computation efficiency is extremely low, so the dynamic submodel method should be used to improve the analysis efficiency. The
finite element software Ansys has a good function of secondary development, so in this paper Ansys program and its parametric
design language APDL is used to analyse the mix-mode crack through this method shown as Fig. 3.

(1) Build the coarse model of the crack

Set the parameters. In the mix-mode crack, the growth angle will change with the propagation of the crack, which is an important
parameter to determine the geometry of the submodel and coarse model. According to the principle of maximum circumferential
tensile stress, the crack growth angle can be obtained by calculating the stress intensity factor component, so we need to define the
crack growth angle and stress intensity factor and set them as array type, making it in accordance with crack propagation steps.
Similarly, this paper also defines such parameters as the crack area variables ‘crackarea’, the crack tip coordinate array ‘crackcor’,the
crack propagation step length ‘cracklength’,and maximum stress value ‘maxstress’ etc., thus a data foundation for the automatic
refactoring of the finite element structure of the extended crack is laid.
According to the actual size of the structure of gantry crane and plate thickness, with Ansys preprocessing function we can build

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Fig. 9. Crack location of the gantry crane.

the model of the gantry crane, then it is meshed to obtain the coarse finite element model of the crack, for large structures, the side
length of each unit is 533.33 mm,we choose beam100 unit for the pull rod of each cylinder, and shell163 unit for the rest, then the
finite element model can be obtained by program automatically completing the grid meshing, the unit number is 9892,and its
distribution is shown in Fig. 9, the crack grid diagram is shown in Fig. 10, the crack unit number is 66, the number of nodes is 88.

(2) Analyse the coarse model of the crack

Solve the coarse model of the structure to determine whether the stress value of the overall structure and the vertical displacement
value exceed the Q345 steel material allowable stress value [σ] and the allowable deflection of structure [f], if not then carry out step
3 to create submodel and input boundary file, otherwise crack makes the structure in dangerous condition and should not continue to
use, and enter the step 8, give the residual life of the crack structure at the load position.

(3) Build submodel and input boundary conditions

When the crack propagates, the crack area will be modified directly as previously mentioned. The fine grid of crack model is
shown in Fig. 11.

(4) Read the data of solved coarse model, generate cutting edge interpolation.
(5) Input the submodel of the crack, impose boundary freedom constraints to the submodel and solve it.
(6) Judge whether Keq has exceeded the fracture toughness of Q345,if it has, then terminate calculation, or calculate the crack growth
angle by Eq. (4). For instance, if the load is on the crack, the initial stress intensity factor components and crack growth angle are
as follows,
KI = 564.1826MPa mm , KII = 4.0051MPa mm , ang = − 0.739°

(7) Modify the finite element model of the global structure after the crack has propagated by the same way as step 3 according to the

Fig. 10. Coarse mesh grid of the crack area

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Fig. 11. Fine grid of the crack model

crack growth angle θi.

(8) repeat step 2, 3, 4, 5 and 6 until the max stress and deflection exceed the allowable value or equivalent stress intensity factor
exceed the fracture toughness of the material, and by step 3 we can obtain crack length and the change curve of the load cycles
according to the stress intensity factors of the crack tip in accordance with different crack lengths which are calculated from array
Keq, finally we obtain the residual life of structure and finish the analysis of crack propagation.

By this method, the stress contour chart of the structure under dangerous state can be obtained where the load position is
XP = 26,133 mmas shown in Fig. 12. Fig. 13 shows the vertical displacement contour under pure load. The crack propagation path is
shown in Fig. 14, and the relationship between the corresponding crack propagation path length and load cycles is shown in Fig. 15.
The residual life of the crack structure under this condition is 53,386,614 load cycles.
When the gantry crane works in port, its load location will change, it can be founded that when Xp < 17,067 mm or
Xp > 38,933 mm,the equivalent stress intensity factor is smaller than the threshold 5.96MPa mm , according to the crack propa-
gation theory, crack will not grow in this interval; so theoretically crack will propagate just between 17,067 mm and 38,933 mm,and
the Xp–N curve in the interval from 24,000 mm to 31,000 mm is shown in Fig. 16, where Xp is load location and N is the residual life of
the crack.
Fig. 16 shows that the residual life of the crack under the most dangerous load is 19,013,730 cycles, the corresponding load

Fig. 12. Stress chart under dangerous state.

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Fig. 13. Vertical displacement contour.

Fig. 14. Crack propagation path.

Fig. 15. Keq–crack length curve.

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Fig. 16. Xp—N curve.

location is Xp = 28,267 mm, it can be considered that the crack at this location will not endanger the structure.

6. Summary

The method referred in this paper builds the coarse model and submodel of the crack on the basis of parameterized description,
and can automatically achieve dynamic modification to the coarse model and submodel of the propagated crack according to the
calculation of each crack growth step, then the analysis of crack growth and residual life is finished, which can improve the analysis
efficiency of the mix-mode crack under the premise of ensuring the analysis precision. The crack analysis of the gantry crane
demonstrates that this method is effective.

Acknowledgement

This research was supported by the Key Laboratory of Performance Evolution and Control for Engineering Structures (Tongji
University), Ministry of Education (No. 2018KF-3) and Science and Technology Committee of Shanghai (project: 15DZ1161203). The
authors also gratefully acknowledge the contribution and support of Shanghai Zhenhua Heavy Industries Co. Ltd.

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