Fdigue Fracr. Engng M a w . Struct. Vol. 17. No. I , pp. 77-91, 1994 8756-758X/94 $6.00 + 0.

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Printed in Great Britain. All rights reserved Copyright 0 1994 Fatigue & Fracture of
Engineering Materials & Structures Ltd

FATIGUE LIFE PREDICTION OF NOTCHED

COMPOSITE COMPONENTS
G. SHEN,G . GLINKAand A. PLUMTREE
University of Waterloo, Department of Mechanical Engineering, Waterloo, Ontario, Canada, N?L 3G1

Abstract-The local stress/strain approach has been used to predict the fatigue lives of notched
composite components. The method was based on a microstress analysis and the application of a
multiaxial fatigue parameter incorporating the alternating strain components on the critical plane. This
parameter was able to correlate the fatigue lives obtained under a variety of multiaxial loading and
geometrical configurations, enabling a generalized fatigue life curve to be determined on the basis of
limited experimental data.
The ability of the multiaxial fatigue parameter to relate the fatigue behaviour of composites
was illustrated by predicting the locations of crack initiation sites in a unidirectional silicon carbide
fibre reinforced titanium plate containing a circular hole tested under constant amplitude cyclic loading.
The same approach was also successfully employed to predict the fatigue lives of graphite reinforced
epoxy composite tubes with circular holes tested under several combinations of cyclic tension and
torsion.

NOMENCLATURE
A , K, m =material constants
A , , Bij= coefficients relating macrostresses S, and microstresses u,, in deformation
states I, 11, I11 (using A o ) and IV, V (using 4 ) respectively
EL,& = axial and transverse elastic moduli for a unidirectional laminate measured
with respect to the fibre direction
E: ,E: = elastic moduli for multilayer laminate in I and y directions
G,,, G:Y = shear modulus for a unidirectional and multilayer laminate respectively
k = subscript defining kth ply
M = laminate stiffness matrix
n = numbers of plies in a laminate
Q, = lamina stiffness coefficients
(Q,),=transformed stiffness coefficients in kth ply
R =stress ratio ( R = Sm~o/S,,,ax)
Sii,5j= macro- and microstress components ( i , j = 1,2,3, R, 0, x, y )
S,, = amplitudes of macrostress components
1, f,=thickness of a multilayer laminate and thickness of the kth ply in a laminate
V , = volume fraction of fibres
pk= angle between loading direction and fibre axis in k th ply
7,Tl3 =shear strain amplitude on critical plane and X,-X3 plane respectively
a* = multiaxial strain parameter
h , , 6, = elastic proportionality factors
E = amplitude of strain component normal to the critical plane
vLT, vTL = Poisson’s ratios in the parallel and transverse directions to fibre
v : ~= Poisson’s ratio for a multilayer laminate
R = volume
77
78 G. SHEN et (11.

INTRODUCTION

Prediction of fatigue lives of notched components is often based on the local notch-tip stress-strain
approach [ 13. Recently, this method has been adopted for multiaxial stress-strain configurations [2].
The aim of this paper is to apply the local notch-tip strain approach to predict the fatigue lives
of notched plates and thin-walled tubes made of composite materials subjected to constant
amplitude cyclic tension in addition to simultaneous torsion and tensile loading.

FATIGUE MODES OF FAILURE IN COMPOSITES

It is generally accepted that in the case of notched isotropic materials the number of cycles to
crack initiation is controlled by the maximum strain range at the notch-tip. However, this is not
always the case for composite materials where the magnitude of the local strain and its location
with respect to the microstructural elements, such as fibre orientation, are important. Consequently,
fatigue cracks in composites need not be located at the notch-tip where the highest stresses occur,
as in isotropic materials. Therefore, the most frequent mode of fatigue failure of off-axially loaded
unidirectional fibre composites occurs as a result of crack initiation and growth in the matrix along
in planes parallel to the fibre direction[3-61. Initiation of these fatigue cracks is controlled by the
stress-strain state associated with these planes, which are known as critical planes. In general the
state of stress in these planes is not uniaxial and is best expressed by a multiaxial fatigue
parameter[7]. Recently it has been found that this approach used for the fatigue analysis of metallic
materials can also be applied for fatigue life predictions of composite components [8].
Such an analysis requires the macrostresses and the microstresses be known in the critical region,
i.e. around the notch contour. This problem will be addressed in the present work.

RELATIONSHIP BETWEEN THE MACRO- AND MICROSTRESSES

The analysis of microstresses in unidirectional composites is usually based on the so-called unit
block approach [9-1 I] taking advantage of the stress distribution symmetry around the composite
fibres. This method described in Refs [8,11] has been adopted in the stress analysis presented below.
The aim is to determine the relationship between the external applied load and the stress field
in the fibre neighbourhood. Therefore two important parameters are used in the method: the
microstresses oijand the macrostresses Sij. The former are the actual point to point stresses in the
material which are determined by considering the different properties of the fibre and matrix. The
macrostresses S,, represent the average values of the microstresses in the unit block and are linearly
related to the applied load. The schematic structure of a multilayered laminate, the representative
unit block of the material and the system of coordinates used in the present work are shown in
Fig. 1.
In the case of a notched multitayered laminate (Fig. la), the stress analysis is carried out in
several steps. First, the laminate gross stress S, have to be calculated in the critical region using
the anisotropic plate theory.

Secondly the macrostresses Sijacting on each lamina are determined. Finally, the macrostresses Sij
at the particular lamina location (i.e. notch-tip region) and the basic block unit are then used to
determine the corresponding microstresses oii.
Fig. I . Repeating unit block model. (a) Schematic structure of notched component. (b) Laminate resulting from local strain approach. (c) Coordinate system used
in microstress analysis. (d) Symmetry of periodic composite structure. (e) Basic block of composite structure together with coordinate system. ( f ) Finite element
4
model of basic block. W
80 G . SHENet al.

Gross stress S;, in a notched laminate

The circumferential stress at the edge of the cutout (Fig. la) in a plate consisting of a pair of
balanced laminates arranged symmetrically with respect to the midplane of the plate and subjected
to unidirectional loading parallel to the x axis can be calculated [12] from the following expression:
(1 + s , ) ( i +6 ,)(1 +6 , + ~ , - ~ , ~ 2 - 2 c o s 2 e ) s , x
So, = (2)
(1 +6:-26,cos28)(1+6:-26,cos28)
In the case of shear loading, the gross stress So, along the circumference of the hole is given by:
6, - 1)sin 28
s’@- - (1 + 6 : - 2 64sxy(61
, ~ 0 ~ 2 8 ) ( 1+ 6 : - 2 6 , ~ 0 ~ 2 8 )
(3)

The parameters 6, and 6, are the elastic proportionality factors given [12] as follows:

Macrostresses S, in one lamina

Knowing the gross stresses Sjin a laminate, the macrostresses S, in each lamina of the laminate
can be determined by solving the constitutive equation of the lamina, provided that each lamina
is subjected to the same deformation and strain. At the edge of the hole, the circumferential gross
stress, So,, exists only. All the other components are zero. Consequently the corresponding
macrostresses in each lamina are [13]:
<Qll>k (Ql2)k (Q16)k
(QIZ)k (Q22)k (&26)k (6)
(Ol6)k (Q26)k (066)k

Table 1. Material DroDerties

Modulus of elasticity Poisson’s
(GW ratio

Material EL ET GLT VLT v~~

Silicon carbide Composite 207 124 55.2 0.24 0.15
titanium (SCS-6/Ti 15-3) Fibre 430 - - 0.25 0.25
( Vc= 0.4) Matrix I15 I15 46 0.36 0.36
graphite/epoxy Composite 133 9.9 6.5 0.35 0.03
(Fiberite T300/934) Fibre 220 22 22 0.35 0.35
( Vr = 0.6) Matrix 3.45 3.45 1.3 0.35 0.35
 Fatigue life prediction of notched composite components 81

where

Subsequently the macrostresses S, in a lamina need to be transformed to the material axis (Fig. Ic)
in order to be used as the input data in the unit block model enabling the microstresses oijto be
calculated.

Lamina microstresses cro

The relationship between the macrostresses Sijand the microstresses oijcan be written as[&1I]:

[:::] [::
012

033
= A31

A,, A42
A 3233 /

A43
(21)

and

The microstresses crlJ for given macrostresses S, or external load can be calculated by using
82 G . SHEN et at.

I
D e f o r m a t i o n s t a t e I1
Deformation state I

u 2 = 1 on x 2 = b
u l = o on xl = O , a
u2 = 0 on x2 = 0
Deformation state 111
Deformation state IV
f x2

u l = o on x1 2’0 , a
u 2 = 0 on x2 = 0 , b
E33= 1

x2 - Deformation state V

Fig. 2. Deformation states and corresponding boundary conditions permissible for basic block.

equations (21) and (22). This is accomplished by determining the parameters A , and B, using
deformation analysis, as outlined in Refs[& 1 11. Because of the periodic structure in the lamina,
adjacent basic blocks which contain one fibre, match exactly without any overlapping. Therefore
the rectangular blocks must retain their shape under deformation. This constraint limits the basic
block unit to only five permissible deformation modes, namely I, 11, 111, IV and V, as shown in
 Fatigue life prediction of notched composite components 83

Fig. 2. The microstresses for each deformation mode can be calculated by finite element analysis,
using the quadrant shown in Fig. If. The corresponding macrostresses are then determined from
the following equation

The calculation is repeated for each of the deformation modes shown in Fig. 2.
Deformation modes, I, I1 and 111 are associated with macrostress components S,, , S,, and S,,
respectively. On the other hand, the only non-zero microstress components which may occur under
such deformation modes are o I 1 ,ci,,, oI2and o,,. Each of the deformation modes I, I1 and I11
provides four equations (equation (21)) so that a total twelve equations are available to determine
twelve unknowns A,, (i = 1 , 2 , 3 , 4 , j = I , 2,3).
In the case of deformation modes IV and V, the associated non-zero macrostress components
are S , , and S,, and the non-zero microstress components are 013 and 02,. Each deformation mode
IV and V provides two equations (equation (22)), given a total of four equations to be solved for
four unknowns B , ( i , j = 1, 2).

Fig. 3. Distribution of fatigue parameter ?* around hole in unidirectional SCS-6/Ti 15-3 composite plate
subjected to axial cyclic loading, R = 0.1. Crack initiation sites observed by Newaz and Majumdar [20]
indicated. Calibration scale for y* = 0.01 included.
84 G . SHENel al.

Fig. 4. Circumferential stress distribution around the edge of hole in SCS-6/Ti 15-3 unidirectional plate
under axial loading. Figure includes calibration scale for stress concentration factor of 4.

THE FATIGUE PARAMETER

One of the fundamental problems in the analysis of material failure under a cyclic multiaxial
stress state is the determination of a parameter which represents the material resistance when
subjected to a variety of loading conditions. There have been several parameters proposed such
as the maximum principal stress (or strain) [14], the Von Mises equivalent stress (or strain) [ 151 and
maximum shear stress (or strain) [16]. A parameter well validated experimentally is one which
combines the shear and normal strain amplitudes on the critical plane[7,17-191:
?* = y’ + KC (24)
The material constant K is usually determined from multiaxial fatigue tests. A value of K = 1 has
been used for steel[l9] and Inconel 718[17]. The same value was adopted in the present study.
In the case of an off-axially loaded unidirectional composite, the critical plane is parallel to the
fibre axis, hence equation (20) is written as follows:
y* = + KCli (25)
Considering the results presented in Refs[7,17-19], the parameter y’* can be related to fatigue life
N c by the power law expression:
y’* = A N ? (26)
 Fatigue life prediction of notched composite components 85

Expression (26) was chosen to correlate the fatigue data obtained under different geometrical and
loading configurations. It is obviously valid for a constant mean stress which is appropriate for
the cases studied below. Naturally, the mean stress effect should be taken into account for those
cases involving variable mean stresses. Unfortunately, the mean stress effect under multiaxial cyclic
loading has not yet been clarified.

PREDICTION OF FATIGUE CRACK INITIATION SITES

The validity of y"* as a fatigue parameter can be illustrated by its ability to predict the
location of crack initiation sites in a notched composite plane subjected to constant amplitude
cyclic tensile loading. The experimental results were taken from work of Newaz and
Majumdar [20] who conducted fatigue tests (R = 0.1, sXx
= 355 MPa) on unidirectional eight-
ply silicon carbide fibre reinforced titanium (SCS-6/Ti 15-3) plates with central circular
holes 9.53 mm in diameter. The specimens were of rectangular shape 152.4 mm long by 19 mm
wide and 1.55 rnm thick. The material properties are given in Table 1. The angle between
the loading direction and the fibre axis was zero and after cycling it was observed that
four cracks initiated at the hole circumference, at angles 0 = (65 +72") and 8 = f(1 55 + 162").
These cracks were symmetric with respect to the x and y axes, as shown in Fig. 3.

Concentration of macrostress S, near the circular hole

The circumferential stress (&) around the edge of the circular hole was calculated using
equations (2) to ( 5 ) inclusive. The resulting normal stress concentration (See/Sxx)
around the edge

_ _
tp
- 0.6mm

254mm

I II I

Fig. 5 . Composite tube with a circular hole [21].

86 G . SHENet al.

I
I

Fig. 6. Distribution of fatigue parameter ?* around edge of hole in [*45-]s graphite/epoxy tube under
cyclic tension. R = 0.1. Calibration scale for y* of 0.05 is included.

of the hole is shown in Fig. 4. It is apparent that the highest stress concentration
( K ,= 3.42) occurred at 8 = f90". Since the highest normal stresses and the fatigue
crack initiation sites occurred at different locations it is apparent that the normal stress S,,
was not the fatigue controlling parameter. Subsequently the macrostress components
S,, around the edge of the hole were used as the input data to calculate the microstress
components c,,.

Distribution of fatigue parameter y"* around circular hole

Using the macrostress component So, at each point on the periphery of the hole, the microstress
components oij at the same location were determined using the unit block approach and equations
(21) and (22). The microstresses were not uniformly distributed in the block and the highest
concentration of the shear oI3and normal c I Istresses occurred in the matrix adjacent to the fibre
at X2 +O.
The amplitudes of the microstress-strain components in the critical plane were calculated using
the same procedure and stress amplitude gxx as the input. Substitution of the calculated shear Y13
and normal illstrain amplitudes into equation (24), enabled the fatigue parameter Y* around the
edge of the hole to be determined. The distribution of parameter y'*, calculated for the macrostress
amplitude gXx = 355 MPa, is shown in Fig. 3. The locations of the maximum y'* value (1.3%)
coincide closely with the observed crack initiation sites, indicating that the parameter y*
can be used to determine the location of fatigue crack initiation sites in notched composite
components.
 Fatigue life prediction of notched composite components 87

PREDICTION OF FATIGUE LIFE UNDER CYCLIC TENSION AND TORSION

Un$cation of fatigue life data for various loading conditions

The aim of the present study is to predict the fatigue lives of notched tubes subjected to a variety
of loading modes such as tension, torsion, and a combination of both by using material data obtained
from simple experiments associated with one loading mode, i.e. cyclic tension. Therefore, the first step
was to determine whether the experimental fatigue data obtained under cyclic tension and torsion
may be unified by using the fatigue parameter y'*. The tension and torsion fatigue data for a
graphite/epoxy ( [ *45'], lay up) tube containing a hole (Fig. 5) were taken from Ref. [21]. The
appropriate material properties are included in Table 1. The specimens were in the form of a laminate
tube 254 mm long, 25.4 mm diameter and 0.6 mm wall thickness. All tubes contained a single through
thickness circular hole of 4.8 mm diameter. The distribution of the parameter y'* around the edge of
the hole in the -45" laminae obtained under cyclic tension with the maximum tension stress of
108 MPa is shown in Fig. 6. That obtained under cyclic torsion with the maximum torsion stress of
1 10 MPa is shown in Fig. 7. Both series of tests were carried out under the same stress ratio of R = 0.1.
The distribution of parameter y* in the +45" laminae can be obtained by a 180" rotation of that
determined for the -45" ply. The maximum values of parameter y'* were found at angles 0 = f90"
in the -45" laminae subjected to cyclic tensile loading. However, in the case of torsion loading four
maxima located at angles 0 = + 123", + 1 4 7 , - 33" and - 57" were found in the - 45" taminae. The
maximum values of parameter y'* at these locations plotted against the experimental fatigue lives are
shown in Fig. 8. It is apparent that the y'* parameter is quite capable of normalizing the fatigue lives
obtained under entirely different loading modes allowing the relationship to be given in a logarithmic
form:
Y-* -- 1.168N;O.OS8 (27)

~ -2'
'\\. . .-
_-/--i_.-- ..
/--__-

Fig. 7. Distribution of fatigue parameter y* around edge of hole in [ + 4 5 '] s grdphite/epoxy tube under
cyclic torsion, R = 0.1. A calibration scale for q* of 0.05 is included.
88 G . SHENet al.

Fig. 8. Fatigue life ?* - N,curve of notched [+45"]s graphite/epoxy tube. Cyclic tension and torsion data
only. R = 0.1.

The numerical coefficients in equation (27) were determined by the least squares method using the
experimental tensile and torsion data[21] shown in Fig. 8. They agree very closely with those results
obtained under combined cyclic axial tension and internal pressure given in Ref. [21] which can be
expressed by:

y'* = 1.19fjN;0.053 (28)

Equation (28) was subsequently used to predict fatigue lives under other modes of loading, as
described below.

Prediction of fatigue liues under combined cvclic tension and torsion

The notched composite tube (Fig. 5) as reported in Ref.[21] was also tested under combined
cyclic tension and torsion loading. For these loading conditions, the ?* parameter around the

Table 2. Location of crack initiation sites ( 8 ) in graphite/epoxy (Fiberite T3001934) tube

Ratio
(tensionitorsion) l:o 1 :0.5 1:l 1:2 0: I
+45" ply + 90" +68' + 62" + 60" + 33
+ 57
-90 - 112' - 118" - 120" - 123
- 147

-45 ply +9 0 + 112' +I18 + 120 + 147

+ I23
- 90" -68- - 62 - 60' - 57
- 33
 Fatigue life prediction of notched composite components 89

2oo/
R = 0.1

401 - predicted, eq.(28)

0 I 1 I 1 1 1 1 1 1 ~ 1 l 1 1 1 1 1 1 , I ,1111111 I 11111111 I , I 1 1 1 1 I, I , l l , J

’ ‘
1 10 10
g* 10 10 10 a

Fig. 9. Fatigue life predictions for notched composite tube under combined tension and torsion. R = 0.1

circumference of the hole was first calculated to determine the locations of the fatigue crack
initiation sites due to the different tension to torsion load ratios. The initiation sites were assumed
to coincide with the sites of maximum y’* and are given in Table 2 for five different tension to
torsion ratios. Unfortunately, since the experimentally determined locations were not given in Ref.
[21], a direct comparison with prediction cannot be made.
The generalized y’* - N,curve (equation (28)) was used for the determination of fatigue lives for
three series of tubes tested under combined cyclic tension and torsion with tension :torsion load
ratios of 1 :0.5, 1 : 1 and 1 :2. The fatigue lives were predicted using equation (28) and the maximum
values of y’* found on the notch circumference. Comparison of the experimental and calculated
fatigue lives is given in Fig. 9. Good agreement between the predicted and experimental fatigue
lives is apparent for the whole range of load combinations.

DISCUSSI 0N

The analysis described above was based on linear elastic behaviour of the fibre and matrix.
However, the maximum microstresses and microstrains shown in Figs 3-7 may exceed the yield
limit of the matrix in the composite materials considered. The data shown in Figs 3 and 4 deals
with the prediction of the location of the maximum local strain parameter and the location of the
maximum normal stresses. It is anticipated that due to localized plastic yielding the microstrains
may be higher than those shown in Fig. 3. However, due to the local nature of plastic yielding the
location of the maximum hypothetical elastic strains should coincide with the location of the
maximum true elastic-plastic microstrains. Therefore, the location of the crack initiation sites
90 G . SHENel al.

should be predicted adequately in spite of the fact that the microstrains (Fig. 3) calculated for the
silicon carbide/titanium (SCS-B/Ti 15-3) composite may be lower than the actual.
A similar situation could be encountered in the case of the glass/epoxy tube with the circular
hole (Fig. 5). The values of the strain parameters shown in Figs 6 and 7 appear to be relatively
high and above the yield limit. However, the data shown in Figs 8 and 9 have been well correlated
using the linear elastic parameter 7* for both the short and long fatigue life regime because the
critical plane parameter concentrates on a very localized and small region surrounded by a
relatively large elastic volume of material. Therefore, the material in the plastic zone is controlled
by the surrounding elastic field which can be characterized by the elastic parameter y"*. The second
reason is that the cyclic yield limit is approximately twice the monotonic, thus plastic yielding is
more restricted than monotonic yielding. It is also known that the epoxy materials behave linearly
for the major part of the stress/strain curve. Additionally, the basic reference data shown in Fig. 8
and the predicted curves given in Fig. 9 are consistently related to the hypothetical elastic
microstrains and stresses. Because of the localized nature of the plastic zone the hypothetical elastic
strains can be used as the controlling parameter. When these are consistently applied good fatigue
life predictions result. It should also be mentioned that this analysis was conducted using a constant
mean stress. In the case of variable mean stresses an extra strain term accounting for the mean
stress (omean/E) would be added to the critical plane parameter.

CONCLUSIONS

The fatigue life of notched composite components is controlled mainly by the local microstrains
which are a function of the applied load, microstructure and mechanical properties of the fibre and
matrix materials. The location of fatigue crack initiation sites can be predicted by using the local
fatigue parameter incorporating the multiaxial alternating strains on the critical plane parallel to
the fibre axis. The application of this parameter enables the generalized strain-life relationship to
be determined from a limited amount of experimental data, which can then be used to predict the
life of notched composite components subjected to complex multiaxial loading conditions.

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