Fracture Mechanics

Outcomes and Expectations

Describe the mechanism of crack

propagation
Define fracture toughness and
understand and apply the equation in
design
STRESS CONCENTRATION AT
FLAWS
0

M
0

0
distance from
center
elliptical crack of length 2a crack tip radius t,
elasticity theory gives
1/ 2
a
m 2 0
t
M stress concn factor,

0 m
1/ 2
a
Kt 2
to t

sharp crack tip is a

distance from center
major problem because

effect in brittle material detection difficult

worse than in ductile because
 STRESS INTENSITY
FACTOR
Is a generalisation of the effect of cracks
on stress distribution
(i.e. deals with any crack)

Mode I: tensile Mode II: sliding Mode III: tearing

Using elastic theory, stresses in
specimen can be found
F y

x x
z
r

F
The stress in any direction, at any point
in the specimen, depends on the relative
position of the crack.

In radial co-ords, it depends on:

- the distance of the point from the
crack
(the farther from the crack, the weaker
the stress)
-the angular position of the point
from the crack
(the greater the angle, the weaker the
stress)
The stress also depends on:

-The applied stress

-the crack size

-the geometry of the specimen

(e.g. edge crack vs centre
crack)
e.g. for stress in x direction at
co-ords and r from crack tip
K
x f x ()
2 r
For stresses in other
directions, ( y and z etc.)
equations are the same
but with fy() and fz()

Effect of crack length, etc?

 K
x f x () applied stress
2 r
K Y a
size of the
geometry of specimen
crack
dimensionless param depending on spec.
and crack geoms

K is the stress intensity factor.

Note; K is not the same as stress concn
factor, Kt
 TWO IMPORTANT Y VALUES
stress stress

2a a

stress stress
interior crack edge crack,
infinite plate semi-infinite plate

Y=1 Y=1.1
 FRACTURE TOUGHNESS
- max stress is a function of K
-fracture occurs when a critical value of
K(=Kc) is exceeded

i.e.when
K c Y a Kc

Units of Kc are MPam

-Kc is a material property:
fracture toughness
 ANALOGY TO YIELD STRESS
geometry independent parameter: STRESS
calculated by: F/ A
Material prop: y (YIELD STRESS)
property defines: RESISTANCE TO PLASTIC
DEFORMATION

geometry independent parameter : STRESS

INTENSITY FACTOR
calculated by: Ya
Material prop: Kc (FRACTURE TOUGHNESS)
property defines: RESISTANCE TO BRITTLE
(CATASTROPHIC)
FRACTURE DUE TO CRACK PRESENCE
 HOW TO USE KC

K c Y a Kc

e.g. For a given loading configuration and stress

Y and
There is a maximum value of crack length
a
OR
For a given loading configuration and crack
length
There is a maximum value of stress
Design of a gas cylinder
MEASURING FRACTURE TOUGHNESS

or Compact Tension
3 point bend
crack grown
by fatigue
loading

Crack opening INCREASE LOAD STATICALLY

displacement
RECORD LOAD AND COD
 EFFECT OF SPECIMEN
RAW DATA SIZE
Load KC
Plane strain
Ideal no thickness
case strain

Thickness, B
COD
Use max load to To measure KIC
calculate KIc
Non-ideal curve? 2
K
COD required B 2.5 IC

y
Problems?
 FRACTURE
TOUGHNESS IS AN
ISSUE WHEN ANY
FLAW EXISTS
EVERY MATERIALS
CONTAIN FLAWS
 Suggested lectures

Callister (7th edidion)

Section 8.5
 Problems
Question 1
A ceramic matrix composite contains internal flaws as large as 0.001 cm in length. The plane strain
fracture toughness of the composite is 45 MPam and the tensile strength is 550 MPa. Will the
stress cause the composite to fail before the tensile strength is reached? Assume Y=1.
Answer: 11 354 MPa

Question 2
An aluminum alloy that has a plane strain fracture toughness of 25000 psiin fails when a stress of
42000 psi is applied. Observation of the fracture surface indicates that the fracture began at the
surface of the part. Estimate the size of the flaw that initiated fracture. Assume Y=1.1.
Answer: 0.093 inch

Question 3
A polymer that contains internal flaws 1mm in length fails at a stress of 25 MPa. Determine the
plane strain fracture toughness of the polymer. Assume Y=1.
Answer: 0.99 Mpa*m0.5
 Problems
Question 4
A structural plate component of an engineering deign must support 207 Mpa in tension. If
aluminum alloy 2024-T851 is used for this application, what is the largest internal flaw size that
this material can support?
Answer: 10.36 mm