Augmenting Generic Fatigue Crack Growth Models Using 3D Finite Element Simulations and Gaussian Process Modeling

2019 ◽  
Author(s):  
Adrian Loghin ◽  
Shakhrukh Ismonov
Keyword(s):  
Finite Element ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Propagation ◽  
Gaussian Process ◽  
Crack Growth ◽  
Life Assessment ◽  
Growth Path ◽  
3D Fem

Abstract Assessing the crack propagation life of components is a critical aspect in evaluating the overall structural integrity of a mechanical structure that poses a risk of failure. Engineers often rely on industry standards and fatigue crack growth tools such as NASGRO [1] and AFGROW [2] to perform life assessment for different structural components. A good understanding of material damage tolerant capabilities, and the component’s loading mission during service conditions are required along with the availability of generic fracture mechanics models implemented in the lifing tools. Three-dimensional (3D) linear elastic fracture mechanics (LEFM) finite element modeling (FEM) is also a viable alternative to simulate crack propagation in a component. This method allows capturing detailed geometry of the component and representative loading conditions which can be crucial to accurately simulate the three dimensionality of the propagating crack shape and further determine the associated loading cycles. In comparison to a generic model, the disadvantage of the 3D FEM is the extended runtime. One feasible way to benefit from 3D modeling is to employ it to understand the crack front evolution and growth path for the representative loading condition. Mode I stress intensity factors (KI) along the predetermined crack growth path can be generated for use in fatigue crack growth tools such as NASGRO. In the current study, such a 3D FEM lifing process is presented using a classical bolt-nut assembly, components that are commonly used in engineering design. First, KI solutions for a fixed crack aspect ratio a/c = 1 are benchmarked against a similar solution available in NASGRO. Next, a predefined set of crack shapes and sizes are simulated using 3D FEA. A machine learning model Gaussian Process (GP) was trained to predict the KI solutions of the 3D model, which in turn was used in the crack propagation simulation to accelerate the life assessment process. Verification of the implemented procedure is done by correlating the crack growth curves predicted from GP to the results obtained directly from 3D FE crack propagation method.

scholarly journals Two- and Three-Dimensional Numerical Investigation of the Influence of Holes on the Fatigue Crack Growth Path

2021 ◽  
Vol 11 (16) ◽  
pp. 7480
Author(s):  
Yahya Ali Fageehi
Keyword(s):  
Finite Element ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Propagation ◽  
Crack Growth ◽  
Three Dimensional ◽  
Real Life ◽  
Growth Path ◽  
Crack Growth Path

Problems in fracture mechanics are difficult when the appropriate analysis is unspecified, which is very common in most real-life situations. Finite element modeling is thus demonstrated to be an essential technique to overcome these problems. There are currently various software tools available for modeling fracture mechanics problems, but they are usually difficult to use, and obtaining accurate results is not an obvious task. This paper illustrates some procedures in two finite element programs to solve problems in two- and three-dimensional linear-elastic fracture mechanics, and an educational proposal is made to use this software for a better understanding of fracture mechanics. Crack modeling was done in a variety of ways depending on the software. The first is the well-known ANSYS, which is usually utilized in industry, and the second was a freely distributed code, called FRANC2D/L, from Cornell University. These software applications were used to predict the fatigue crack growth path as well as the associated stress intensity factors. The predicted results demonstrate that the fatigue crack is turned towards the hole. The fatigue crack growth paths are influenced by the varying positions and sizes of single holes, while two symmetrically distributed holes have no effect on the fatigue crack growth direction. The findings of the study agree with other experimental crack propagation studies presented in the literature that reveal similar crack propagation trajectory observations.

A research on fatigue crack growth monitoring based on multi-sensor and data fusion

2019 ◽  
pp. 147592171986572
Author(s):  
Chang Qi ◽  
Yang Weixi ◽  
Liu Jun ◽  
Gao Heming ◽  
Meng Yao
Keyword(s):  
Finite Element ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Data Fusion ◽  
Crack Propagation ◽  
Finite Element Model ◽  
Crack Length ◽  
Crack Growth ◽  
Lamb Wave ◽  
Element Model

Fatigue crack propagation is one of the main problems in structural health monitoring. For the safety and operability of the metal structure, it is necessary to monitor the fatigue crack growth process of the structure in real time. In order to more accurately monitor the expansion of fatigue cracks, two kinds of sensors are used in this article: strain gauges and piezoelectric transducers. A model-based inverse finite element model algorithm is proposed to perform pattern recognition of fatigue crack length, and the fatigue crack monitoring experiment is carried out to verify the algorithm. The strain spectra of the specimen under cyclic load in the simulation and experimental crack propagation are obtained, respectively. The active lamb wave technique is also used to monitor the crack propagation. The relationship between the crack length and the lamb wave characteristic parameter is established. In order to improve the recognition accuracy of the crack propagation mode, the random forest and inverse finite element model algorithms are used to identify the crack length, and the Dempster–Shafer evidence theory is used as data fusion to integrate the conclusion of the two algorithms to make a more accountable and correct judge of the crack length. An experiment has been conducted to demonstrate the effectiveness of the method.

Numerical simulation of fatigue crack propagation in mixed-mode (I+II) using the program BemCracker2D

2019 ◽  
Vol 10 (4) ◽  
pp. 497-514
Author(s):  
Pedro G.P. Leite ◽  
Gilberto Gomes
Keyword(s):  
Numerical Simulation ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Propagation ◽  
Crack Growth ◽  
Mixed Mode ◽  
Mode I ◽  
Post Processing ◽  
Content Type

Purpose The purpose of this paper is to present the application of the boundary element method (BEM) in linear elastic fracture mechanics for analysis of fatigue crack propagation problems in mixed-mode (I+II) using a robust academic software named BemCracker2D and its graphical interface BemLab2D. Design/methodology/approach The methodology consists in calculating elastic stress by conventional BEM and to carry out an incremental analysis of the crack extension employing the dual BEM (DBEM). For each increment of the analysis, the stress intensity factors (SIFs) are computed by the J-Integral technique, the crack growth direction is evaluated by the maximum circumferential stress criterion and the crack growth rate is computed by a modified Paris equation, which takes into account an equivalent SIF to obtain the fracture Modes I and II. The numerical results are compared with the experimental and/or BEM values extracted from the open literature, aiming to demonstrate the accuracy and efficiency of the adopted methodology, as well as to validate the robustness of the programs. Findings The paper addresses the numerical simulation of fatigue crack growth. The main contribution of the paper is the introduction of a software for simulating two-dimensional fatigue crack growth problems in mixed-mode (I+II) via the DBEM. The software BemCracker2D coupled to the BemLab2D graphical user interface (GUI), for pre/post-processing, are very complete, efficient and versatile and its does make relevant contributions in the field of fracture mechanics. Originality/value The main contribution of the manuscript is the development of a GUI for pre/post-processing of 2D fracture mechanics problems, as well as the object oriented programming implementation. Finally, the main merit is of educational nature.

scholarly journals Numerical Simulation of Fatigue Crack Growth Rate and Crack Retardation due to an Overload Using a Cohesive Zone Model

2014 ◽  
Vol 891-892 ◽  
pp. 777-783 ◽  
Author(s):  
Sarmediran Silitonga ◽  
Johan Maljaars ◽  
Frans Soetens ◽  
Hubertus H. Snijder
Keyword(s):  
Finite Element ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Propagation ◽  
Crack Growth ◽  
Cohesive Zone ◽  
Cohesive Zone Model ◽  
Crack Tip ◽  
Zone Model ◽  
Cohesive Elements

In this work, a numerical method is pursued based on a cohesive zone model (CZM). The method is aimed at simulating fatigue crack growth as well as crack growth retardation due to an overload. In this cohesive zone model, the degradation of the material strength is represented by a variation of the cohesive traction with respect to separation of the cohesive surfaces. Simulation of crack propagation under cyclic loads is implemented by introducing a damage mechanism into the cohesive zone. Crack propagation is represented in the process zone (cohesive zone in front of crack-tip) by deterioration of the cohesive strength due to damage development in the cohesive element. Damage accumulation during loading is based on the displacements in the cohesive zone. A finite element model of a compact tension (CT) specimen subjected to a constant amplitude loading with an overload is developed. The cohesive elements are placed in front of the crack-tip along a pre-defined crack path. The simulation is performed in the finite element code Abaqus. The cohesive elements behavior is described using the user element subroutine UEL. The new damage evolution function used in this work provides a good agreement between simulation results and experimental data.

Fatigue Crack Growth Prediction of Elliptical Corner Crack Using 3D FEM

2012 ◽  
Vol 248 ◽  
pp. 469-474
Author(s):  
M.H. Gozin ◽  
M. Aghaie-Khafri
Keyword(s):  
Finite Element ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Crack Closure ◽  
Crack Front ◽  
Crack Opening ◽  
3D Fem ◽  
Corner Crack ◽  
Closure Method

Plasticity induced crack closure (PICC) simulation using finite element analyses has been concerned by many researchers. In the present investigation elliptical corner fatigue crack growth from a hole was predicted using PICC method. An elastic-plastic finite element model is built with a suitably refined mesh and time-dependent remote tractions are applied to simulate cyclic loading. In a 3D geometry the crack opening value will vary along the crack front. For simplicity this shape evolution is neglected and the crack front is extended uniformly. Predicted fatigue life using crack closure method for elliptical corner crack is in good agreement with the experimental data. The results obtained highlighted the sensitivity of crack closure method to the opening stress intensity values.

Fatigue Crack Growth Life Prediction for Surface Crack Located in Stress Concentration Part Based on 3D-FEM

2002 ◽  
Author(s):  
Youichi Yamashita ◽  
Masaharu Shinozaki ◽  
Yuusuke Ueda ◽  
Kenji Sakano
Keyword(s):  
Finite Element ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Surface Crack ◽  
Influence Function ◽  
Fe Analysis ◽  
3D Fem ◽  
Paris Law ◽  
Influence Function Method

Fatigue crack growth prediction methods using three dimensional finite element analyses were investigated to improve the predictability of part-through surface crack growth life. First, a direct analysis method of cyclic finite element analysis was adopted. Fatigue crack growth was predicted on a step by step basis from the Paris’ law using stress intensity factor range (ΔK) calculated by 3D-FEM. This method takes the procedure of cyclic operation of FE-analysis modeled with crack tip elements, crack growth increment calculation and remeshing of FE-model. Second, a method based on influence function method for ΔK calculation directly using 3D-FE-analysis result has been developed and applied. It was found that crack growth prediction based on step by step finite element method and the method based on the influence function method showed good correlation with the experimental results if Paris’ law coefficient C determined by CT specimen was appropriately used for semi-elliptical surface crack.

Research on Microstructure Dependence of Near-Threshold Fatigue Crack Propagation by Combined Analyses of Fracture Surface and Fatigue Crack Growth Path

2009 ◽  
Author(s):  
Ming-Liang Zhu ◽  
Fu-Zhen Xuan ◽  
Guo-Zhen Wang ◽  
Zheng-Dong Wang
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Propagation ◽  
Crack Growth ◽  
Crack Advance ◽  
Growth Path ◽  
Austenite Grain Size ◽  
Fatigue Crack Growth Resistance ◽  
Crack Growth Path ◽  
Near Threshold

Near-threshold fatigue crack growth behavior was investigated in a newly developed steel 25Cr2NiMo1V with different heat treatments to meet different property requirements of high-pressure (HP) and low-pressure (LP) parts in the combined steam turbine rotor. The load-shedding method was adopted in the near-threshold fatigue crack growth experiment at room temperature with a constant load ratio of 0.1. Combined analyses of crack surface and fatigue crack growth path were carried out to identify the dominant crack growth mechanisms in both HP and LP. Results show that in the threshold regime, fatigue crack growth resistance of the HP is clearly superior to that of LP and hence shows strongly dependence on the microstructure of 25Cr2NiMo1V. The distributed bainitic microstructures and larger prior austenite grain size in HP result in more tortuous crack propagation path than that in LP. Compared with ferritic blocks in HP, the tempered martensitic laths in LP do not play a dominate role in stopping the fatigue crack advance.

Numerical Analysis of JNES Seismic Tests on Degraded Combined Piping System

2011 ◽  
Vol 134 (1) ◽  
Author(s):  
Tao Zhang ◽  
Frederick W. Brust ◽  
Gery Wilkowski ◽  
Do-Jun Shim ◽  
Jinsuo Nie ◽  
...  
Keyword(s):  
Finite Element ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Growth ◽  
Low Cycle Fatigue ◽  
Small Scale ◽  
Cycle Fatigue ◽  
Small Scale Yielding ◽  
Scale Yielding

Nuclear power plant safety under seismic conditions is an important consideration. The piping systems may have some defects caused by fatigue, stress corrosion cracking, etc., in aged plants. These cracks may not only affect the seismic response but also grow and break through causing loss of coolant. Therefore, an evaluation method needs to be developed to predict crack growth behavior under seismic excitation. This paper describes efforts conducted to analyze and better understand a series of degraded pipe tests under seismic loading that was conducted by Japan Nuclear Energy Safety Organization (JNES). A special “cracked-pipe element” (CPE) concept, where the element represented the global moment-rotation response due to the crack, was developed. This approach was developed to significantly simplify the dynamic finite element analysis in fracture mechanics fields. In this paper, model validation was conducted by comparisons with a series of pipe tests with circumferential through-wall and surface cracks under different excitation conditions. These analyses showed that reasonably accurate predictions could be made using the abaqus connector element to model the complete transition of a circumferential surface crack to a through-wall crack under cyclic dynamic loading. The JNES primary loop recirculation piping test was analyzed in detail. This combined-component test had three crack locations and multiple applied simulated seismic block loadings. Comparisons were also made between the ABAQUS finite element (FE) analyses results to the measured displacements in the experiment. Good agreement was obtained, and it was confirmed that the simplified modeling is applicable to a seismic analysis for a cracked pipe on the basis of fracture mechanics. Pipe system leakage did occur in the JNES tests. The analytical predictions using the CPE approach did not predict leakage, suggesting that cyclic ductile tearing with large-scale plasticity was not the crack growth mode for the acceleration excitations considered here. Hence, the leakage was caused by low-cycle fatigue with small-scale yielding. The procedure used to make predictions of low-cycle fatigue crack growth with small-scale yielding was based on the Dowling ΔJ procedure, which is an extension of linear-elastic fatigue crack growth methodology into the nonlinear plasticity region. The predicted moments from the CPE approach were used using a cycle-by-cycle crack growth procedure. The predictions compare quite well with the experimental measurements.

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