Fracture Mechanics Simulation Lab

Report on Tutorial problems (Lab Assignment 2)

Submitted in fulfillment of the requirements of

AEZG614- Fracture Mechanics

By

Anuj Shukla

(ID NO: 2021TH55539)

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI CAMPUS

Semester 2022-2023
Tutorial 3 - Plate with an edge crack
Problem Statement
Observations
This case study describes the simulation of crack propagation in a plate with a
circular hole and a crack. The Stress Intensity Factor (SIF) was found to be highest
in the K1 mode, and the crack was expected to propagate. However, the simulation
stopped automatically when the stress intensity factor exceeded the Kth value
before the crack reached the end of the plate. The crack length increased
exponentially, and the fatigue life prediction showed a short lifespan due to the
high initial stress.
Conclusions
The simulation was stopped as the maximum stress intensity factor (Kmax)
exceeded the Critical Stress Intensity value (Kc), which is also known as the fracture
toughness value. This indicates that the plate is likely to experience sudden failure
once the stress exceeds this critical value.
Tutorial 4 - T Joint with LOP defect
Problem Statement
In a critical welded structure by quenched and tempered (Q&T) steel of ASTM 517 ‘F’ grade, an
lack of penetration (LOP) defect was detected in a T-Joint location during inspection. The T-Joint
is subjected to a load of 120 MPa as shown in figure. Determine the path of crack propagation
and estimate the fatigue life of the joint before it fracture. ΔKth = 130 MPa√mm, KC = 1600
MPa√mm, C = 1.27E-14, m = 3.4.

Observations
This study highlights the behavior of stress concentration and SIF in a plate with a
circular hole under tensile pressure. The static crack analysis shows that the K1 mode has
the highest SIF value, which is above the Kth value, indicating potential crack
propagation. On the other hand, the SIF value in K2 mode is much lower. Overall, these
findings can provide insights into designing plates with holes under tensile loads to
 prevent crack propagation.

• Crack growth analysis is carried out using the Paris law.

Crack growth – simulation Crack growth – Practical

The crack growth in simulation is matching with the practical test, which is in
the arc form.
• After simulation Its observed that the stress intensity factor is crossed Kth
value i.e. 1600 MPa√mm and the simulation stopped automatically.
During the initial stages of crack growth, both the crack growth and Stress Intensity
Factor (SIF) values were low. However, as the crack continued to propagate, the SIF
values increased rapidly. This is because the area of the plate available to bear the
load reduces as the crack grows, while the load remains constant. This results in an
increase in stress over a smaller area, leading to a rapid increase in the SIF value as
the crack moves towards the edge.

It should be noted that the K value increases exponentially with an increase in the
value of stress (σ), according to a given formula.
The graph below shows the variation of K value versus crack growth distance.
The relationship between crack length and fatigue life indicates that the crack
length increased exponentially over time. In this case, the crack length increased
from around 9 mm to 24 mm.It was also observed that the K value increased up
to 1618, which is above the fracture toughness value given. This suggests that the
material is likely to experience sudden fracture after this value is exceeded.

• Fatigue life prediction shows a life of 146396 cycles.

Conclusions
This case study reveals that the simulation was stopped due to the maximum stress
intensity factor exceeding the Critical Stress Intensity value (Kc), which implies that
the T joint is prone to sudden failure when the stress surpasses this critical value.
Furthermore, the accurate match between the theoretical simulation of crack
growth and practical experiment suggests that the simulation model used in this
study is reliable and accurate. These findings can provide valuable insights into the
behavior of T joints under stress and help in designing better and more robust joints
in the future
Tutorial 5 Surface crack in a Pipe bend

Observations
• The Paris law was used to simulate crack growth, and a simulation value of
0.4mm was set for the crack growth size. It was estimated that around 8
steps were required for the crack to reach the remaining 3 mm of the pipe
wall thickness.
•
• • During simulation, it was observed that the SIF increased rapidly as the
crack grew. This was due to the reduced cross-sectional area of the pipe wall
available to withstand the load.
•
• • After approximately 13 steps, the stress intensity factor exceeded the Kth
value, which led to automatic termination of the simulation. This indicates
that the crack grew beyond the critical limit, and failure was imminent.
•
• • The fatigue life prediction showed a lifespan of 26,587 cycles. However,
since the initial stress was already high, the lifespan was short.
•
• Overall, the study highlights the importance of crack propagation simulation
and fatigue life prediction to prevent sudden failures in pipelines. It also
shows that it is crucial to consider the stress intensity factor and Kth value in
predicting the crack growth and failure of the pipeline.

• The crack growth and SIF was low in the initial steps and as the crack
increased SIF rose rapidly.

• This is because, as the crack grows the area of the plate available to take the
load reduces however the load remains constant, hence the stress increases
over less area resulting in SIF value to increase rapidly as the crack grows
towards the edge.
 • Depth of the crack is from 2 mm to 4.5 mm and Fatigue life prediction
shows that 128000 cycles.
Conclusions
It should be noted that the estimated life of the pipe is based on the assumption
that the pipe will be subjected to the same operating conditions throughout its
lifetime. If there are any changes in the operating conditions, such as an increase
in pressure or temperature, the estimated life of the pipe may change. Therefore,
it is important to consider all factors that may affect the integrity of the pipeline
and take appropriate measures to ensure safe operation.
Tutorial 6 Crack in a bracket with bolt pretension

Observations
• The sub-modeling approach has allowed for a more detailed analysis of the
crack behavior and performance, which is essential for predicting the
remaining life of the flange. Based on the results of the crack growth
simulation, it has been estimated that the remaining life of the flange is
approximately 3,000 cycles. Therefore, it is recommended that the crack be
repaired or the flange be replaced before this point is reached to prevent
 any potential failure or safety hazards.

• On grow crack analysis it is observed that the bracket has shown very high
life of 58650039 cycles.

• Based on the analysis, it has been observed that the stress levels in the
bracket are relatively low. As a result, the life of the bracket is expected to
 be very high. Additionally, since the crack is not in a critical zone, it is
unlikely to propagate even if the stress levels are increased from 80 to 160
MPa√mm.

•
• The crack length is increased from 4 mm to 13.8 mm, but it took a very long
time to reach this length.
• Crack depth vs fatigue life shows that the depth increase is gradual. Depth
increased from around 1 mm to 4 mm.
Conclusions
However, it is important to continue monitoring the component periodically to
detect any changes in its behavior or performance. This can help identify any
potential issues before they become more severe, allowing for timely repairs or
replacements to be made. It is also recommended to periodically review the
design and material selection of the component to ensure that it continues to
meet the required performance and safety standards.
Tutorial 7 Revit Joint – Multiple crack

Observations
Based on the analysis, it is predicted that the crack will propagate to the end of
the plate before the Critical Stress Intensity value of 1600 MPa√mm is reached.
Therefore, it is crucial to monitor the crack growth and address any potential
issues or make necessary repairs in a timely manner to prevent catastrophic
failure. The simulation results can be used to determine the expected life of the
plate and the number of cycles it can endure before the crack propagates to a
critical level. It is important to note that the accuracy of the simulation results
depends on the reliability of the input parameters, such as material properties
and loading conditions. Therefore, it is essential to ensure that the input
parameters are accurately measured or obtained through reliable sources.

• Crack growth analysis is carried out using the Paris law.

• The K value versus crack growth distance shown below

• Fatigue life prediction shows that 211457 cycles.

• Crack length vs fatigue life shows that the length increased exponentially.
Length increased from around 7 mm to 22 mm.
Conclusions
This sudden increase in SIF and the exponential crack growth can be attributed to
the stress concentration caused by the neighboring rivet hole. As the crack
approaches the hole, the stress concentration increases, leading to a significant rise
in SIF and the resulting exponential crack growth. This observation highlights the
importance of considering the influence of neighboring features on crack
propagation behavior during design and analysis to prevent catastrophic failure.
Tutorial 8 Damage tolerance studies on Frame
Problem Statement 8

Observations
Calculating the stress intensity factor (SIF) of an initial crack in the frame is crucial
in preventing catastrophic crack propagation. If the SIF surpasses the critical Kth
value, there is a high probability of crack propagation, which can ultimately result
in failure.
Trial 1: @10kNm bending moment

Under given bending load condition i.e. 10kNm, SIF observed is starting from 620
to 930 MPa√mm which is much higher than the ΔKth = 160 MPa√mm. Hence the
crack in the frame will propagate.
Trial 2: @5kNm bending moment

For Bending moment of 5 kNm, SIF observed is starting from 320 to 460 MPa√mm
which is much higher than the ΔKth = 160 MPa√mm. Hence the crack in the frame
will propagate.
Trial 3: @1kNm bending moment

For Bending moment of 1 kNm, SIF observed is starting from 65 to 95 MPa√mm

which is well below the ΔKth = 160 MPa√mm. Hence the crack will not propagate.
Conclusions
To ensure that a structure can handle the applied loads without experiencing cracks
or failure, a safe Stress Intensity Factor (SIF) analysis is conducted. In the case of
the given frame with a crack of 2a = 6 mm and c = 1 mm, it was found through an
iterative process that the maximum allowable bending moment is 1kNm. It is
important to note that in situations where cracking is unacceptable, it is crucial to
perform SIF analysis to determine the structure's ability to withstand the applied
loads without experiencing any cracks or failure.