International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 4, Issue 2, March - April (2013), pp. 373-382 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com

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DETERMINATION OF STRESS INTENSITY FACTOR FOR A CRACK EMANATING FROM A HOLE IN A PRESSURIZED CYLINDER USING DISPLACEMENT EXTRAPOLATION METHOD
AKASH.D.A (1), Anand.A (2), G.V.GNANENDRA REDDY(3), SUDEV.L.J(4)
(2)

Department of Mechanical Engineering, SJCIT Chickaballapur, 562101 Department of Mechanical Engineering, Vidyavardhaka College of engineering, Mysore, 570002 (3) Department of Mechanical Engineering, SJCIT Chickaballapur, 562101 (4) Department of Mechanical Engineering, Vidyavardhaka College of engineering, Mysore, 570002

(1)

ABSTRACT The machine elements with cylindrical profile such as pressure vessel, cylindrical shells, which have been used extensively as the structural configuration in aerospace and shipping industries needs to be leak proof. But however its not possible to fabricate 100% leak proof pressure vessel / cylindrical shell as the industrial materials do not have uniform composition. Thus defects or cracks are inevitable in their substructure, also during their service life a crack may initiate on an internal/external boundary of circular cylinder which has important influence on stress distribution in the structure. Hence the structural assessments of hallow cylinders ranging from thick walled pressure vessel to thin walled pipes has to be carried out, that in-turn relays on availability of Stress Intensity Factor ( S.I.F) for fracture analysis. The magnitude of the S.I.F determines the propagation of crack. In this paper, Considerable effort has been devoted for computation of the S.I.F of crack emanating from a hole in pressurized cylinder. The objective of this work is to determine SIF (Plane Strain) for a crack emanating from a hole in a Pressurised cylinder using Finite Element Method (FEM). From this study it was observed that the value of SIF rises suddenly when the crack tip is near to the hole and it stabilises as the crack tip move far from the hole. The SIF values evaluated for different crack length using FEM is normalised with the analytical values obtained from theoretical equation with respect to (a/D) ratio which provides important information for subsequent studies such as the crack growth rate determination and prediction of residual strength with plane strain and plane stress conditions.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Keywords: Fracture Mechanics, S.I.F and crack emanating from Hole 1. INTRODUCTION

Pressure vessel and cylindrical shells have been used extensively as the structural configuration in aerospace and shipping industries needs to be leak proof. However new advancement in computers has made Finite Element Analysis (FEA) a practical tool in the study of pressure vessels [1], especially in determining stresses in local areas such as penetrations and service holes. The most likely places for crack initiating and development of cracks are the service holes. Due to the high stress concentration in this area cracks may grow in time, leading to a loss of strength and the reduction of the lifetime of the product as shown in Figure1. If the structure is concerned with different loading, the crack behaviour must be assessed in order to avoid catastrophic failures. For this, the knowledge of the crack size, service stress, material properties and Stress Intensity Factor (SIF) is required [2]. Hence the structural assessments of hallow cylinders /shell ranging from thick walled pressure vessel to thin walled pipes has to be done, that in-turn relays on availability of stress intensity factor for fracture and fatigue analysis. Thus it has been recognized that the stress intensity factor is an important parameter to determine the safety of a cracked component, but the basic practical problem a designer faces, is to make a decision to opt the method for determining stress intensity factors. It is not easy to strike a balance between the accuracy of the method, time required to get a solution, and cost. Numerous equations for stress intensity factors are available in the literature [1 6]. These factors represent various geometries and loading conditions of fundamental importance in the prediction of structural failure of cracked cylindrical bodies. In all there are probably more than 600 formulas for calculating K values for different crack configurations, body geometries, and loading situations. Here the objective of the work is to determine S.I.F for a crack emanating from a hole in a pressurized cylinder.

Fig.1: Larger crack formed by the link-up of fatigue cracks at adjacent rivets. 2. FRACTURE MECHANICS Fracture mechanics involves a study of the presence of the cracks on overall properties and behaviour of the engineering component. The process of fracture may be initiated at defect locations like micro-cracks, voids, and the cavities at the grain boundaries. These defects can lead to the formation of a crack due to the rupture and disentanglement of molecules, rupture of atomic bonds or dislocation slip [3]. Cracked body can be subjected to three modes of loads as shown in Figure 2. In some cases, body may experience combination of the three modes:
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

1. Opening mode: The principal load is applied normal to the crack surfaces, which tends to open the crack. This is also referred as Mode I loading (Figure 2a). 2. In-plane shear mode: This mode corresponds to in-plane shear loading which tends to slide One crack surface with respect to the other. This is also referred as Mode II loading (Figure2b). 3. Out-of-plane shear mode: This is the tearing and anti-plane shear mode where the crack surfaces move relative to one another and parallel to the leading edge of the crack (Figure 2c).

(a)

(b)

(c)

Fig. 2: Three modes of loading that can be applied to a crack The Stress Intensity Factor (SIF) is one the most important parameters in fracture mechanics analysis. It defines the stress field close to the crack tip and provides fundamental information of how the crack is going to propagate. In this study, A typical and practical point matching technique, called Displacement Extrapolation Method (DEM) is chosen for the numerical analysis method. Plane strain assumption is valid for very thin-walled structures; the evaluation of S.I.F (KI) by Displacement Extrapolation Method (DEM) is as discussed bellow for plane strain condition. The stress intensity factors at a crack for a linear elastic fracture mechanics analysis may be computed using the KCALC command. The analysis uses a fit of the nodal displacements in the vicinity of the crack. The actual displacements at and near a crack for linear elastic materials are K r u = + 11 (1 + k ) (1) 2G 2

v=+

K1 2G

r (1 + k ) 2 r 2
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w =+

2 K 111 G

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Where: u, v, w = displacements in a local Cartesian coordinate system as shown in figure 3 r, = coordinates in a local cylindrical coordinate system as shown in figure 3. G = shear modulus In Plane Stress (4) K= 1+ v
K= 3 - 4 In Plane strain..(5) = Poisson's ratio For Mode-1, SIF at crack tip is expressed as G V K1 = 2 (6) 1+ k r Where v, are the motions of one crack face with respect to the other. Then A and B are determined so that V = A + Br (7) r At points J and K. Next, let r approach 0 V lim r 0 =A (8) r

Fig. 3: Nodes Used for the Approximate Crack-Tip Displacements for Full crack Model Thus, Equation 5 becomes: 2GA N K 1 = 2 mm 1 + k mm 2

(9)

3. OBJECTIVE OF WORK AND METHODOLOGY The objective of this work is to determine S.I.F for a longitudinal crack emanating from a hole in a pressurized cylinder as shown in figure 4. The objective is achieved by developing a model of a cylinder with hole and a through crack using CATIA V5 software .The CATIA model is imported to ANSYS.The FE model is meshed using 8-node quadrilateral doubly curved SHELL 93 elements in the pre-processor of the ANSYS software . Further as a part of the finite element work, a mesh sensitivity Study was conducted.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

A shell with a longitudinal crack was meshed using three different mesh densities. Mainly, the area around the imperfection was modelled with a finer mesh. Further the crack tip singular elements were created using KSCON command. For this model there are 36 singular elements around the crack tip and the radius of the first row elements is a (Where a = a/100).The model is then solved (Static Analysis) by subjecting it to an internal pressure of 1MPa load with appropriate boundary conditions. Then the S.I.F is evaluated in general postprocessor by using KCALC command. The geometry of the meshed test model with crack tip singular elements in ANSYS 12 is as shown in the Figure 5.The material considered is 304 steel (ASME). The material is assumed to be linear elastic with youngs modulus of 2.5GPa and poisons ratio 0.3

Where, D= Diameter of the hole (20mm), a= Half Crack length =applied hoop stress (Pr/t) P= Internal pressure 1MPa t=Thickness of the cylindrical shell 10mm

Fig.4: Geometry of model

(a)

(b)

(c)

Fig. 5: (a) Finite Element Model meshed with Boundary Condition (b) Zoomed View of elements near crack tip (c) Zoomed View of Crack Tip Singular Elements

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

4. VALIDATION OF PROPOSED METHODOLOGY The methodology proposed to determine Mode-1 S.I.F in previous section is validated using the practical problem Determination of S.I.F of longitudinal cracks in a pressurized cylindrical shell from reference 3.A cylindircal shell with varying longitudinal crack length given in reference 3 is as shown in Figure 6.

Fig.6: Longitudinal crack in internally pressurized cylinder

Mode I S.I.F (KI) is given by KI(Theo)= a. f 1 ( ) (10) Where

f1 ( ) = (1 + 0.52 x + 1.29 x 2 0.07 x 3 ) x= a ( Rt )

The half crack length was varied from 20mm to maximum half crack length of 439.53mm .The maximum crack length in a given dimensions of cylindrical shell was determined using curvature parameter [9]

a 4 12(1 2 ) .(11) Rt

if =8 for longitudinal cracks , thickness of the cylindrical shell is 10mm and radius of the cylindrical shell is 1000mm then the maximum crack length for given set of cylindrical shell dimension is 439.53mm. The values of S.I.F obtained by the theoretical and FEA is given in table 1.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Table 1: Mode-1 S.I.F (KI) Using FEA and theoretical KI(Theo) for different Half Crack lengths (a)
Half Crack Length (a) mm 20 40 60 80 100 120 140 180 220 260 300 340 380 400 439.532 Mode -I SIF by FEA
MPa mm

Mode -I SIF by Analytical

MPa mm

% error 3.50 3.61 4.33 3.71 3.42 2.99 3.42 1.74 1.09 0.53 0.00 -0.58 -0.94 -1.54 -2.29

821.49 1282.6 1749.6 2265.4 2831.4 3448.9 4114.8 5570.8 7168.4 8886.5 10711 12634 14608 15685 17798

851.322 1330.62 1828.751 2352.63 2931.63 3555.117 4221.655 5669.381 7247.292 8933.523 10710.546 12561.166 14471.544 15446.58 17398.911

Fig.7: variation of theoretical and FEA values of S.I.F Vs crack length for longitudinal crack in Pressurized cylinder
From the Fig 7 it is indicated that the results which were obtained by using the finite element method are in good agreement with theoretical equation for a longitudinal through crack emanating in internally pressurized cylindrical shell with an average percentage of error 1.53% which is negligible. Thus the proposed methodology to determine the Mode-1 S.I.F for longitudinal cracks in pressurised cylindrical shell is validated against a standard Procedure.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

5. RESULTS AND DISCUSSIONS

For the problem Determination of SIF for a Crack Emanating from a Hole in a Pressurized cylinder the test models containing a through crack emanating from a hole are meshed and with plane strain condition it was internally pressurized and respective SIFs are calculated.Theoritical Mode-1 is calculated using the relation
K1 (Theo ) = a eff N mm 2 mm (12)

The variation of normalized Stress Intensity Factor (KI/KO) (By Plane Strain Method) with respect to a/D ratio [actual crack length (a) to the Diameter of the hole (D)] is as shown in Figure 8. The normalized SIF (KI/KO) is used to obtain the characteristic curve of SIF which depends only on the geometrical factor and its variation within the given domain (a/D). Its observed that as the crack is near to the hole the stress concentration around holes has a strong influence on the SIF value. For a/D ratio 0.5 there is a steep rise in SIF KI, this is due to crack is small and the crack tip is near to stress concentration at the hole from which crack in emanating. As the crack grows further (for a/D ranging from 0.1 to 25) the crack tip moves far from the stressed areas hence the value of SIF increases the system will fail with increase in crack length.

Table 2: The normalized Stress Intensity Factor (KI/KO) with respect to a/D ratio
Half Crack Length (a) mm 10 20 40 60 80 140 180 200 220 260 300 320 380 400

Hole dia(D) mm 20 20 20 20 20 20 20 20 20 20 20 20 20 20

a/D

Mode -I SIF by FEA(KI)

MPa mm

aeff

Mode -I SIF by Theoritical(Ko)

MPa mm

KI / Ko

mm 15 20 30 40 50 80 100 110 120 140 160 170 200 210

0.50 1.00 2.00 3.00 4.00 7.00 9.00 10.00 11.00 13.00 15.00 16.00 19.00 20.00

743.96 853.01 1085.8 1310.4 1540.1 2302.5 2881.6 3191.3 3514.8 4200.3 4932.1 5313.5 6519.8 6938.3

686.51 792.72 970.88 1121.07 1253.40 1585.43 1772.57 1859.09 1941.75 2097.33 2242.14 2311.15 2506.79 2568.70

1.08368 1.076059 1.118372 1.168882 1.228742 1.452284 1.625663 1.716596 1.810118 2.002688 2.199727 2.299075 2.600855 2.701098

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Fig.8: Variation of normalized S.I.F for a crack emanating from circular hole in pressurized cylinder Vs a/D
The Deformed Geometries for crack length (a) of 20 mm is as shown in Figures 9, The maximum Von-Misses stress is found to be at crack tip.

Fig 9: (a) VonMises Stress Distribution for Pressurised cylinder containing hole dia D=20mm and crack length a=20mm 6. CONCLUSION
The problem of determining stress intensity factors for a crack emanating from a hole in a pressurized cylinder is of prime importance in damage tolerance analysis. In the present study ANSYS12, unified FEA software is chosen. It has the required pre-processing capabilities for finite element modeling and analysis of cracked shell structures as demonstrated in this paper.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

The variation of normalized S.I.F (Ki/Ko) with respect to a/D ratio is used to obtain the characteristic curve of SIF which depends only on the geometrical factor and its variation within the given domain (a/D). The fracture mechanics analysis on effects of pressure bulging near the crack on the stress intensity factor is described in this paper that provides an explanation for the lower strength of cracked cylinders. The presented stress intensity factors in this paper are essential to predict (1) Mixed mode fracture under static, dynamic and sustained loads (2) Residual strength (3) Crack growth life under cyclic loading conditions. However there is a clear need to verify the predictions using experimental investigations, but the method used in this paper can be utilized for calculating the stress intensity factor for many other loading cases and many values of the crack length. This provides important information for subsequent studies, especially for fatigue loads, where stress intensity factor is necessary for the crack growth rate determination.

REFERENCES
Heckman david: Finite element analysis of pressure vessels, MBARI 1998 Chuin-Shan Chen, Paul A. Wawrzynek, and Anthony R. Ingraffea, 1999, Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages, NASA/CR-1999-209115. [3] Fracture mechanics-Fundamentals and Applications by T.L.Anderson published by Taylor and Francis group 2005 [4] Gustavo V. Guinea, Jaime Planas and Manuel Elices, 2000, KI Evaluation by the Displacement Extrapolation Technique, Engineering Fracture Mechanics 66 (2000), pp. 243255. [5] Miloud Souiyah, A. Muchtar, Abdulnaser Alshoaibi and A.K. Ariffin, 2009, Finite Element Analysis of the Crack Propagation for Solid Materials American Journal of Applied Sciences 6 (7), pp. 1396-1402. [6] Craig A. Barwell, Lorenz.,A Study of Failure in Small Pressurized Cylindrical Shells Containing a Crack., NASA/CR-1998-208454 [7] Yao-Chen Li, 1984, The Finite Element Method By Employing The Singular Element With Concordant Displacement At The Crack Tip Engineering Fracture Mechanics, Vol. 19, No. 5, pp. 959-972. [8] Agne Karlsson and Jan Backlund, 1978, Summary of SIF Design Graphs for Cracks Emanating From Circular Holes International Journal of Fracture, Vol. 14, No. 6 [9] Richard D. YoungNon-linear local bending response and bulging factors for longitudinal and circumferential cracks in pressurised cylindrical shells. [10] Kannan.P, K.Balamurugan and K. Thirunavukkarasu, Experimental Investigation on the Influence of Silver Interlayer in Particle Fracture of Dissimilar Friction Welds, International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 2, 2012, pp. 32 - 37, ISSN Print: 0976 6340, ISSN Online: 0976 6359. [11] I.M.Jamadar, S.M.Patil, S.S.Chavan, G.B.Pawar and G.N.Rakate, Thickness Optimization of Inclined Pressure Vessel using Non Linear Finite Element Analysis using Design by Analysis Approach, International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 3, 2012, pp. 682 - 689, ISSN Print: 0976 6340, ISSN Online: 0976 6359. [1] [2]

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