Numerical Simulation of Fatigue Crack Growth: Cohesive Zone Models vs.

XFEM

Thomas Siegmund Purdue University

T. Siegmund, Purdue
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Funding
JOINT CENTER OF EXCELLENCE for ADVANCED MATERIALS, FAA Cooperative Agreement 04-C-AM-PU. Damage Tolerance and Durability of Adhesively Bonded Composite Structures Technical Monitor: Curt Davies Cost share: Purdue University Additional Funding: Catterpillar Inc.
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Research Accomplishements
Compare cohesive zone model approach to XFEM. Implement fatigue crack growth in XFEM Study contact fatigue failure

T. Siegmund, Purdue

XFEM-ABAQUS
eXtended Finite Element Method Extension of conventional FEM based on the concept of partition of unity;

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XFEM-ABAQUS
u = N I ( x ) [ u I + H ( x )a I ]
I =1 N

N I shape function u I conventional nodal dispalcement a I enriched nodal displacements

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Traction-Sparation Law
Tn,0 K 0 = Tt ,0 0 0 n K0 t =1

Tn,0 Tt ,0 max , max,0 max,0

Tn = (1 D )Tn,0 ,Tt = (1 D )Tt ,0 Teff d m Dm = 0 m T. Siegmund, Purdue 0 el

m

Example: CZM vs. XFEM

Plate with a central hole Remote displacements CZ elements along several radial lines XFEM enrichment throughout

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Damage Accumulation Rule

Damage accumulation starts if a deformation measure, accumulated or current, is greater than a critical magnitude. There exists an endurance limit which is a stress level below which cyclic loading can proceed infinitely without failure. The increment of damage is related to the increment of absolute value of deformation as weighted by the ratio of current load level relative to strength.

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Damage Accumulation Rules

T m eff CZM : dDc = Cf max , Dc = dDc

p1 p1 Cf , Dc = dDc XFEM : dDc = max

f..cohesive endurance limit .cyclic cohesive length

K0 = E0

f..cohesive endurance limit cyclic reference strain

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Fatigue Damage Model

Cyclic damage variable: DC = = Effective tractions: T n Since: Adamaged A0

F Tn = A0 (1 DC ) (1 DC ) =T ( T n n max,0 , 0 )

Tn = Tn max,0 (1 DC ), 0 Current Cohesive Properties:

max = max,0 (1 DC ) , n = max 0 = max,0 (1 DC ) 0

, , T , T ... ) =D (D , Need to define : D C C C n t n t

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Monotonic Loading
1.4E+07 1.2E+07 1.0E+07 ELASTIC XFEM

22 [Pa]

8.0E+06 6.0E+06 4.0E+06 2.0E+06 0.0E+00 0 0.002 0.004

CZM

0.006

0.008

E22

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Cyclic Loading: Damage Evolution in Mode I

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Cyclic Damage [ ]

0.8

0.6

0.4

0.2

0 0 1 2 3 4 5 6 7 8 9 10

the first three elements of the row of elements emerging from the hole at . --- 1st element CZM (both integration points shown), - - 1st element XFEM, ---- 2nd element CZM (lagging integration point shown), - - 2nd element XFEM, ---- 3rd element CZM (lagging integration point shown), - - 3rd element XFEM.
Normalized Time [ ]

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Cyclic Loading: Mixed Mode

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Contact Fatigue
Multiaxial Fatigue Criteria:

Critical Plane Approach E.g.: Findley Criterion: max { a + f n ,max } = f

a shear stress amplitude on a plane n ,max max. normal stress on that plane
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Contact Fatigue
Multiaxial Fatigue Criteria:

Critical Plane Approach E.g.: Findley Criterion: max { a + f n ,max } = f

a shear stress amplitude on a plane n ,max max. normal stress on that plane
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Example Result

Provides location of crack initiation but not: -- number of cycles to failure -- not applicable to variable amplitude loading T. Siegmund, Purdue
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CZM Approach
Cohesive Zone Model
LE CE CE LE LE CE CE LE

LE CE LE CE LE CE LE CE LE LE

Mesh generator available Tie CZ mesh to main model T. Siegmund, Purdue

CE

CE LE CE LE

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Redefine: Effective Traction

Common Fatigue Crack Growth Contact Fatigue

T =

(Tn )

+ (Tt )

T =

( Tn )

+ ( Tt )
2

T =

0.64 2 T + T ( ) t n 3 if Tn > 0 T = 0.64 T n + Tt 3 if Tn < 0

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Pmax = 16800 N at Failure

Contact Radius

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Damage Evolution

Subsurface Crack Initiation Site

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Contact Radius

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Damage Evolution Pmax = 2800 N

Subsurface Crack Initiation Site Contact Radius

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Comparison
Damage Accumulation Rate

0.25 0.2 0.15 0.1 0.05 0 0 5000 10000 15000 20000

Load
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Subsurface Surface

Summary
CZM vs. XFEM:
Provide close results if correctly calibrated CZM is mesh dependent, XFEM less

Contact Fatigue:
Multifacet CZM Effective traction Variable amplitude loading or tilted geometry

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