Fracture Mechanics Conf09!09!10 14

Ansys V12 Fracture mechanics capabilities: crack meshing and propagation
Florent Galland
PhD Student
David Roche
Support engineer
ANSYS, Inc October 2009

2009 ANSYS, Inc. All rights reserved.
ANSYS, Inc. Proprietary
Fracture mechanics capabilities in Ansys V12

I. Application context and difficulties:
Modern issues and challenges for high technology industries. Simulating the whole life span of the product.
II.
Fracture mechanics interesting quantities:

The energy release rate and the mixed mode stress intensity factors can easily be computed by mean of the CINT command.
III. Fracture meshing :

A new fracture meshing workflow for Ansys V12 was developed. It allows for full fracture mechanics computations in Workbench.
IV. Examples :
Damage tolerance sensitivity analysis, crack propagation analysis.
Application context and difficulties Fracture mechanics science was born in the 20th century and for many applications, is still an open problem. Accident of the German train ICE in 1998:
Accident of the flight Aloha 243 in 1988:
Application context and difficulties Simulating fatigue crack growth: an opening challenge for the commercial finite element analysis softwares. A wide range of industrial applications are concerned by 3D fatigue crack growth simulations. aeronautic, aerospace, military engineering, nuclear structures applications...
High need of robust automatic numerical tools for 3D fatigue crack growth
4
Application context and difficulties Life span definition:
Simulation context
The initiation stage can represent a large part of the life span During the stable propagation stage the crack speed grows exponentially with the crack size The crack grows unstably until the ductile fracture
Ansys V12 enhanced fracture mechanics commands
FRACTURE MECHANICS INTERESTING QUANTITIES

Fracture mechanics: The global energetic approach

The energy release rate [Griffith1921]:
G=
W p A
The energy release rate is the quantity of dissipated energy per unit of newly created fracture surface area
A simple crack growth criterion:
G Gc
Reference: A. A. Griffith, The phenomena of rupture and flow in solids, Philosophical Transactions of the Royal Society of London, Harrison and Sons 1921
Fracture mechanics: The asymptotic approach

The 3 fracture modes:
From a kinematics point of view, 3 fracture modes can be defined

Fracture mechanics: The asymptotic approach

Stress singularity at crack tip:
yy
r singularity
crack
The stress tensor writes then [Irwin1957]:
ij = K I . fijI ( ). r + K II . fijII ( ). r + K III . fijIII ( ). r + O( r )

Where the f ij ( ) are known functions.
k
The scalars K I , K II , K III are called the stress intensity factors

Reference: G. Irwin, Analysis of stresses and strains near the end of a crack traversing a plate, Journal of applied mechanics 24, 361-364, 1921
Fracture mechanics: Ansys V12 enhanced commands

The energy release rate and the stress intensity factors are computed by energetic methods: the J-integral and the Interaction integral
Advantages
Preciseevenwith coarsemesh (G method) Robustness (pathindependency)
Drawbacks
Implementation
1 J = qi , j kl klij kj uk ,i dV V 2
Easeofuse
Reference: JR. Rice, A path independent integral and the approximate analysis of strain concentration by notches and cracks, Journal of applied mechanics 35, 379-386, 1968
10
Simple example: Inclined crack in a 2D plate

Problem description: Inclined crack in a 2D plate subjected to uniformed distributed tension load. A linear elastic material behavior is used.
11
Simple example: Inclined crack in a 2D plate

Comparison with analytical results of an inclined crack at various angles in an infinite plate yields a maximum relative error of 0.4% (100m mesh refinement at crack tip)
Inclinedcrackina2Dplate Stressintensityfactors
8,00E+06 7,00E+06 6,00E+06 5,00E+06 4,00E+06 3,00E+06
Stressintensityfactor(Pa*m)
k1analytical k2analytical k1numerical
2,00E+06
k2numerical
1,00E+06 0,00E+00 1,00E+06
10
20
30
40
50
60
70
80
90
Angleindegrees
12
Simple example: embedded inclined elliptical crack

Problem description: Inclined elliptical crack embedded in a 3D block subjected to uniformed distributed tension load. The crack is inclined at 45 with respect to the loading. A linear elastic material behavior is used.
13
Simple example: embedded inclined elliptical crack

Good agreement is found between the computed stress intensity factors and the analytical solution of Kassir and Sih. Crack tip mesh refinement is of a/75, and there are 120 nodes along the front.
14
Ansys V12 enhanced workflow
FRACTURE MESHING
15
Fracture meshing Fracture meshing has always been a complicated task:

Significant mesh refinement Radial meshing at crack tip Specific geometry (coincident faces)
A workflow has been developed using the Ansys V12 schematic approach, and allows for fracture computation in workbench
16
Fracture meshing workflow in Ansys V12
Solve fracture mechanics test-cases and review CINT results in workbench

17
Welded tubular structure
X-JOINT CRACK EXAMPLE
18
Industrial example: X-Joint tubular structure

Problem description:
An offshore structure tubular joint. A surface crack is introduced at the welded join. Due to symmetry considerations, only a quarter of the structure is simulated.
Reference: Chong Rhee and Salama, Mixed-mode stress intensity factor solutions of a warped surface flaw by three-dimensional finite element analysis, Engineering fracture mechanics 28, Elsevier 1987
19

To make the crack meshing easier (intense refinement at the vicinity of the front) a submodelling approach is used:
First an analysis of the x-joint structure is performed, without any crack
Then the crack is introduced in a submodel of the interest zone

20
First an analysis of the x-joint structure is performed, without any crack

21

Computed stress intensity factors are in fairly good agreement with the paper from Chong Rhee and Salama
K1
K2 Paper
K3
Reference: Chong Rhee and Salama, Mixed-mode stress intensity factor solutions of a warped surface flaw by three-dimensional finite element analysis, Engineering fracture mechanics 28, Elsevier 1987
22
Damage tolerance sensitivity analysis
CRACKED TURBINE BLADE
23
Industrial example: Cracked turbine blade

Objective: Identify the most critical locations of a crack
A turbine blade is submitted to a pressure and a rotational velocity. A submodel geometry is set up in the zone of interest.
24
First an analysis of the blade structure is performed, without any crack
Finally, a response surface and an optimization are computed to determine the most critical locations of the crack
25
First an analysis of the blade structure is performed, without any crack

26
Industrial example: Cracked turbine blade Identify the most critical locations of the crack:
Parameterize the position of the crack Create a Design of Experiments Automatic solving for several positions of the crack
27
Response surface:
G atthefreesurface
G inthebulk
Postprocess the variations of the energy release rate G versus the location of the crack
28
Optimization: Screening for candidates locations giving G > GC :
For which location does the energy release rate G exceed a certain criterion Gc?
29
Crack propagation in an aeronautical part
CRACKED HELICOPTER FLANGED PLATE

30
Industrial example: Cracked helicopter flanged plate An open problem: The helicopter round-robin challenge
Initiated in 2002 by the American helicopter community to benchmark the fatigue crack growth simulation methods.
- Complicated 3D part - Complicated variable loading - High number of cycles
31
Industrial example: Cracked helicopter flanged plate An open problem: The helicopter round-robin challenge
Objective: solve fatigue crack propagation analysis with minimal user intervention
32
Industrial example: Cracked helicopter flanged plate Hypothesis:

Mode 1 solicitation: planar propagation Paris propagation law:
StageA StageB StageC
da = C.K m dn
Free crack front shape: No assumption on the front nature
Kth
K ( MPa. m )
Kc
Newcrackfront
Initial front
Reference: P.C Paris et al., A rational analytic theory of fatigue, The trend in engineering 13, 528-34, 1961 S. Pommier, Principaux mcanismes physiques de fissuration par fatigue en mode 1, ENS Cachan, 2009
33
Industrial example: Cracked helicopter flanged plate Hypothesis:

Free crack front shape: No assumption on the front nature. At the geometrical level, the front is now defined by a spline
34
Industrial example: Cracked helicopter flanged plate

First an analysis of the whole structure is performed, without any crack
Draw the initial crack in a submodel of the interest zone and initialize the 3D curve with that geometry
Solve the problem, compute the new crack front position, send back parameters to workbench
35
Industrial example: Cracked helicopter flanged plate Scripting workbench: Automatic propagation loop
DesignModeler Refreshthe 3Dcurves Updatethe geometry Mechanical Meshthe model Setupthe boundary conditions Mechanical APDL Solvethe model Computethe crackadvance (Parislaw)
JScript
APDL
Python
36
Industrial example: Cracked helicopter flanged plate Postprocess the crack growth:
37
Industrial example: Cracked helicopter flanged plate Postprocess the crack at the final step:
38
Industrial example: Cracked helicopter flanged plate Ensure the solution validity all along the propagation:
Mesh quality:
Stress intensity factors quality:

contour independency property of the interaction integral
39
Industrial example: Cracked helicopter flanged plate Postprocess the crack front evolutions:
The obtained front shapes are in fairly good agreement with experimental results
Reference: J.C. Newman et al., Crack growth predictions in a complex helicopter component under spectrum loading, Fatigue & Fracture of Engineering Materials & Structures 29 (11), 949-958, Blackwell Publishing Ltd 2006
40
Industrial example: Cracked helicopter flanged plate Postprocess the crack front evolutions:
The obtained front shapes are in fairly good agreement with experimental results
Reference: J.C. Newman et al., Crack growth predictions in a complex helicopter component under spectrum loading, Fatigue & Fracture of Engineering Materials & Structures 29 (11), 949-958, Blackwell Publishing Ltd 2006
41
Concluding remarks
Direct computation of the mixed mode stress intensity factor is possible in Ansys V12 Fracture mechanics problem can be solved entirely in workbench, thanks to a new workflow It gives the opportunity of using all the workbench project page features. Solve problems with:
Contact Confined plasticity, thermal loading Submodelling Parametric update Design of experiment
Performing fatigue crack growth analysis on realistic 3D industrial parts is now possible
42
THANKS FOR YOUR ATTENTION

43

Fracture Mechanics Conf09!09!10 14

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Ansys V12 Fracture mechanics capabilities: crack meshing and propagation

ANSYS, Inc October 2009

ANSYS, Inc. Proprietary

Fracture mechanics capabilities in Ansys V12

Fracture mechanics interesting quantities:

III. Fracture meshing :

ANSYS, Inc. Proprietary

Accident of the flight Aloha 243 in 1988:

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Application context and difficulties Life span definition:

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Ansys V12 enhanced fracture mechanics commands

FRACTURE MECHANICS INTERESTING QUANTITIES

ANSYS, Inc. Proprietary

Fracture mechanics: The global energetic approach

A simple crack growth criterion:

ANSYS, Inc. Proprietary

Fracture mechanics: The asymptotic approach

From a kinematics point of view, 3 fracture modes can be defined

ANSYS, Inc. Proprietary

Fracture mechanics: The asymptotic approach

The stress tensor writes then [Irwin1957]:

ij = K I . fijI ( ). r + K II . fijII ( ). r + K III . fijIII ( ). r + O( r )

The scalars K I , K II , K III are called the stress intensity factors

ANSYS, Inc. Proprietary

Fracture mechanics: Ansys V12 enhanced commands

ANSYS, Inc. Proprietary

Simple example: Inclined crack in a 2D plate

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Simple example: Inclined crack in a 2D plate

k1analytical k2analytical k1numerical

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Simple example: embedded inclined elliptical crack

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Simple example: embedded inclined elliptical crack

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Ansys V12 enhanced workflow

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fracture meshing Fracture meshing has always been a complicated task:

ANSYS, Inc. Proprietary

Fracture meshing workflow in Ansys V12

Solve fracture mechanics test-cases and review CINT results in workbench

ANSYS, Inc. Proprietary

Welded tubular structure

X-JOINT CRACK EXAMPLE

2009 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Industrial example: X-Joint tubular structure

ANSYS, Inc. Proprietary

Industrial example: X-Joint tubular structure

First an analysis of the x-joint structure is performed, without any crack

Then the crack is introduced in a submodel of the interest zone

ANSYS, Inc. Proprietary

Industrial example: X-Joint tubular structure