A stress-weighted ductile fracture model for steel subjected to Ultra Low Cycle Fatigue

Abstract

A new criterion is proposed to simulate the initiation of ductile fracture due to Ultra-Low Cycle Fatigue (ULCF). Building on previous research, the new fracture criterion broadens the scope of ULCF models to account for a broader range of multi-axial stress and strain states that may be encountered in steel structures. The model formulation, supported by observations from finite element plasticity simulations of void growth and fractographic analyses of fracture surfaces, describes damage accumulation as a function of plastic strain, stress triaxiality, and the Lode stress parameter. The damage rate model is integrated over arbitrary cyclic loading histories of local strains and stresses to predict ULCF fracture. The proposed criterion (termed the Stress Weighted Ductile Fracture Model – SWDFM) is supported by a series of 66 coupon scale experiments on two grades of low-carbon structural steel (A572 and A36). These tests interrogate a range of positive and negative stress triaxiality with absolute values between 0.1 and 1.6, Lode stress parameters between 0 and 1, and monotonic and cyclic loading histories. The SWDFM criterion, which requires the calibration of only two material parameters for the materials investigated in this study, is evaluated against the experimental test data using an average-error assessment as well as a cross-validation analysis. Three other ULCF rupture criteria are similarly assessed and compared. The SWDFM is shown to accurately predict ULCF initiation over a wide range of stress states and loading histories, suggesting that the model represents well the micro-mechanical mechanisms of ULCF.