Abstract
A systematic methodology of three-dimensional (3D) finite element (FE) modeling for computational fracture mechanics analysis is established to study the fatigue damage limit of straight titanium tubes of a rotor aircraft. A laser micromachining technology is applied to provide sharp notch in the specimen, therefore only crack growth stage is considered herein. A series different outer diameter (OD) and tube wall thickness (TWT) are studied. The Jintegral and stress intensity factors (SIF) are calculated from 3D FE models for different sizes of initial cracks on the outside surface of Ti tubes. Those cracks are modeled as longitudinal surface cracks with different aspect ratios which cover a very wide range from 0.004 to 0.5, i.e., from normal cracks to very long cracks. The 3D FE results of J-integral and SIF agree well with NASGRO results whereas NASGRO is only valid within a limited range of aspect ratio. The 3D FE results of J-integral and SIF provide the fundamental of the calculation of fatigue damage limit of Ti tubes.
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