Crack Propagation Analysis Research Articles

Mesh characteristic changes of spiral bevel gear pair with assembly errors during tooth crack propagation

Spiral bevel gears (SBGs) are often used because of their strong carrying capacity and lower vibration. However, this heightened load capacity can sometimes result in the development of tooth surface cracks. This study aims to simulate the three-dimensional propagation of cracks in SBGs under various assembly conditions and explore how the presence of cracks affects mesh characteristics. This paper investigates crack propagation in SBGs by applying principles of fracture mechanics. Employing a combination of finite element software ABAQUS and fracture mechanics software FRANC3D, the study conducts a three-dimensional analysis of crack propagation in SBGs. The study analyzes the impact of crack propagation on the lifespan and mesh characteristics of SBGs, including crack propagation morphology, transmission error, time-varying meshing stiffness (TVMS), gear life, and tooth surface force, under various assembly errors.

Finite element analysis of crack propagation, crack-gap-filling, and recovery behavior of mechanical properties in oxidation-induced self-healing ceramics

The oxidation-induced self-healing of cracks is an attractive function for the application of ceramics in high-temperature structural components requiring high reliability. To further optimize materials or components for practical applications, the development of numerical simulation techniques is of importance. In this study, we examined crack growth, crack-gap-filling by oxide, and re-cracking behaviors in chevron-notched specimens under various load and temperature conditions by adopting a finite element analysis (FEA) approach incorporating a damage-healing constitutive model based on fracture mechanics and oxidation kinetics. Furthermore, by implementing the mechanical properties and oxidation kinetic parameters of reported self-healing ceramics composites into the FEA, we examined the effects of the composition and composite structure on the cracking and healing behaviors. Crack-gap-filling simulations suggested that the damage variables gradually decreased from the crack tip, and the minimum healing time was determined by the time required for the complete filling of the element at the crack mouth with the largest crack opening width. Furthermore, the recovery of the stiffness and strength could be successfully reproduced after complete healing with a reasonable healing temperature and time. The proposed FEA approach could also contribute to estimating the minimum healing time required at various temperatures to heal a given damage for various composites.

Peridynamic analysis of rolling contact fatigue crack propagation in rail welding joints with pore defects

Pore defects are prevalent in rail welding joints and significantly contribute to the propagation of fatigue cracks. This study develops a peridynamic (PD) model that incorporates the characteristics of pore defects to analyze their impact on rolling contact fatigue behavior. Initially, compact tension (CT) fatigue tests were performed to derive and validate the bond fatigue failure model specific to rail weld materials. Subsequently, pore defects were modeled as holes in the CT specimens, with experimental results being compared to PD simulation outcomes for validation. Finally, a wheel-rail contact PD model was constructed to investigate the mechanisms of fatigue crack propagation in rail welding joints affected by pore defects.

An adaptive fatigue crack growth model at the welded joints of steel bridge

Under the influence of random loads such as those from vehicles, the welded details in steel bridges tend to gradually develop into macrocracks, typically originating from manufacturing defects or stress concentration points. As the service life of the steel bridge increases, the continuous generation and propagation of fatigue cracks lead to a decline in the bridge's service performance, potentially resulting in catastrophic failures such as bridge collapse. Accurately analyzing the fatigue crack growth patterns at welded joints is a prerequisite for reliably assessing the structural service performance. The analysis of fatigue crack propagation depends on both the crack growth step size and the cyclic stress–strain response at the welded joint under loading. Considering the complexity of the material properties and stress concentration at the welded joint, which leads to a lack of analytical solutions for the cyclic stress–strain characteristics at the crack tip, numerical analysis was employed to obtain the cyclic stress–strain response at the crack tip of the welded joints. Using the size of the cyclic plastic zone at the crack tip as an adaptive crack growth step size, a model for fatigue crack growth was developed based on the plastic strain energy of the cyclic plastic zone. Fatigue test specimens extracted from the welded toe of cruciform welded joints were tested, providing cyclic stress–strain (Ramberg-Osgood material parameters) and fatigue damage characteristics (Manson-Coffin material parameters) of the material at the welded toe. High-cycle fatigue tests using cruciform welded joint specimens determined a good correlation between the crack propagation characteristic dimensions obtained from the adaptive numerical analysis model and the experimental results. The experimental findings confirmed the applicability of the established adaptive numerical analysis model for studying fatigue crack growth in cruciform welded joints. The parameters introduced in this model are physically meaningful, easy to obtain, and suitable for engineering applications.

Parameter analysis and prediction of crack propagation for thermoplastic composite pipes under lateral pressure

ABSTRACT The research investigates the process of crack propagation in thermoplastic composite pipes (TCPs) with initial racks subjected to lateral pressure, through a combination of numerical simulations and experimental studies. In the numerical analysis, a TCP is subjected to lateral pressure, considering parameters such as initial crack length, initial crack angle, and lateral displacement. This analysis employs the extended finite element method (XFEM). The results reveal that crack propagation predominantly occurs perpendicular to the fibre winding angle. Moreover, it is observed that longer initial cracks result in lower crack initiation loads, while the final extent of crack propagation increases with the initial crack length. The experimental study considers three distinct initial crack angles and verifies the conclusions drawn from the numerical simulations. Furthermore, a crack propagation prediction model is developed that combines particle swarm optimization (PSO) with backpropagation (BP) neural networks. The predictive results demonstrate a high level of accuracy.

Mechanical properties and failure mechanism of 3D printing ultra-high performance concrete

Steel fiber reinforced 3D printing ultra-high performance concrete (3DP-UHPC) is prepared and experimentally studied. The effects of steel fiber content and various interlayer reinforcing materials on compressive, flexural, and splitting tensile properties are investigated, supplemented by Digital Image Correlation (DIC) technique for crack propagation analysis. Fabricated 3DP-UHPC specimens exhibited compressive strengths exceeding 160 MPa, with a peak at 205.2 MPa. Incremental increases in steel fiber content slightly enhanced compressive strength, whereas the addition of interlayer reinforcing materials, textile/steel wire mesh (SWM), reduced it due to altered interlayer bonding characteristics. The incorporation of textile/SWM significantly improved the flexural performance, enhancing energy absorption capacity and toughness. Specimens reinforced with SWM exhibited excellent flexural performance, with their flexural strength and ultimate deflection reaching 110.9 % and 192.5 % respectively of those before reinforcement. The splitting test revealed typical fractures along the interfaces between printed layers, with higher splitting strength obtained in the bottom layers. In specimens reinforced with carbon textile, glass textile, and SWM, the splitting strengths were more than double those of the subsequent layers. These insights contribute to a deeper understanding of 3DP-UHPC, paving the way for optimized use of reinforcing materials to improve structural integrity and performance.

High-performance bamboo-wood composite materials based on the natural structure and original form of bamboo: Fracture behavior and mechanical characterization

Reducing the destruction of bamboo's original structure to produce high-utilization and high-performance engineered bamboo products has long been a goal in the industry. This study developed a new natural arc-shaped laminated bamboo-wood lumber (NALBWL) based on the natural structure and original form of bamboo, using equal arc-shaped bamboo split (EASB) and poplar veneer. A multi-scale analysis of the bending performance and crack propagation dynamics of EASB and NALBWL was conducted. EASB's modulus of elasticity (MOE) and rupture (MOR) were 1.06 and 1.17 times higher than those of air-dried bamboo, respectively, exhibiting excellent mechanical properties. Additionally, its toughness in the full and elastic-plastic stages were 1.24 and 1.38 times higher than those of air-dried bamboo. NALBWL's MOE and MOR were 12.73 GPa and 174.41 MPa, fully meeting structural material requirements and even surpassing most engineered bamboo products. Moreover, NALBWL's radial bending load values were 2.29 and 2.24 times higher than that of EASB and air-dried bamboo, respectively, and it also demonstrated excellent water heat and drying resistance in impregnation and peeling performance. Real-time crack propagation analysis indicated that NALBWL's superior mechanical properties benefited from the respective advantages of bamboo and poplar veneer. This work showcased the application of "natural form-inspired design" in developing bamboo-wood composite materials, and the conclusion provided a reference for the sustainable development of engineered bamboo products and the study of biomass material fracture mechanisms.

Study on the dynamic fracture mechanical properties of ultra high-performance concrete under the influence of steel fiber content

Ultra-high performance concrete (UHPC) is characterized by its ultra-high strength and durability, making it suitable for use in large-span bridges, super high-rise buildings, and other special structures. These types of structures often have high requirements for crack control, making the exploration of UHPC's fracture mechanics properties of significant importance. Therefore, this paper sets up four steel fiber contents (0 %, 0.6 %, 1.2 % and 1.8 %) and four strain rates (10−5/s, 10−4/s, 10−3/s and 10−2/s), totaling 16 working conditions. The hydraulic servo system combined with digital image correlation (DIC) technology was used to conduct fracture mechanics tests on UHPC three-point bending beams. The test results show that the unstable fracture load of UHPC increases with the increase of strain rate and steel fiber content, and increasing the steel fiber content can enhance the strain rate effect of UHPC to a certain extent. Additionally, combined with the J-criterion model, this study proposed a dynamic criterion for the unstable fracture load of UHPC considering the influence of steel fiber content. The initial fracture toughness, unstable fracture toughness, and fracture energy of UHPC are significantly more affected by steel fiber content than by strain rate. Through DIC technology, the analysis of UHPC crack propagation shows that UHPC without steel fibers experiences rapid crack expansion in the Pre-90 % to Peak stage, with less influence from the strain rate. However, UHPC with steel fibers exhibits a more uniform crack growth rate, with the crack emergence phase gradually lagging as the strain rate increases. For UHPC without steel fibers, the crack opening displacement (COD) at the unstable fracture load point surges suddenly, while the COD development in UHPC with steel fibers is slower. At lower strain rates, an increase in steel fiber content leads to an earlier sudden increase phase in UHPC's COD; at higher strain rates, the influence of steel fiber content on the sudden increase phase of UHPC's COD is more scattered. The research results of this paper provide a theoretical basis for the calculation and analysis of the dynamic response of UHPC structures under seismic loads.

Analysis of micro-defect-induced cracking in the IPyC layer of TRISO particle with the XFEM

PurposeWe use the extended finite element method (XFEM) to model the whole process of initiation and propagation of cracks in the inner dense pyrolytic carbon (IPyC) layer of tri-structural isotropic (TRISO) particle induced by the microdefect in an irradiation-induced thermomechanical coupling environment and study the effect of microdefect sizes on the propagation path.Design/methodology/approachThe irradiation-induced thermal–mechanical coupling analysis is first conducted for the representative volume element (RVE) of the TRISO particle by using the conventional finite element method (CFEM) so that the stress distribution is obtained. The stress results are then restored for the enriched elements, and the simulation of crack initiation and propagation is eventually carried out by using the XFEM.Findings1. As a crack initiates in the IPyC layer, it will terminate at the free edge of the RVE TRISO particle in the end. 2. The size of the microdefect has a significant impact on the propagation path.Originality/valueThe ceramic dispersion microencapsulated (CDM) fuel is a good accident-resistant fuel whose safe operation is crucial to the safety and reliability of the whole nuclear reactor. It is of great scientific significance and practical value to study the irradiation-induced thermomechanical coupling stress distribution and cracking behavior in the IPyC layer of TRISO particles for the CDM fuel. Crack initiation and propagation analysis is challengeable for this complex multi-layer structure. This can help understand the failure mechanism of TRISO particles and evaluate the operation safety of the reactor.

Models analyzing the response of the adhesive joint between FRP and concrete: a comparative analysis

Fiber-reinforced polymers (FRP) for structural elements’ strengthening and rehabilitation are increasingly gaining popularity because of their proven efficiency and ease of application. The response of the adhesive joint formed between the FRP and concrete is a crucial factor influencing the overall behavior of FRP structures. The analysis of the interface crack propagation is a complex task involving the consideration of multiple interacting mechanisms. This work aims to provide a background to a recently proposed model that analyzes the behavior of the adhesive joint formed at the interface between the FRP and concrete, by creating its counterpart. The study presented herein discusses a model based on fracture mechanics to obtain a reference point needed to assess the output provided by an algorithm utilizing a damage-based model for concrete and an empirical-based procedure for the loss of bond action. Typically, model validation is performed via a comparison against experimental data. However, additional insights into the interacting phenomena can be provided by comparing the results of various applicable models.

3D analysis of crack propagation in nuclear graphite using DVC coupled with finite element analysis

The initiation and propagation of cracks within nuclear graphite components compromise the lifespan of advanced gas-cooled reactors and even lead to safety incidents. A thorough understanding of fracture properties in nuclear graphite is crucial for the effective management and design of graphite structural components. In this work, an in-situ test of a double cleavage drilled compression (DCDC) specimen was conducted using X-ray tomographic imaging to fully analyze the 3D crack propagation behavior in IG-11 nuclear graphite. “Subvolume Splitting” digital volume correlation (SS-DVC) was employed to accurately quantify the displacement fields surrounding the crack. The entire 3D crack propagation and crack surface around the crack front were precisely captured through 3D imaging processing of the gray level residual (GLR) field. Additionally, crack opening displacements (CODs) and stress intensity factors (SIFs) were determined using finite element (FE) analysis with extended finite element method (XFEM). Experimental results indicate that although mode I crack remains predominant throughout the whole process, complex crack propagation exists around the crack front. The utilization of irregular crack surfaces in FE analysis helps to obtain refined displacement fields and accurate SIFs of the crack front. This work provides comprehensive insights into crack propagation and reveals the influence of complex crack morphology on SIF calculations, facilitating accurate prediction of structural integrity and rational design of graphite components.

Unveiling the quantitative relationship between microstructural features and quasi-static tensile properties in dual-phase titanium alloys based on data-driven neural networks

The quasi-static mechanical properties of α+β dual-phase titanium alloys are susceptible to their microstructural features, presenting a complex, high-dimensional nonlinear relationship, which hinders the rapid development of high-performance materials. In this work, 4065 micro-representative models were virtually constructed with varying volume fractions of α and β phases and characteristic dimensions via high-throughput finite element simulation, incorporating a cohesive zone model to simulate the interfaces between the two phases. Especially, the established representative models were experimentally verified by two groups of real material microstructures, and the results showed that the relative errors were not more than 9.5 % in microstructural characteristics and quasi-static mechanical properties. Afterward, a neural network model was developed to correlate the quasi-static tensile properties with the microstructural features of the dual-phase TC6 titanium alloys, achieving an 88.2 % accuracy in predicting overall mechanical performance. Utilizing the Shaply Additive Explanation method, it was found that the primary α phase's volume fraction and the secondary α phase's width were the most significant microstructural features affecting quasi-static strength. Specifically, the volume fraction of the primary α phase and the width of the secondary α phase negatively affected strength, while the width of the secondary α phase positively influenced plasticity. Notably, the primary α phase's volume fraction had a quadratic curve pattern of influence on plasticity. The intrinsic mechanisms behind these laws were further revealed based on local stress-strain responses and crack propagation analysis. Ultimately, the optimal microstructural features with strength-plasticity balance were identified through the lower threshold method: a secondary α phase width of about 1 μm and a primary α phase volume fraction ranging from 0.1 to 0.2, effectively facilitating microstructure design.

An Investigation of Tensile, Fatigue, and Fracture Behavior of 3D-Printed Polymers

Abstract The progression of manufacturing technology has significantly benefited from the adoption of 3D printing techniques, which enable the production of parts with intricate geometries. However, it is important to acknowledge that components fabricated through this additive manufacturing method frequently manifest defects and are prone to failure under severe conditions. Therefore, a thorough examination of the mechanical properties of these parts is essential to effectively reduce the failure. This study aimed to explore the mechanical properties of two prevalently used 3D-printed polymers, specifically Onyx and acrylonitrile butadiene styrene (ABS), by integrating computational and experimental analyses. The experimental study utilized a material testing system and digital image correlation (DIC) technology, while the computational analysis covered the finite element (FE) modeling of the 3D-printed samples. The research focused on evaluating the tensile strength and fatigue resistance of the specimens printed in various orientations, alongside a detailed investigation of their fracture behavior. The crack propagation analysis was carried out using the DIC system and the separating morphing and adaptive re-meshing technology (SMART) scheme in ansys. It was observed that upright build orientation produced the weakest samples for axial loading and specimens with notches failed earlier than those without. Moreover, Onyx was found to have a higher resistance to fracture or failure compared to ABS. The FE modeling results demonstrated strong agreement with the experimental results, validating their accuracy and reliability in characterizing the critical mechanical response of 3D-printed parts rapidly and cost effectively.

Analysis of crack propagation of PLA fabricated by the additive manufacturing technique

Understanding crack propagation is crucial for evaluating the structural integrity and reliability of additive manufacturing components, as cracks can compromise mechanical properties and potentially lead to catastrophic failures. The study of crack propagation in additive manufacturing components is used to develop strategies for mitigating crack initiation and growth, improving material properties, and optimising the design and manufacturing processes. Crack propagation in additive manufacturing components can be influenced by various factors, including material properties, design considerations, manufacturing defects, and loading conditions. Due to the identified issue, the study was carried out to investigate the crack propagation of the Fused Deposition Modeling (FDM) component using compact tension fracture testing. The experimental work started with fabricating the samples using PLA material, followed by a fracture test based on the compact tension specimen test to get a response of the structure and its crack propagation under tensile. Material properties were also collected using the dog bone tensile test. The material properties of the testing were then imported to Finite Element Analysis for further investigation of fracture mechanics. It was found that the maximum force of the sample was 141.7 ± 28 N at 1.70 ± 0.26 mm displacement, and cracks initiated around the tip and propagated upward or downward based on the initial crack location. The deformation patterns of PLA material have shown it to be brittle plastic deformation and low energy absorption before fracture.

Resistance Analysis of Crack Propagation in Concrete Subjected to Hydraulic Pressure.

The KR resistance curve for hydraulic crack propagation in a concrete beam was determined and discussed. A semi-analytical method was introduced to calculate the hydraulic crack propagation in concrete. A series of concrete beams with various hydraulic pressures and initial crack depths were tested, and the hydraulic crack propagation in these beams was calculated. The calculated P-CMOD curves were first verified, and then the calculated KR resistance curve for hydraulic crack propagation was determined. Based on the test results and calculation results, the following conclusions can be drawn: The proposed analysis method can accurately predict the hydraulic crack propagation process in concrete. The KR resistance to hydraulic crack propagation in concrete decreases with the increase in hydraulic pressure but is less influenced by the initial crack depth of the test beams. In addition, the concrete beams collapse immediately under hydraulic fracturing once the KIw curve reaches the KR resistance curve. This indicates that the failure of concrete structures under hydraulic fracturing occurs immediately once the driving force of crack propagation, dominated by the hydraulic pressure in the crack, becomes significant.

Mechanical properties and failure behavior of additively manufactured Al2O3 lattice structures infiltrated with phenol-formaldehyde resin

The lightweight design and load-bearing capacity of underwater vehicles remain perennial focal points. Ceramic lattice structures (CLSs) offer significant weight reduction while maximizing structural strength; however, their inherent brittleness poses a limitation. To optimize the performance of CLSs for underwater vehicle applications, a biomimetic Al2O3/phenol-formaldehyde (PF) resin composite structure (APCS) was proposed and fabricated by infiltrating additive-manufactured Al2O3 lattice structures (ALSs) with PF. Comprehensive assessments of the quasi-static mechanical properties were conducted using both experimental and simulation methods. The specific compressive strength and specific energy absorption of the APCSs under quasi-static compressive loading exhibited remarkable improvements, with the maximum values achieved from the body-centered cubic (BCC)/PF structure increasing by ∼15.23 and ∼307.93 times, respectively. In contrast to ALSs, the failure process of APCSs was gradual, with the confining pressure introduced by the PF promoting transverse crack propagation and layer-by-layer failure, thereby strengthening the ceramic lattice. Toughing mechanisms (i.e., crack arrest, crack deflection, and branching) were also observed in the APCSs. Furthermore, the simulation results aligned well with the experimental results, providing an in-depth analysis of internal damage and crack propagation. The improvements introduced by the composite structure in this study provide a reliable approach for obtaining lightweight and strong materials, thereby accelerating the application of ceramic-based materials in underwater vehicles.

Development of corrosion-fatigue analysis method of cable hangers in tied-arch bridges considering train-bridge interaction

This study proposes an integrated corrosion-fatigue analysis method for bridge hangers by combining the dynamic bridge-train interaction analysis for random train arrivals with various speeds and the linear elastic fracture mechanics (LEFM)-based crack propagation analysis considering the corrosion-fatigue effects. Accordingly, a three-stage process, namely, zinc coating corrosion, pit-crack transition, and corrosion-fatigue crack propagation for wires in hangers, was proposed to simulate the total service life. A train-bridge-interaction analysis was conducted on a tied-arch bridge with multiple cable hangers using the vector form intrinsic finite element method, where the stresses in the hangers were generated under high-speed train loads. The pit-crack transition was analyzed based on the pit growth and fatigue growth; whose rates compete to dominate the transition phenomenon. The fatigue crack growth rate was estimated using a LEFM approach considering the equivalent stress ranges and number of stress cycles. The effects of reducing the cable cross-section and updating the internal stress of the multi-layered wires were investigated. The present method was compared with the continuum damage mechanics model for validation. A relatively short remaining corrosion-fatigue life was found in the cables under the train loads, after corrosion of the zinc coating and pit-crack transition in the steel wires were developed.

Failure analysis of fatigue crack propagation in specimens of AlSi10Mg aluminum alloy produced by L-PBF: Effect of different heat treatments

Fatigue crack growth behavior of AlSi10Mg aluminum alloy processed by laser powder bed fusion (L-PBF) was studied for three material conditions: as-built, stress relieved and hot isostatic pressed. An improvement in the fatigue crack growth resistance was found for the heat-treated conditions which was attributed to the residual stress relief induced by the heat treatments. The stress ratio did not affect the fatigue crack growth in regime II which was explained by the absence of crack closure. Fatigue crack growth rates were predicted using a model based on the cyclic plasticity of the tested aluminum alloy. The proposed model agreed well with the experimental results.

Strength and Crack Propagation Analysis of Layered Backfill Based on Energy Theory

The strength of backfill is greatly influenced by its inclination angle and interlayer concentration. In order to study the influence of inclination angle and interlayer mass concentration on the strength of backfill, a group of layered cemented backfill with cement-sand ratio of 1:4, interlayer mass concentration of 66%, 67% and 68% and inclination angles of 0°, 10°, 20° and 30° were prepared by using tailings as aggregate. The uniaxial compression test was carried out to analyse the effect of interlayer mass concentration and inclination angle on layered cemented backfill. The crack propagation and energy change law of the specimen during compression were analysed by J-integral and energy conservation law. The relationship between the crack initiation and propagation and strain energy of two representative three-layer backfill specimens was analysed by numerical modelling. The results show that the increase in the layer number and the inclination angle of the backfill can weaken the strength of the backfill. In a certain range of inclination angles, the weakening coefficient of the backfill caused by the inclination angle is very consistent with the cosine value of the corresponding angle. Due to the release of crack energy and the existence of interface J integral, the uniaxial compressive strength of different mass concentration backfill is different at various positions. When the displacement reaches a certain value, the crack and strain energy no longer increase.

Development of Strength Evaluation Methodology for Independent IMO TYPE C Tank with LH2 Carriers

Given the inadequate regulatory framework for liquefied hydrogen gas storage tanks on ships and the limitations of the IGC Code, designed for liquefied natural gas, this study introduces a critical assessment procedure to ensure the safety and suitability of such tank designs. This study performed a heat transfer analysis for boil-off gas (BOG) calculations and established separate design load cases to evaluate the yielding and buckling strength. In addition, the study assessed methodologies for both high-cycle and low-cycle fatigue assessments, complemented by comprehensive structural integrity evaluations using finite element analysis. A comprehensive approach was developed to assess the structural integrity of Type C tanks by conducting crack propagation analysis and comparing these results with the IGC Code criteria. The practicality and efficacy of these methods were validated through their application on a 23K-class liquefied hydrogen carrier at the concept design stage. These findings may have important implications for enhancing safety standards and regulatory policies.