Fatigue Crack Propagation Analysis Research Articles

A Physics-Based Tweedie Exponential Dispersion Process Model for Metal Fatigue Crack Propagation and Prognostics

Most structural faults in metal parts can be attributed to fatigue crack propagation. The analysis and prognostics of fatigue crack propagation play essential roles in the health management of mechanical systems. Due to the impacts of different uncertainty factors, the crack propagation process exhibits significant randomness, which causes difficulties in fatigue life prediction. To improve prognostic accuracy, a physics-based Tweedie exponential dispersion process (TEDP) model is proposed via integrating Paris Law and the stochastic process. This TEDP model can capture both the crack growth mechanism and uncertainty. Compared with other existing models, the TEDP taking Wiener process, Gamma process, and inverse process as special cases is more general and flexible in modeling complex degradation paths. The probability density function of the model is derived based on saddle-joint approximation. The unknown parameters are calculated via maximum likelihood estimation. Then, the analytic expressions of the distributions of lifetime and product reliability are presented. Significant findings include that the proposed TEDP model substantially enhances predictive accuracy in lifetime estimations of mechanical systems under varying operational conditions, as demonstrated in a practical case study on fatigue crack data. This model not only provides highly accurate lifetime predictions, but also offers deep insights into the reliability assessments of mechanically stressed components.

Accelerating SPH-Fatigue Computation by Using Single Precision Program on GPU

The fatigue crack propagation analysis based on the SPH framework “SPH-Fatigue” is accelerated by using the single precision program on GPU. It is found that the single precision program slightly disorders the stress wave but doubles the computational speed. In addition, the computational results of the fatigue crack propagation by the single precision program show almost the same crack shapes as the experimental ones. Accordingly, it is concluded that the use of the single precision program is one of the choices to accelerate the SPH-Fatigue computation.

A peridynamic model for structural fatigue crack propagation analysis under spectrum loadings

Engineering structures usually bear cyclic loads with varying amplitude in serving conditions, and thus, fatigue crack propagation analysis, which accounts for spectrum loadings, plays an important role in structural design. This paper presents a novel numerical approach to crack propagation analysis in structures bearing spectrum loadings based on peridynamic (PD) theory. PD model is introduced to deal with the displacement discontinuity across damage and crack. Because the stress ratio has an innegligible influence on crack growth rate in many circumstances, a new PD bond fatigue criterion based on Walker’s law is proposed to address this influence. Then, the numerical implementation of discretization and the computational methods applied for solving the PD fatigue model are introduced. The model is verified by comparing the numerical crack propagation with the corresponding analytical solution for a bi-axial loaded fatigue case and validated by compact tensile experiments under random loadings. The results demonstrated the accuracy of the proposed PD fatigue model for structural crack propagation analysis under spectrum loadings. Furthermore, a numerical example of fatigue crack growth in a two-phase material with irregular interfaces is simulated by using the new model to demonstrate the model’s feasibility.

Microstructural size effect on the notch fatigue behavior of a Ni-based superalloy using crystal plasticity modelling approach

Fatigue performances of critical structures are strongly affected by the microstructural (e.g. grain, defect, inclusion, etc.) size effect, and it is thus important to quantify their detrimental effect. In this work, a numerical procedure is constructed to quantify the influence of microstructure on the mechanical and fatigue behaviors of Ni-based superalloy GH4169. Specifically, by combining sub-modelling approach with crystal plasticity constitutive model, a dual-scale modelling approach is developed for studying grain-level mechanical behavior of Ni-based superalloy GH4169 notched components. In addition, the dislocation-based Tanaka-Mura-Wu model is applied for fatigue crack initiation life prediction. The Paris law is then utilized for fatigue crack propagation analysis based on the simulated short crack. To study the microstructural size effect on fatigue crack initiation and propagation behaviors, sub-models containing various grain orientation, grain size, defect size/shape are built and analysed. Finally, a series of fatigue tests on notched specimens of Ni-based superalloy GH4169 were carried out for method validation. Results indicate that the established dual-scale modelling approach and fatigue life prediction framework yields good agreement with experimental results.

Optimizing structural topology design through consideration of fatigue crack propagation

This paper presents an advanced approach for structural topology optimization by incorporating fatigue crack propagation analysis. The extended finite element method (X-FEM) is employed to model initial crack propagation, while the Paris model serves as the basis for simulating fatigue crack growth. The proposed methodology aims to optimize the structural design by minimizing compliance while considering volume and fatigue constraints. The proposed method employs the developed bi-directional evolutionary structural optimization (BESO) algorithm. The accuracy of the proposed technique is validated through the solution of benchmark problem and is further demonstrated in its effectiveness and robustness by examining several numerical examples. The optimization process considers various crack conditions, including the absence of cracks, horizontal and vertical cracks of different lengths. The optimized topologies obtained through the proposed algorithm clearly demonstrate the impact of crack presence, crack direction, and crack length on the material distribution. Furthermore, the convergence histories of the objective function, represented by mean compliance, highlight the influence of crack length on the stiffness and converged compliance of the structure. The results demonstrate its ability to adapt the material distribution based on fatigue cracks propagation conditions and achieve optimal topologies that balance structural integrity and performance.

Fatigue Life Assessment in the Typical Structure of Large Container Vessels Based on Fracture Mechanics

Welding defects are known to cause crack propagation and reduce structural fatigue performance. Based on the Paris theory of fracture mechanics, research is conducted on evaluation methods for analyzing fatigue crack propagation by adopting random loads with long-term distribution that follows the Weibull distribution for the stress ranges of fatigue loads. This approach is combined with the corrective stress intensity factor (SIF) equation and the method for calculating the reference stress and failure criterion. A large container ship is selected for a simulation, and fatigue crack propagation analysis is conducted on typical critical locations. A detailed comparison of the forecasted fatigue life is carried out between fracture mechanics theory and the S-N curve. The results indicate that the fatigue life values obtained using the two methods are of the same magnitude. In general, for the welded structure, the fatigue life value obtained via the fracture mechanics method is shorter than that obtained via the S-N curve method, while, for the free edge of the structure and the unwelded structure, the predicted fatigue life value is closer than that predicted via the S-N curve method. Moreover, the influence of initial crack defects on the fatigue life is investigated, and the results show that the depth of the initial crack will greatly affect the fatigue life of the target ship in typical locations, but the influence of the shape ratio on the fatigue life is limited. Therefore, in the actual ship construction process, controlling the initial crack depth of components is effective for limiting crack propagation and improving fatigue life. The above conclusions and suggestions can serve as a reference for the structural design and fatigue life evaluation of large container ships.

Fatigue Crack Extension and Life Calculation Based on Finite Element Analysis

With compact tension specimen static stress analysis and fatigue life of crack as the research object, through the three-dimensional modeling software to establish compact tension specimen, using the finite element analysis software to sample statics analysis, get the maximum deformation and maximum stress, and the compact tensile samples prefabricated crack, using the fatigue crack propagation analysis software, The cycle times and a-N curves were obtained. This method can be used to calculate the fatigue crack propagation life and visualize the crack propagation process, which is convenient to analyze and master the fatigue mechanism.

Fatigue Analysis of an Inclined Crack Propagation Problem by the X-FEM Method

The extended finite element method (X-FEM) has been used to solve fracture mechanics, problems in materials with various behavior laws (for example, isotropic, orthotropic or piezoelectric materials... For each type of material, it is necessary to obtain “enrichment functions” which model the behavior of the fields of displacement and stresses in the vicinity of the front of crack. In this paper, fatigue crack propagation analysis was modeled, by the extended finite element method X-FEM to evaluate the total energy and strain energy at the angled crack length, and to have the development of the increment time concerning the different values of α which is equal to 15°, 30° and 45, this development has been studied numerically by solving the problem of finite elements by the computer code ABAQUS. Quadratic 4-node elements (CPS4R) were used.

Study on two-dimensional mixed-mode fatigue crack growth employing ordinary state-based peridynamics

Mixed-mode fatigue crack propagation analysis is studied using ordinary state-based peridynamics. By introducing the concept of “remaining life”, the fatigue crack nucleation and propagation can be simulated in the PD framework. The PD fatigue modelling and the crack path prediction is carefully investigated. For the comparison purpose, the maximum circumferential stress criterion is introduced. The interaction integral and the peridynamic differential operator is employed to evaluate the fracture mechanics parameters. Two pre-cracked structures under mixed-mode loading conditions are provided with the validations from reference solutions.

Fatigue performances of helicopter gears

Abstract Gears are widely used machine elements to transmit power and motion in the industry. During the power transmission, the gears are subjected to cyclic loads. Thus the fatigue resistance of the gears should be deeply investigated. In particular, this issue is gaining much more importance in the space and aviation fields. In this study, the fatigue life of gears made of 9310-VIM-VAR steel used in the aviation field was determined experimentally, and the crack propagation paths obtained were numerically verified. To this end, the SAE J1619 standard single-tooth bending fatigue test apparatus was redesigned and manufactured in order to adapt it to the helicopter gears. Totally 28 single-tooth bending fatigue tests were carried out for various loading conditions. Accordingly, the S–N curves for the helicopter gears were created. The experimental results were verified by the finite element fatigue crack propagation analysis in terms of the initial crack location, crack initialization angle, and crack propagation paths. Conducted experiments and numerical studies are found as compatible with each other.

Fatigue crack propagation analysis in an aero-engine turbine disc using computational methods and spin test

This article presents a study on applying the fracture mechanics-based method to predict the fatigue crack growth (FCG) characteristics of the turbine disc in a turboshaft engine. According to the stress analysis results, the electric discharge machining (EDM) method introduced notches for initiating cracks of a specific size into the critical locations of the turbine disc. The FCG of these cracks under cyclic load was predicted utilising a three-dimensional (3D) numerical analysis method and a simplified rectangular plate model with relevant fracture mechanics properties. Meanwhile, the full-scale spin test was performed using a pre-flawed turbine disc under intentional loads at an isothermal temperature. After the test, the crack surface fractography and the quantitative fracture striation analysis revealed the practical crack propagation behaviour. There was a relatively small difference between the experimental results and the 3D finite element method, which indicated the good predictability of FEM for turbine disc crack growth. Furthermore, the rectangular plate models could predict the front stage of steady-state crack growth but were overall conservative due to their inability to precisely calculate the effects of crack growth and structure geometry on the stress intensity factor.

XFEM-based Fatigue Crack Propagation Analysis on Key Welded Connections of Orthotropic Steel Bridge Deck

XFEM-based Fatigue Crack Propagation Analysis on Key Welded Connections of Orthotropic Steel Bridge Deck

Fatigue Crack Propagation and Life Analysis of Stud Connectors in Steel-Concrete Composite Structures

To investigate the fatigue performance of the stud connectors of steel-concrete structures, fatigue crack propagation analysis and fatigue life calculation were carried out. Firstly, the finite element model with the initial crack based on linear elastic fracture mechanics (LEFM) was established, and the parameter analysis of the stress intensity factors (SIFs) of the studs and cracks with different geometric sizes was performed. Then, the propagation with mixed-type fatigue crack and I-type fatigue crack of the stud were calculated, and the variation of effective SIFs with the fatigue crack depth was analyzed. Finally, the flow chart of stud fatigue life evaluation which considers crack initiation and stable propagation was presented, and the short stud of steel-UHPC composite structures was taken as an example and verified. The calculation results show that the fatigue crack propagation type and the initial crack have an obvious influence on the fatigue life of the stud. It has acceptable accuracy that the fatigue life of short stud in UHPC simulated by considering the crack initiation. The critical damage parameters are greatly affected by the fatigue stress amplitude, and the initiation life of fatigue crack can account for more than 90% of the total fatigue life. This paper can provide a reference for evaluating the fatigue performance of studs in steel-concrete composite structures. Accurate evaluation of the fatigue life of stud connectors conforms to the concept of sustainable development.

Fatigue crack propagation analysis in offshore mooring chains and the influence of manufacturing residual stresses

The main objective of this work has been the validation of a methodology to assess fatigue crack propagation in offshore mooring chains under service conditions. For this purpose, analytical Stress Intensity Factor (SIF) solutions with step-by-step application of the Paris law and the Extended Finite Element Method (XFEM) implemented in the Abaqus® 2018 software have been studied. The fatigue crack propagation analysis is divided in two stages. First, a static analysis -pre-stretch and subsequent unloading-representative of the manufacturing process is performed. Next, the fatigue crack propagation simulation is performed under simplified loading conditions and taking into account the residual stresses induced in the previous analysis. Finally, analytical solutions, numerical simulations and experimental results have been compared. Results justify the use of the Extended Finite Element Method (XFEM) for fatigue crack propagation analysis in mooring chains.

Fatigue Crack Growth Evaluation of IMO Type B Spherical LNG Cargo Tank Considering the Effect of Stress Ratio and Load History

The crack propagation on a spherical IMO Type B LNG tank deployed on a 150K class LNG carrier is studied. IMO Type B tanks require a high level of safety . Therefore, analyses such as strength evaluation, fatigue analysis, fatigue crack propagation analysis, and LNG leak rate should be conducted to ensure safety. Various fatigue crack growth models were proposed for fatigue crack propagation analysis. The Forman model and the Walker model consider the stress ratio. Furthermore, the Huang model, and the Lee and Kim model consider the stress ratio and the effects of overload and underload present in the past load history on crack propagation.To examine the effects of stress ratio and load history for the fatigue crack propagation models, the crack growth of the LNG tank was evaluated by considering the stresses under full load and ballast load operating conditions, and three stress amplitude sequence cases.

Analysis of biaxial proportional low-cycle fatigue crack propagation for hull inclined-crack plate based on accumulative plasticity

Fracture failures of ship plates subjected to in-plane biaxial low-cycle fatigue loading are generally the coupling result of accumulative plasticity and biaxial low-cycle fatigue damage. A biaxial low-cycle fatigue crack growth analysis of hull structure that accounts for the accumulative plasticity effect can be more suitable for the actual evaluation of the overall fracture performance of the hull structure in severe sea conditions. An analytical model of biaxial low-cycle fatigue crack propagation with a control parameter for ∆CTOD is presented for hull inclined-crack plate. A test was conducted for cruciform specimens made of Q235 steel with an inclined crack to validate the presented analysis. The biaxial accumulative plasticity behavior and the effects of biaxiality and stress ratios were investigated. The results of this study reveal a strong dependence of biaxial low-cycle fatigue crack propagation on biaxial accumulated plasticity.

Fatigue crack propagation analysis of a CT test specimen with cladding

In this study, a system for fatigue crack propagation analysis based on XFEM referred to as sim2d, which can model crack independently of finite elements, has been developed. A fatigue crack propagation analysis of a carbon steel CT specimen with stainless steel cladding has been performed by the system. The stress intensity factor for initial crack front obtained by sim2d is compared with that by FEM. In addition, crack propagation analysis was performed and the geometry of propagating crack front was simulated.

Investigating the Structural Dynamics and Crack Propagation Behavior under Uniform and Non-Uniform Temperature Conditions.

The robustness and stability of the system depend on structural integrity. This stability is, however, compromised by aging, wear and tear, overloads, and environmental factors. A study of vibration and fatigue cracking for structural health monitoring is one of the core research areas in recent times. In this paper, the structural dynamics and fatigue crack propagation behavior when subjected to thermal and mechanical loads were studied. It investigates the modal parameters of uncracked and various cracked specimens under uniform and non-uniform temperature conditions. The analytical model was validated by experimental and numerical approaches. The analysis was evaluated by considering different heating rates to attain the required temperatures. The heating rates were controlled by a proportional-integral-derivative (PID) temperature controller. It showed that a slow heating rate required an ample amount of time but more accurate results than quick heating. This suggested that the heating rate can cause variation in the structural response, especially at elevated temperatures. A small variation in modal parameters was also observed when the applied uniform temperatures were changed to non-uniform temperatures. This study substantiates the fatigue crack propagation behavior of pre-seeded cracks. The results show that propagated cracking depends on applied temperatures and associated mass. The appearance of double crack fronts and multiple cracks were observed. The appearance of multiple cracks seems to be due to the selection of the pre-seeded crack shape. Hence, the real cracks and pre-seeded cracks are distinct and need careful consideration in fatigue crack propagation analysis.

A reliability approach to fatigue crack propagation analysis of ship structures in polar regions

Fatigue is a common failure mode in ship structures. For structures with an initial crack, the fatigue crack propagation behavior needs to be considered. The purpose of this study is to establish a procedure for analysis of fatigue crack propagation of ship structures in combination with reliability methods. The stress intensity factor (SIF) and geometry correction factor are calculated by means of finite element analysis. Validation for the SIF calculation is achieved by comparing the computed results with those based on related solutions. Since fatigue damage usually occurs in weld areas, the effect of such components on the fatigue crack propagation behavior was also considered in this work. The Paris law in combination with the Monte Carlo technique are employed for the fatigue crack propagation analysis in this study. Reliability updating based on inspection for cracks is also carried out. A computer program was developed for the purpose of fatigue crack propagation analysis within the framework of reliability methods. An application example of fatigue crack propagation in relation to the hull of the icebreaker Xuelong 2 is presented. The sensitivity of the procedure to key analysis parameters (sample size, initial crack size) is also considered. Finally, the effect of low temperatures on the computed results is also analyzed.

Three-dimensional modeling of non-planar fatigue crack growth in spur gear tooth using tetrahedral finite elements

In this paper, a numerical methodology for prediction of crack growth path and life of structures containing cracks and its application to three different case studies on spur gear tooth are presented. Three-dimensional non-planar fatigue crack propagation analyses are carried out using FRAC3D, which is part of Fracture and Crack Propagation Analysis System (FCPAS), employing fully unstructured tetrahedral elements along the crack front and in the whole model. Fatigue crack growth path predictions are performed using recently developed crack growth criteria that combine different equations used to predict crack deflection angle and to determine equivalent stress intensity factor. Comparisons of obtained results from numerical simulations with available data from the literature in terms of crack growth trajectories show very close agreement. Therefore, it is concluded that FCPAS is capable of performing three-dimensional non-planar crack growth modeling using fully tetrahedral elements in the whole finite element model, which requires less user intervention, time and effort for modeling. Moreover, the presented methodology and the recently developed crack growth criteria can be used for three-dimensional crack growth analysis.