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Exercises
Fracture Mechanics Computations
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Part I.
Problems
1.1. A long metal strip of width b containing a centered through-thickness crack of length
2a is symmetrically loaded at infinity with the traction σ ∞ . The strip breaks along
the crack ligaments when σ ∞ = σc∞ is reached. Calculate the critical stress intensity
factor KIc for the given values σc∞ = 215.28 MPa, a = 5 cm and b = 20 cm. The
stress intensity factor KI is defined by
√ (1 − 0.5ζ + 0.37ζ 2 − 0.044ζ 3 ) 2a
KI = σ ∞ πa F (ζ) , F (ζ) = √ , ζ= .
1−ζ b
1.2. The strength of a silicon wafer strip (rectangular cross-section with width B = 40 mm
and height h = 0.6 mm) is tested in a four point bending experiment (Figure 1a,
L = 37, 5 mm). The specimen breaks at a load of F = Fc = 90 N.
a) Determine the length c of the surface defect leading to fracture. Use the model
of a surface flaw (Figure 1b), with the stress intensity factor being given by
√
KI = σ πc · Y , Y = 1.12 .
√
The fracture toughness of silicon is given by KIc = 1.2 MPa m.
b) Calculate the critical load for fracture, assuming that by means of previous
mechanical polishing there are not any surface flaws larger than cpol = 50 nm.
F
c
σ σ
h
2L
4L
(a) (b)
1.3. A cylindrical pressure vessel with radius R contains a through thickness crack of
length 2a (2a R) far away from the hemisphere closings. The crack orientation is
slanted by the angle β with respect to the circumferential direction of the cylinder
(see Figure 2). Furthermore, the wall thickness of the pressure vessel is substantially
smaller than its radius (t R).
Calculate the stress intensity factors KI and KII under the given assumptions, if the
vessel is loaded by an internal pressure p.
σᵩ
β
β
σz σz
2a
p
R
σz t σᵩ
Calculate the fracture toughness KIc of the tested material for the given definition
of the stress intensity factor for a three point bending specimen
3S F √ a
KI = π a · Φ
2B W2 W
thickness B W
a
S=4W
a0 a0
a) Calculate the critical crack lengths ac for a given critical stress intensity factor
KIc for both loading conditions.
b) What can be stated regarding crack stability after KI has exceeded KIc for
both loading conditions ?
y y
F F F
b b b
x x
2a 2a
F F F
(a) (b)
b) Prove that the stress intensity factor at the crack tip x = a is given by
1/2
√
F a+b
KI = lim 2πr σ22 (x = a + r, y = 0) = .
(π a) /2
1
r→0 a−b
c) Show that in case of two symmetrical concentrated force couples (see Figure
5b) the Westergaard stress function and the stress intensity factor can be
calculated by
1/2
a2 − b 2
2F z 2F a 1/2
Z(z) = , KI = .
(a2 − b2 ) /2
1
π (z 2 − b2 ) z 2 − a2 π
1.7. The linear elastic boundary value problem at a crack tip in polar coordinates (r, θ)
(see Figure 6) is to be evaluated using series expansion . A separation ansatz
F = rλ+1 h(θ)
with a still unknown function h(θ) is chosen for the Airy stress function.
y P
r
θ
x
b) Introduce the given separation ansatz in the differential equation of the bound-
ary value problem ∆∆F = 0. The Laplace operator ∆(·) in polar coordinates
is given by
∂ 2 (·) 1 ∂(·) 1 ∂ 2 (·)
∆(·) = + + .
∂r2 r ∂r r2 ∂θ2
Solve the resulting ordinary differential equation for the unknown functions
h(θ). Regard only the even part h(−θ) = h(θ) of the function (corresponding
to mode I) in the following.
1 ∂F 1 ∂ 2F
σrr = + 2
r ∂r r ∂θ2
∂ 2F
σθθ =
∂r2
∂ 1 ∂F
τrθ =− .
∂r r ∂θ
d) Determine the exponent λ from the condition that the obtained stresses fulfill
the boundary conditions of the problem and that they are nontrivial, i.e. dif-
ferent from zero (→ eigenvalue problem).
e) Addition: Repeat c) and d) for the uneven part h(−θ) = −h(θ) of the function
corresponding to mode II.
Hint: In order to obtain finite displacements as well as a finite stored strain energy,
only solutions satisfying λ ≥ 0 are admissible.
1.8. The eigenfunctions at the crack tip can be determined by using the complex Kolosov-
Muschelischwili stress functions (equivalent to problem 1.7). The corresponding
ansatz is
b) Determine the stresses corresponding to the given ansatz by using the following
relation:
σyy + iτxy = 2Re [Φ0 (z)] + zΦ00 (z) + χ00 (z) .
d) Calculate the exponent λ from the condition, that the calculated stresses fulfill
the boundary conditions from part a) and that they are nevertheless nontrivial,
i.e. different from zero (→ eigenvalue problem).
σ σ
Figure 7: Strip specimen containing a surface flaw
Hint: The stress intensity factors for a surface flaw in a strip specimen loaded under
pure tension or pure bending, respectively, can be calculated for a/b < 0.6 by
√
a a 2 a 3 a 4
KItens = σ0 π a 1.12 − 0.23 + 10.55 − 21.72 + 30.39 ,
b b b b
6M0 √
a a 2 a 3 a 4
KIbend = 2 π a 1.12 − 1.40 + 7.33 − 13.08 + 14.0 ,
b b b b b
Start from the given displacement solution for this configuration under constant
1. Linear elastic fracture mechanics 9
σ σ
x
σ σ
2a
(2) √
KI = σ∞ πa .
1.11. The maximum admissible internal pressure of a thick-walled pressure vessel with
inner radius ri = 700 mm and wall thickness t = 150 mm (see Figure 9) shall be
determined.
First, calculate the radial distribution of the circumferential stresses σθθ induced
by the internal pressure p for the pressure vessel not containing any crack. Then,
determine the admissible internal pressure by means of the following models:
Evaluate the stress intensity factor at the deepest point C of such a crack by
10 Part I. Problems
A-A
A
t
ri C
p b
2a
using the handbook solution (see Figure 12 on page 13) assuming pure tension
with an amplitude equal to the circumferential stress at the inner surface √
of the
pressure vessel. The fracture toughness of the material is KIc = 50 MPa m.
c) Extend the model from part b) by using a linearized stress function (normalized
by the pressure at the inner surface) as superposition of tension and bending
stresses.
1. Is it useful to include further terms of the Taylor-series than the first bending
terms?
1.12. During the growth of a void in an elastic medium under tension loading strain energy
is dissipated due to surface extension. The growth of a spherical void of radius a by
the extension ∆a in an infinite isotropic elastic body should be investigated in the
following, see Figure 10.
Derive the Griffith equation1 for this case by calculating the limit load σ = σc .
Take into account:
a) the elastic strain energy density under uniaxial tension (in terms of stress),
b) the difference in strain energy density between an infinite elastic body under
tension load, containing a spherical void of radius a and the undamaged body
1
The energy release rate is proportional to σ 2 a
1. Linear elastic fracture mechanics 11
σ σ
Δa
a
(without void),
d) the energy balance of this extension, if the dissipated elastic strain energy is
transformed into surface energy with the density γ ([γ] = MPa · m).
(x + ∆x)n − xn
Hint: lim = n · xn−1
∆x→0 ∆x
1.13. Calculate the energy release rate during crack propagation in a double cantilever
beam (DCB) specimen as depicted in Figure 11. The given condition h a allows
the application of beam theory.
h
d thickness b
1.14. Calculate the energy release rate for a crack in an isotropic linear elastic material
loaded in mode III by using the J-integral. The near field solution at the crack tip
is given by:
r
KIII r θ
u3 = 2 sin
µ 2π 2
( ) ( θ
)
τ13 KIII − sin 2
=√ .
τ23 2πr + cos 2θ
Hints:
The transformation from cartesian (x, y) into polar coordinates (r, θ) has to be
considered during differentation.
sin(−φ) = − sin φ
sin2 φ + cos2 φ = 1
Figure 12: Extract from Murakami et al. (Ed.): “Stress Intensity Factors”
2. Elastic plastic fracture mechanics 15
2.1. Find a functional representation for the two-dimensional extension of the plastic
zone rp involving only the yield stress σy , the stress intensity factor KI and dimen-
sionless constants.
2.2. The fracture toughness of an engineering steel S235 (yield stress 235 MPa) shall be
determined at room temperature by using a compact tension (CT) specimen, see
Figure 13. In order to use the stress intensity factor concept the plastic zone must
be small in comparison to the dimensions of the specimen.
Usual standards for the determination of the fracture toughness (e.g. ASTM) require
that the size of the plastic zone rp calculated by the Irwin estimation does not
exceed the twentieth part of the dimensions of the specimen:
1
rp . min a, (W − a), B .
20
Calculate the minimal specimen size by fulfilling this requirement, taking into ac-
count the given ratio of the specimen dimensions B = a and√W = 2a. The fracture
toughness is expected to be in the range of KIc ≈ 100 MPa m.
F
thickness B
F a
W
2.3. Analyse the shape of the plastic zone under plane stress and plane strain conditions
in the following way:
a) Evaluate the von Mises yield criterion in terms of principal stresses for plane
stress and plane strain.
b) Compute the principal stresses at the crack tip under mode-I loading from
the near field solution (first term of the asymptotic expansion) for plane stress
16 Part I. Problems
and plane strain. Discuss the distribution of the principal stresses and the
maximum shear stresses at the crack tip depending on the polar angle θ.
c) Estimate the size of the plastic zone at the crack tip by means of the yield
criterion (see part a) and the principal stresses calculated in part b).
d) Discuss and compare the results for plane stress and plane strain by creating
a sketch of the shapes of the corresponding plastic zones.
2.4. Estimate the shape and the size of the plastic zone at a crack tip loaded by mode-III
by using small scale yielding assumptions. Insert the near field solution
( ) ( )
τ13 KIII − sin 2θ
=√
τ23 2πr + cos 2θ
into the von Mises yield criterion for a given yield stress σy .
2.5. A semi-infinite crack is loaded by a pair of concentrated forces F (force per thickness)
located at a distance c from the crack tip (see Figure 14a). The stress intensity factor
for this configuration in a linear-elastic material is given by
2F
KI = √
2πc
a) Estimate the size of the plastic zone d according to the Irwin relation under
plane stress and small scale yielding assumptions.
b) Derive the solution according to the Dugdale model for this crack configu-
ration as depiceted in Figure 14b. Assume that there must not be any stress
singularity at the crack tip (c + d). How large is the plastic zone d?
F F
σF
c c d
F F
(a) (b)
F
1
c σF
and
F
1
c σF
√
Hint: 1 + z 2 ≈ 1 + 21 z 2 for z 1
3. Fatigue crack growth 19
Since the crack is small compared to the dimensions of the structure, the model
of the Griffith crack can be used (see √Figure 15). The stress intensity factor for
this configuration is defined by K = σ∞ π a. The parameters of the Paris crack
growth law
da m
= C ∆K(a)
dN
√
are C = 2.5 · 10−12 m · (MPa m)−4 and m = 4.
Calculate the remaining lifetime of the structure under the given assumptions. Pro-
ceed as follows:
a) Calculate the critical crack length, at which instable crack propagation occurs,
√
assuming a fracture toughness of the used aluminum alloy of KIc = 35 MPa m.
b) Calculate the remaining number of cycles Nc until the structure finally fails.
σ∞
x
2a
σ∞
3.2. At the circumference of a rotating disc with radius R = 300 mm (see Figure 16)
fatigue cracks are detected, which grow subcritically in radial direction. That occurs
due to the swelling load, caused by the rotation speed of the disc varying from 0 to
10000 rpm.
ω
a
One of the cast iron discs contains a crack of length a0 = 15 mm. The material
parameters are given as follows
Calculate
b) the remaining lifetime. Use a constant geometry factor Y = Y (a/R) for the
mean crack length a = 1/2 (a0 + ac ) in order to simplify the calculation.
3. Fatigue crack growth 21
3.3. For calculating fatigue crack growth the Paris equation is given by
da h im
= C ∆K(a) .
dN
A Griffith crack under uniaxial tension load is considered. The crack is loaded in
∞ ∞
the range of σmin = 0 to σmax = σ ∞ . The cyclic stress intensity can be calculated
by
√
∆K = ∆σ ∞ π a .
√
Crack growth starts at the initial crack length a0 with ∆K(a0 ) = 100 MPa cm.
Calculate the remaining cycles of lifetime N , until the critical value ac = 7.5 mm is
reached. Use the following parameters:
- a0 = √
5 mm,
- C = 10 · 10−11 MPa−3 mm−1/2 ,
- m = 3.
2∆F
∆K (a) = √ .
πa
Discuss the difference of the fatigue crack growth behavior in contrast to that in
problem 3.3.
ΔF
a0 a0
ΔF
Part II.
Results
√
1.1 KIc = 101.0 MPa m
1.2 a) c = 0.74 µm
b) Fc = 346.0 N
R√
1.3 KI = p πa 3 − cos(2β) ,
4t
R√
KII = p πa sin(2β)
4t
3 S Fc √ a
1.4 KIc = π a · Φ
2B W2 W
√
KIc = 15.8 MPa m
2
1 KIc
1.5 a) loaded at infinity: ac = ,
π σ∞
2
1 2F
loaded with concentrated forces: ac =
π KIc
1.6 a) The given stress function fulfills the bipotential equation. Furthermore, the
stress function is the solution of the boundary value problem since it fulfills
the given boundary conditions.
r
F a+b
b) KI = √
πa a−b
r
2F a
c) Ksym =√
π a2 − b2
b) h = hI + hII
k
d) λ = , k = 1, 2, 3, . . .
2
b) σyy + iτxy = 2 Re (λ + 2)Az λ+1 + Az(λ + 1)(λ + 2)z λ + (λ + 2)Bz λ+1
k
d) sin(2λπ) = 0 ⇒ λ = , k = 1, 2, 3, . . .
2
(1) 2 √
1.10 KI = σ πa
π
5.5
linearized
exact
5
σθθ /p
4.5
crack region
3.5
700 750 800 850
r [mm]
1 σ2
1.12 a) w =
2 E
4
b) ∆U (a) = − πwa3
3
4
c) ∆U (a + ∆a) = − πw(a + ∆a)3
3
dΠ F 2 a2 F 2 a2
1.13 G = − = = 12 2 3
b da b EI b Eh
2
KIII
1.14 J =
2µ
( ) ( θ
)
σI 1 + sin 2
√KI θ
b) = 2πr
cos 2 θ
σII 1 − sin 2
2 (
3 sin2 θ
1 KI 2 θ
2
+1 (plane stress)
c) rp (θ) = cos 2
2π σF 3 sin2 θ
2
+ (1 − 2ν)2 (plane strain)
27
d) Shape of the plastic zone: ESZ is plane stress state, EVZ is plane strain state
2
3 KIII
2.4 rp (θ) =
2π σF
2 2
Irwin 1 KI 2c F
2.5 a) d = 2 rp = = 2
π σF π c σF
s
2
c F
b) dDugdale = 1+ − 1
2 c σF
2
c F F
c) dDugdale
SSY = , dDugdale
LSY =
4 c σF 2σF
3.1 a) ac = 39 mm
b) Nc = 192247.8 ≈ 192248
3.2 a) ac = 37.8 mm
b) Nc = 29333.3 ≈ 29333
28 Part II. Results