FRANC3D V6 Training June 2012

FRANC3D Workshop/Training
Corning Glass
May 7, 2012
Drs. Paul Wash Wawrzynek,

Bruce Carter, Tony Ingraffea,
and Omar Ibrahim
Fracture Analysis
Consultants, Inc.
1
Objectives
General introduction to FRANC3D:

- capabilities and limitations
Present theory and approaches to
computational fracture mechanics built into the
program.
Hands-on sessions give participants a chance
to try the code with tutors here to help.
Opportunity for participants to ask questions.
2
Agenda
Introduction to FRANC3D
Demo/Hands-on: build an uncracked model
Overview of the crack insertion process
Demo/Hands-on: insert initial crack and run analysis
Stress Intensity Factor (SIF) computation - theory
Demo/Hands-on: SIF computation - practice
Crack growth - theory
Demo/Hands-on: Crack growth - practice
Demo/Hands-on: Student generated models
3
FRANC3D Product
FRANC3D (FRacture ANalysis Code 3-D)
uses finite element method to simulate crack
growth analysis
Adaptively remeshes a finite element model to
simulate crack growth.
Has several elements to be used for modeling
the crack front
4
FRANC3D Product
Designed to work in conjunction with a commercial
finite element solvers:
ANSYS
ABAQUS
NASTRAN
The FRANC3D program has a programming
interface that is an extension to the Python
programming language.
Written in the C++ programming language
Support the following operating systems:
Windows
Linux
5
FRANC3D Development History
1988 to 1994
FRANC3D v1.0 BEM only
1994 to 2001
FRANC3D v2.0 BEM & Thin Shell FEM
2001 to 2005
FRANC3D v3.0 BEM & Thin Shell & Solid FEM (ANSYS)
2005 to 2009
FRANC3D v4.0 Solid FEM only (ANSYS, ABAQUS, NASTRAN)
Completely new code written in C++
2009 to 2010
FRANC3D v5.0 Additional enhancements
2010 to 2011
FRANC3D v6.0 Fretting Fatigue, Fatigue Life, Post-processing & other enhancements
2012
FRANC3D v7.0 is under development
6
FRANC3D Development History
Development of FRANC3D was funded

by:
USA Air Force
USA Navy
NASA
Others
7
What Does FRANC3D Do?
insert a flaw into an existing finite element mesh

and remesh locally, using special crack-front
elements.
compute stress intensity factors (SIFs) for all
nodes along a crack front for isotropic and
anisotropic materials.
predict how a crack will grow (relative extension
and angle) using engineering growth criteria, and
will then extend the crack geometry and remesh
locally.
8
What FRANC3D is NOT
not a general finite element pre-processor or post-
processor. External codes are required to build
uncracked FE models and to visualize results
(FRANC3D can display deformations).
not a finite element analysis program. An external
FE code is required (e.g., ANSYS or ABAQUS) to
perform stress analysis.
not a general purpose fatigue life prediction code,
although some basic life prediction models are
available. An external lifing code (e.g., AFGRO,
NASGRO or DARWIN) can be used.
9
FRANC3D Typical Work Flow
ANSYS/ABAQUS/NASTRAN ANSYS/ABAQUS/NASTRAN
Full 3D FE Model
Stress Analysis
portion to be
remainder of model
cracked
Combine
portions
FRANC3D
Insert crack(s) into
Define crack(s) portion of model displacements,
geometry and remesh temperatures,
crack surface tractions
Compute stress Extend crack(s)
intensity factors geometry
10
Global and Sub-models
sub-model
crack growth region
global model
FE package (e.g., ANSYS or ABAQUS) is used to define a global model and a sub-
model. The sub-model should encompass the crack growth region with space11for
remeshing.
FRANC3D Modifies the Sub-model
uncracked model after crack insertion
FRANC3D
FRANC3D modifies the sub-model, inserting a

crack and remeshing the model locally. It
outputs an input file that combines the global
and sub-model (ABAQUS) or it outputs the
sub-model and a macro command file that will
combine the models (ANSYS).
12
FRANC3D Maintains Compatibility
mesh compatibility
FRANC3D can retain surface meshes on cut surfaces so that there is FE
compatibility between the global and sub-model. This is the preferred approach.
However, FRANC3D can also instruct the FE program to insert constraint equations.
13
Combined (Full Model) Analysis
FRANC3D does not use a global/local approach. The FE analysis is

performed with the full combined model. (However, a global/local
approach can be used.) 14
Crack Growth
after 21 steps of crack growth
Crack growth is simulated by FRANC3D repeatedly reading and

modifying the initial sub-model. At each step, the global and modified
sub-model are re-combined and the full model is analyzed.
15
Sub-models for free meshes
free mesh cut surfaces
It is possible to cut out a FRANC3D sub-model from a free (unstructured)

mesh. (However, surface facets of tetrahedral elements with poor aspect ratios
can cause local meshing problems.)
16
Agenda
17
FRANC3D Tutorials
Using ANSYS: Using ABAQUS:
simple global
model vs sub-
model with
global model
through-crack
extract sub-model
automated
crack insertion & crack growth
automated growth
crack face
crack face
traction vs
traction vs
far-field
far-field
loading
loading
18
FRANC3D Tutorials
Step 1: Build the FE model
Step 2: Extract small portion from the full FE model
Step 2.1: Separate element components
Separate the FE model into a small portion
(local model) and the remaining of the FE model
(global model)
Local FE model will be used for fracture
analysis
Local Model
Global Model 19
FRANC3D Tutorials
Step 2.2: Create node component for cut-surface
Select the nodes on the cut surfaces of each component
and save a node component. For the 3x3x3 local model,
name this node component CUT_SURF.
Step 2.3: Save local and global

Archive each element component as a separate model
for the local and other for global
Global model, which consists of the exterior elements,
will include the boundary conditions and material
properties
Local model will include the CUT_SURF node component
and FRANC3D will use this information to retain those
mesh facets
20
FRANC3D Tutorials
Step 3: Read the local FE
model into FRANC3D
Step 3.1: Reading
Local FE Model
Start with the
FRANC3D graphical
user interface
Select File and Open
Switch File Filter in
the Open Model File
dialog box to proper
file extension name
and select the file
name for the local
model
Click Accept.
21
FRANC3D Tutorials
Step 3.2: Selecting the Retained Items in the Local FE
Model
Material, mesh facet groups, contact/constraint
& residual stress
22
FRANC3D Tutorials
Step 3.3: Selecting Cut Surface Nodes
Lists the node components present in the local
FE model file
23
FRANC3D Tutorials
Step 3.4: Importing and Displaying the Local FE Model
User can turn on the surface mesh and manipulate
the view
24
Agenda
25
FRANC3D Wizard
for Defining the Crack Type and
Meshing Process for the Cracked
Portion of the FE Model
26
Current Crack Type Options in
FRANC3D
Elliptical Crack
Through-the-thickness
One crack front
Two crack fronts
Long-shallow surface
crack shape
Elliptical crack shape
with two fronts
User-defined crack
27
Defining Crack Geometry
Crack geometry and location can be
prescribed either by:
Interactively using the Graphical User
Interface (GUI)
Using FRANC3D extensions to the Python
programming language
28
Crack Insertion Wizard (Elliptical Flaw)
crack size/shape
parameters
Define the crack

surface geometry,
position and orient
crack
crack-front template
Fracture Analysis parameters
Consultants, Inc. 29
Crack Insertion Wizard Flaw Library
30
User Defined Crack Front Points
User-defined flaw allows an

analyst to define an arbitrary
(planar) shape by entering (or
reading from a file) a series of
points that define the vertices of a Crack front vertices
polygon. should be flagged.31
Surface Meshes after Crack Insertion
crack surface mesh
Fracture Analysis
Crack-Front Template Element Types
tetrahedral elements are used

for the bulk of the volume
quarter-point singular wedge

crack-front elements
pyramids enforce compatibility

between brick and tetrahedral
elements two or more rings
Fracture Analysis of brick elements
Crack Insertion: Input Sub-model Mesh
The first major input to the crack insertion procedure is a finite element mesh.
Usually this is a sub-model, but a full model mesh is acceptable. In the case of a
sub-model, the cut surfaces are flagged.
sub-model
cut surface
cutting planes
This model has brick elements only. However, brick,

wedge, pyramid, and tetrahedral elements of both first and
Fracture Analysis
second order are okay. Currently, FRANC3D can handle
Consultants, Inc. ANSYS, ABAQUS and NASTRAN models. 34
Crack Insertion: Approximate Surface Geometry
Curved surface geometry is approximated from the faceted surface of the input
finite element mesh. Locally refined meshes near flaws will fall on the curved
surface rather than on the faceted finite element input.
Step 1: compute weighted average normals at all nodes.
Step 2: define 1 or 2 triangular Bezier patches for each
FE facet.
Step 3: identify topological edges and group together
facets that form logical faces.
Bezier patches
Note that FE facets on the cut

Fracture Analysis Topological edges and surfaces are retained for
Consultants, Inc. logical faces compatibility
35
Crack Insertion: Flaw Definition
The second major input to the crack insertion procedure is a description of a flaw
shape and location. FRANC3D has tools to define and place a flaw interactively.
Flaws can be zero volume (cracks) or finite volume (voids).
The crack above appears to have a piecewise linear crack front, but that is a just a
display artifact. Flaw surfaces are defined as Bezier patches and can have curved
crack fronts. In theory, initial flaws can be non-planar, but there is currently no
practical user-interface for such a capability.
Fracture Analysis
Crack Insertion: Crack-Front Templates
Crack-front templates are generated to emplace regular well-shaped elements
near crack fronts. The template elements are a combination of brick and quarter-
point wedge elements.
Additional processing is required where
templates intersect free surfaces. Locally
template element topology and geometry
must be modified to conform to the surface
geometry.
Fracture Analysis A typical template

Consultants, Inc. cross-section 37
Crack Insertion: Intersections & Trimming
Surface/surface intersections are computed for all body and flaw patches. The
body and flaw patches are trimmed and combined into one composite object.
Outside Inside
Trimmed patches are divided into triangular sub-

patches to keep the model water-tight.
Fracture Analysis
Crack Insertion: Surface Meshing
Surface meshes are generated for all logical model surfaces. The surface
meshes are constrained to conform to the meshes on cut surfaces.
retained cut surface meshes
Fracture Analysis
Crack Insertion: Pyramids & Volume Meshing
Pyramid elements are generated to enforce compatibility between quadrilateral facets
on both the template and cut surfaces and triangular faces in the volume mesh.
template
cut surfaces surfaces
An advancing front meshing algorithm* is used to generate a tetrahedral volume

mesh (not shown). This algorithm respects the special case of distinct nodes on
opposite sides of crack faces, which are geometrically coincident.
Fracture Analysis *Neto, J.B., Wawrzynek, P.A., Martha, L.F., and Ingraffea, A.R., An algorithm for three-
Consultants, Inc. dimensional mesh generation for arbitrary regions with cracks, Engng with Comp.,40 vol. 17,
75-91 (2001)
Volume Meshing
After completing the surface, the
volume mesh starts
Options for performing volume meshing:
FRANC3D
ANSYS
ABAQUS CAE
Final mesh smoothing are used to
improve the elements quality
41
A Sub-Volume Definition Issue
Retained cut-
surface facet
It can be difficult to mesh a thin section

that is constrained with a large quadrilateral
patch on one side.
There is not enough room for a well shaped
pyramids and transition tetrahedral
elements.
42
Workshop Agenda
43
FRANC3D Tutorials Crack Insertion Steps
Step 1: Selecting Cracks from FRANC3D Menu

From the FRANC3D menu, select Cracks and New Flaw Wizard.
The first panel of the wizard should appears. The default flaw type is
Crack (zero volume flaw) and select Next.
44
Step 2: Selecting Crack Type

The next panel allows the user to choose type of crack, hint
Next after the selection.
45
Step 3: Specify the Crack Size

The next panel allows us to specify the size of the ellipse.
Select Next after the size definition.
46
Step 4: Specify Crack Location and Orientation

The next panel allows us to specify location and orientation of the
flaw. After defining the location and orientation; select Next.
47
Step 5: Specify Crack Front Template

Parameters
The next panel allows us to specify the crack front template
parameters. After specifying the parameters; select Finish.
48
Step 6: Surface and Volume Meshing of Local Model after

the Crack Insertion
FRANC3D begins the process of inserting the flaw into the original
model and then meshes the resulting cracked model.
Operations is displayed on the screen
When meshing is completed, the newly meshed cracked model will be
displayed.
49
FRANC3D Tutorials Static analysis Steps
Step 1: Select Static

Crack Analysis
From the FRANC3D menu,
select Analysis and Static
Crack Analysis. The first
panel of the wizard should
appear, specify the file
name for the FRANC3D
database first.
50
Step 2: Select FE Solver

Next panel allows you to specify the solver
51
Step 3: Select
Analysis Options
Next panel allows you to
specify the solver output
and analysis options
Specify global models
Use all quadratic elements
Solver executable should
be defined
52
Step 4: Merging
Local/Global FE
Models
Next panel allows for the
specification of whether the
local and global models are
combined by merging
nodes or by defining
constraints or contact
conditions.
Specify node component
names in the local and
global models for nodes
that will be merged or you
can let the programs
(FRANC3D and Solver) do
the work.
Select Finish
53
Workshop Agenda
54
Stress Intensity Factors
55
Continuum Fracture Modes
y,v y,v y,v
x,u x,u
x,u
z,w z,w z,w
Mode I Mode II Mode III

Basic modes of crack loading. Positive sense shown for each:
Mode I = crack opening
Mode II = in-plane sliding
Mode III = anti-plane tearing
EACH MODE HAS ITS OWN STRESS INTENSITY FACTOR
56
Stress Intensity Factors
FRANC3D Computes the stress intensity factors
associated with all three modes of fracture for
the mid-side nodal points along the crack front
Under conditions of small-scale yielding, all crack
front displacement fields (crack behavior) are
controlled by the stress intensity factors
Stability will the crack tip move?
Trajectory in what direction?
Rate how fast?
57
Computing Stress Intensity Factors
FRANC3D has two methods to compute stress intensity factors (SIFs):
Displacement Correlation:
Relatively simple to understand and implement
Relatively poor accuracy (~5% error for a reasonable mesh)
Good sanity check but not for production work
M-Integral (Interaction Integral):

Somewhat involved formulation and implementation.
In the literature, the M-Integral is sometimes known an
"interaction integral.
Relatively good accuracy (<1% error for a reasonable mesh)
Requires special additional terms for crack face tractions, residual
58
stresses, FGMs, etc.
Computing Stress Intensity Factors
M-Integral (Interaction Integral):
Numerically the M-Integral is similar to the J-Integral.
M-Integral is used to compute the strain energy release
energy rates (GI, GII, and GIII) and stress intensity factors
(KI, KII, and KIII) associated with the three modes of fracture.
Mode II (KII) is needed to predict the crack kink angle to
determine the crack front direction
M-integral implementation in FRANC3D allows the
computation of the three modes of SIFs for isotropic and
anisotropic materials.
FRANC3D is the only available code that will compute
stress intensity factors for generally anisotropic materials
The method to use for production work
59
Stress Intensity Factor Computations
SIFs are computed with the M-integral for isotropic and

generally anisotropic materials.
60
60
Fracture mechanics gives the theoretical
asymptotic displacement fields.
2
1/ 2
,v K r
u I cos 1 2 sin
2 2 2
2
1/ 2
K r
v I sin 2 2 cos
2 2 2
,u
Note: for plane stress, let = /(1+ )
2
1/ 2
K r
u II sin 2 2 cos
2 2 2
2
1/ 2
K r
v II cos 1 2 sin
Set r = ra-b, and = 180
2 2 2
K II ra b
vb va
K I ra b
2 2 ub ua 2 2
2 2
61
Displacement Correlation Methods
For plane strain case:
2 v b v a
KI
ra b 2 2
2 ub ua
ra-b K II
ra b 2 2
w b w a
K III
2 ra b
where is the shear modulus, is Poisson's ratio, r is the distance from the crack tip to
the correlation point, and ui, vi, wi are the x, y, and z displacements at point i
The same expressions can be used for plane stress assumptions if is replaced
with = / (1+).
62
Energy Release Rates
The crack-tip energy release rates can be determined from Irwins
crack closure integral
2 1
G lim
0 0
2 j ( r ,0) u j (r , ), j 1,2,3
u
r

Substituting crack-tip stress and displacement fields yields
1 2 2 1 2 2 1 2
G KI K II K III
E E E
63
The J-Integral
The J-Integral* measures the energy flux
into the crack-tip region
u
J Wnx Ti i ds W 12 ijij
x
Under conditions of small scale yielding the
J-Integral is equal to the energy release rate
The contour J-Integral can be recast as an equivalent area (volume in 3D)

integral**, which is more accurate and stable in a finite element context
u q
J ij i W1 j ds
x1
jx
q is a function that is one at the crack tip and zero on the boundary of the
integration domain. It can be interpreted as a virtual crack extension.
* Rice, J.R. (1968) A path independent integral and approximate analysis of strain concentrations by notches and cracks, Journal of
Applied Mechanics, 35, 379-386
** Li, F.Z., Shih, C.F., and Needleman, A. (1985) A comparison of methods for calculating energy release rates, Engineering 64
Fracture Mechanics, 21, 405-421
The 3D J-Integral
In 3D, the J-Integral is evaluated within a cylindrical domain centered on a
portion of the crack-front
In 3D J J ( s) qt ( s) ds J

qt (s) ds Aq
65
Formulating the M-Integral From the
Stress and Displacement Fields
For linear analysis, we can add two valid solutions and the result is a valid solution
take the (1) solution to be the FEM results
ij ij(1) ij( 2) ij ij(1) ij( 2) ui ui(1) ui( 2)
the (2) solution(s) are solutions we get to select
Substituting these into the expression for the J-integral
(1) ui(1) u ( 2)
u (1)
u ( 2) q

J ij ij
(1 ) i ij
( 2 ) i ij
( 2 ) i W 1 j W 1 j W
(1) ( 2) (1, 2)
1 j ds
x x x x x
1 1 1 1 j
where
W (1,2) ij(1) ij( 2) ij( 2) ij(1)
66
Formulation of the M-Integral (cont.)
Collecting terms
(1) ui(1) q ( 2) ui( 2) q

J ij W 1 j
(1)
ds ij W 1 j
( 2)
ds
x x x x
1 j 1 j
J (1) J ( 2)
(1) ui( 2) u (1) q
ij
x1 ij x1 W 1 j x j ds
( 2 ) i (1, 2)

M (1,2)
or J J (1) J ( 2) M (1,2)
(1) ui( 2) u (1) q
with M (1, 2)
ij ij
( 2 ) i W (1, 2)
1 j ds
x1 x1
x j
A definition of M in terms of the crack tip field variables we can get from an
FEM analysis (solution 1) or form the theoretical expressions if we know KI,
KII, and KIII (solution 2) 67
Formulating the M-Integral From the
Definition of the Energy Release Rate
K I K I(1) K I( 2) K II K II(1) K II( 2) K III K III
(1)
K III
( 2)
for small scale yielding

1 2 2 1 2 2 1 2
GJ KI K II K III
E E E
substituting into the expression for the energy release rate
J J (1) J ( 2) M (1, 2)
KI
1 2 (1) 2

1 2 (1)
K II
2

1 (1) 2
K III
E E E

E
KI
1 2 ( 2) 2

E

1 2 ( 2)
K II
2

E

1 ( 2) 2
K III

1 2 (1) ( 2) 1 2 (1) ( 2) 1 (1) ( 2)
KI KI K II K II K III K III
E E E 68
1 2 (1) ( 2) 1 2 (1) ( 2) 1 (1) ( 2)

M (1, 2)
E E E
A definition of M in terms of Ks and material properties.
equating the two definitions for the M-Integral
(1) ui( 2) u (1) q

ij
x1 ij x1 ds Aq
( 2 ) i (1, 2)
W 1j
x j
1 2 (1) ( 2) 1 2 (1) ( 2) 1 (1) ( 2)

E E E
69
We use the FEM results for the (1) solution
KI KII KIII
We select three simple auxiliary solutions a 1.0 0.0 0.0

(2a), (2b), and (2c) b 0.0 1.0 0.0
c 0.0 0.0 1.0
( 2 a ) , ( 2b ) , ( 2 c )
From the analytical expressions for the
( 2 a ) , ( 2b ) , ( 2 c )
crack-front fields, we obtain
u ( 2 a ) , u ( 2b ) , u ( 2 c )
Substitution gives three equations for the unknown K(1)s

2 1 2 0 0

(1)
K I M Aq
(1, 2 a )
E
0
2 1 2 (1) (1, 2b )
0 K II M

Aq
E (1) (1, 2c ) A
21 K III M q
0 0
E
70
Independent FRANC3D Mode I SIF Verification
S S
CCT SEN
Analyses performed by
2 2 Dawn Phillips of the
2h
2a 3
1
2h
a 3
1
NASA Langley
Research Center
2w w
t t
S S
Fracture Analysis
Independent FRANC3D Mode I & II SIF Verification
S
Analyses performed by
Slant edge crack Dawn Phillips of the
2
starting from a NASA Langley
a
2h
R
3
1
circular hole Research Center
c
2w
Mode I
Mode II
Fracture Analysis
Typical Isotropic M-Integral Verification
Stress intensity factors are computed at
Surface crack, a = c = 0.8, remote unit traction
all nodes along the crack front
1.3
Raju-Newman
stress intensity factor (psi*in^.5)
FRANC3D
f3dng
1.25
1.2 crack front
1.15 The oscillations arise because different

virtual crack extension are used for
element corner and mid-side nodes.
1.1
1.05
0 0.2 0.4 0.6 0.8 1
virtual crack extensions
normalized distance along crack front
corner node mid-side node

Fracture Analysis
Anisotropic Stress Intensity Factors
FRANC3D includes an M-Integral

implementation for general anisotropic
materials.1,2
1 Wawrzynek, P.A., Carter, B., and Banks-Sills, L. The M-integral for computing stress
intensity factors in generally anisotropic materials, NASA/CR-2005-214006
2Banks-Sills, L., Wawrzynek, P.A., Carter, B., Ingraffea, T.R., and Hershkovitz, I.,
Methods for computing stress intensity factors in anisotropic geometries: Part II
arbitrary geometry, Engng. Fracture Mech., in review
74
Workshop Agenda
75
FRANC3D Tutorials SIF Computation
Steps
Step 1: Re-Open FRANC3D restart file
From the FRANC3D menu, select File and
Open.
Choose the *.fdb file and select OK.
FRANC3D will automatically read the FE
solver results
76
Steps
Step 2: Select Compute SIFs
From the FRANC3D menu, select Cracks and Compute SIFs. The
Stress Intensity Factor wizard is displayed
Use the M-Integral
User can select thermal or crack face traction terms if they are
used.
Select Finish, the SIFs Plot dialog is displayed
77
Steps
Step 2 (contd): Select Compute SIFs
View the three stress intensity factor (SIF) modes and export
the data
78
Workshop Agenda
79
Crack Growth
80
Crack Growth
predicted front (blue)
local kink angle

local extension
smoothed front (red)
original front
Stress Intensity Factors are used to predict the

direction and relative extent of crack growth
81
Crack Growth Prediction within
FRANC3D
Computing crack front growth is a three-step process:
Kink angle for each node (direction)
Based on the crack-front stresses in polar coordinates
Five options for computing kink angle
Relative amount of local crack extension for each node
Computed using a fatigue growth model (using one node
extension with a median SIF or using a specify number of load
cycles)
Simplest model is Paris growth model
Smooth the crack front
Polynomial curves are used to fit the crack front
User can specify the order of the polynomial or FRANC3D find
the polynomial order that will give the best fit
82
Crack Growth
after 21 steps of automatic crack growth

Confidential 83
83
84
Crack Extension
Cracks are extended by reinserting an extended crack definition. This
approach to extension: 1) simplifies the code, 2) reduces the amount of
information stored between steps, and 3) allows the sub-volume to be changed
between crack growth steps.
initial crack
non-planar crack growth
crack extension
meshed extended crack

Fracture Analysis

2 1 2 0 0

K I M Aq
(1) (1, 2 a )
E
0
2 1 2
0 K II(1) M (1, 2b ) Aq

E (1) (1, 2c ) A
21 K III M q
0 0
E

2 v b v a
KI
ra b 2 2
2 ub ua
K II
ra b 2 2
w b w a
K III
2 ra b 86

c such that
k p
max
k p (90 )
n=
n=2
n=1
n = .5
n = .3
k p ( )
k p (0 )
1 2l
2 l 2 l 2 l
n n n
k p k p n, a 12 22 32
k1 k2 k3

1 2 n
2 n n
2 a j ak2
ki a 1 ai 2
K K
2
ij ik 87
Kink Angle: Max Stress Criterion (orthotropy)
The orthotropic max stress criterion says that the crack will kink in the direction
where the ratio of the hoop stress to the effective toughness is maximum.
K eff
n12
1 a12
K
12 a2
2
K13a32
n22
1 a22

K 23 a3
2
K 21a12 1 a2 K31a12 K32a22
n32
3
Where Keff is a function of six principal toughnesses and crack

orientation relative to the material kink for max
Keff a, n

predicted direction of
n y
crack propagation
Keff a, n
Fracture Analysis
K max PK analysis
K min PRKanalysis
K K analysis
K max PKanalysis 1 R
K min K min PRKanalysis 1 R
K Kmax Kmin R
K max
Kmax
SIF (K) K
K min
time
89
K max Pa Kload _ case _ a
K min Pb Kload _ case _ b
K min
K Kmax Kmin R
K max
Kmax
load case a
SIF (K) K
K min
load case b
90
time
K max Pa Kload _ case _ a Pb Kload _ case _ b
K min Pa Kload _ case _ a Pb Kload _ case _ b
Kmax
Kload _ case _ b
Kload _ case _ a K
K min
time
91
kink 0
kink such that ( ) max
kink such that

K Ic
2

2

MAX ( ) max , 2 K

r ( ) Ic z ( )
2
K IIc K IIIc

kink such that

2 2

( ) 2 K Ic r ( ) 2 K Ic z ( ) 2
K IIc K IIIc
max
92
Kink Angle: Max Stress Criterion (isotropy)
The max stress criterion says that the crack will kink in the direction of a
maximum value of a stress component.
Some materials show a transition from Mode I
to Mode II crack growth for stable tearing.
y
r
LEFM Max stress
Amstutz (1995) 2024-T3, L-T
Amstutz (1995) 2024-T3, T-L
Hallback & Nilsson (1994) 7075-T6
Maccagno & Knott (1989), PMMA
Maccagno & Knott (1991), HY130 @ -196C

80
70

60 Mode I x
50
40
c 30 Transition Mode I only:

20 Transition 2024-T3
10 7075-T6
kink for max
0
-10
-20
Mode II Mode I or Mode II:
-30
0 10 20 30 40 50 60 70 80 90
kink for maxmax , max r
Mode mixity , tan 1K II K I
Fracture Analysis
kink such that ( , K I , K II ) max
kink such that ( , K I , K II , K III ) max

kink such that
K p , K12 , K13 , K 23 , K 21 , K31 , K32 , l , n
max
94
under development, ignore for now
95
n
Ki
ai am
K m
f
ai am NASGRO
Ki , R,...

f NASGROK m , R,...
f Ki , R,...
ai am user
fuser K m , R,...
predicted new
crack front
point i ai computed
point with the extension
median K value
am specified
current extension
crack front 96
ai NC Ki n
ai Nf NASGROKi , R,...
ai Nfuser Ki , R,...
predicted new
crack front
point i ai computed
extension
current
crack front 97
NASGRO Equation Dialog
98
Can read AFGRO formatted files and excel
CSV or text files.
User Equation Dialog
99
no crack front fitting
user specified polynomial order
Program selected polynomial order
polynomial fit
no smoothing
100
rt
rt value
rt amin
value ai
100
value
rt ai
100
101
a1 a2 value
ai a1 i 1m
All crack increments are specified
102
N1 N2 value
Ni N1 i 1m
All cycle increments are specified
103
Workshop Agenda
104
FRANC3D Tutorials Manual Crack Growth Steps
Step 1: Select Grow

Crack
From the FRANC3D menu,
select Cracks and Grow
Crack
Crack Growth wizard is
displayed
Choose Quasi-Static or
Fatigue growth type
Select Next
105
Step 2: Specify
Growth Rate
Second panel of the Crack
Growth allows you to specify
the growth rate model data
Use the Paris model and set C
to 1e-10 and leave n at 2
Select Next.
106
Step 7.3: Specify

Extension or Cycles
Third panel of the Crack
Growth allows you to
specify whether you will
grow the crack based on a
median extension or a
number of cycles
Use a median extension
Select Next.
107
Step 7.4: Specify

Fitting and
Extrapolation
Fourth panel of the Crack
Growth allows you to specify
a value for median extension
as well as the fitting and
extrapolation parameters
Specify a median extension
of 0.1 and use a fixed 3rd
order polynomial with 3%
extrapolation on both ends to
ensure the fitted end points
fall outside the model
Select Next 108
Step 7.5: Specify

Crack Front Template
Final panel allows you to
specify the crack front mesh
template parameters
Set the template radius to
0.06
Select Next to proceed with
growing the crack and
remeshing
Once the remeshing is
completed, another Static
Crack Analysis can be
performed
109
FRANC3D Tutorials Automatic Crack Growth
Steps
Assuming the crack insertion and static

analysis was completed
Step 1: Re-Open FRANC3D restart file
From the FRANC3D menu, select File and Open.
Choose the *.fdb file and select OK.
FRANC3D will automatically read the FE model and solver results
110
Steps
Step 2: Select Crack Growth Analysis

From the FRANC3D menu, select Analysis and Crack Growth
Analysis
First panel of the wizard allows you to choose the method for
computing SIFs
Use all the default values.
Select Next
111
Steps
Step 3: Specify Growth Parameters

Second panel appears
Select Quasi-Static for simplicity
All other values are left as defaults
Select Next.
112
Steps
Step 4: Specify Growth Model Data

Third panel appears
Set the value of n to 2 for the power-law crack growth model
Select Next
113
Steps
Step 5: Specify Fitting

and Template
Parameters
Fourth panel appears
Set the value for the template
radius to 0.06. The
extrapolation could be increased
from 3 to 5%, but 3% should
suffice for the first 5 steps
Select Next.
114
Steps
Step 6: Specify
Extension or Cycle Data
Fifth panel appears
Grow the crack for 5 steps using
a Constant Median Crack
Growth Increment of 0.1
Select Next.
115
Steps
Step 7: Specify Analysis Code

Sixth panel appears
Use ANSYS and the Current crack growth step is 1 as if you
are starting from the initial crack
116
Steps
Step 8: Specify
Analysis Options
Seventh panel appears
Select your FE Solver
Select global model
FRANC3D transfers all
the boundary conditions
from the global model to
the combined model, so
leave the Transfer all
retained bcs checked.
Click Next
117
Steps
Step 9: Specify
Local/Global Model
Connection
Final panel allows you to
choose how the local and
global models will be
connected
Click Finish to start the
automatic crack
118
The Python Programming Interface
The FRANC3D program has a programming

interface that is an extension to the Python
programming language.
Python is an open source, object oriented,
scripting language, which is popular in engineering
and scientific computing community (e.g., it is
used to drive the ABAQUS GUI).
The Python interface allows one to automate
repetitive and possibly error prone tasks.
It also provides a possible strategy for coupling
FRANC3D with other computational applications.
119
A simple PyF3D Program
import PyF3D # create a flaw object
# file names for the models flaw = PyF3D.Flaw("Ellipse",[a,b])

flaw.Translate([0.499,4.179,-.374])
uncracked_fname = "minidisk_submodel.cdb flaw.Rotate(1,"Y",90.0)
fname_base = "minidisk_crack" flaw.Rotate(2,"Z",-53.61)
# lists of crack size parameters to # open an uncrack model, insert the flaw
a_sizes = [0.0160, 0.0320, 0.0480, app.OpenModel(uncracked_fname)

0.0640, 0.0787, 0.2362, 0.3937] app.InsertFlaw(flaw)
b_sizes = [0.0160, 0.0787, 0.2362, 0.3937]
# generate a new file name like:
app = PyF3D.F3DApp() # minidisk_crack_160_320.fdb
# loop through the crack size matrix
fname = "%s_%d_%d.fdb" % \
for a in a_sizes: (fname_base,int(a*1000),int(b*1000))
for b in b_sizes:
# save the file
# skip cases with really
#bad aspect ratios app.SaveModel(fname)
if b > 0.2 and a < 0.065: continue
Fracture Analysis
Some FRANC3D Known Bugs
If any of the original body patches fall completely inside

the template (no intersections) the crack insertion will
not be successful.
121
If the none of the crack mouth or template edges intersect any

of the edges of any of the original boundary patches the crack
will not be inserted successfully.
122
FRANC3D can have difficulties

meshing in situations where the
crack-front template (the
singular crack-front element and
the two surrounding rings of
brick elements) intersects one of
the corner of the models.
123
The code is currently able to detect

that the template intersects a
corner and in many cases does a
reasonably good job making the
external mesh compatible with
both the template and the
geometry of the body.
However, reasonable pyramid elements

cannot be added on the outside of the
template. The Simple Template
Intersections Only option may work
around this issue.
124
What to do when something goes wrong
If the program crashes before you see the Flaw Insertion Status
window:
Use the Advanced -> Flaw to File Wizard option to create a
.crk file that describes the flaw you are trying to insert.
Send the .crk file along with the mesh file (.inp or .cdb) to us.
If the program crashes during flaw insertion or the program reports that it
cannot insert the flaw:
Check to make sure that no part of the flaw or crack-front

template is in the retained (cut surface) portion of the sub-model.
Look for a file called debug.tst in your working directory and
send it to us.
125
Workshop Agenda
126

FRANC3D V6 Training June 2012

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FRANC3D Workshop/Training

Drs. Paul Wash Wawrzynek,

General introduction to FRANC3D:

Development of FRANC3D was funded

insert a flaw into an existing finite element mesh

uncracked model after crack insertion

FRANC3D modifies the sub-model, inserting a

FRANC3D does not use a global/local approach. The FE analysis is

after 21 steps of crack growth

Crack growth is simulated by FRANC3D repeatedly reading and

free mesh cut surfaces

It is possible to cut out a FRANC3D sub-model from a free (unstructured)

Step 2.3: Save local and global

Define the crack

User-defined flaw allows an

crack surface mesh

tetrahedral elements are used

quarter-point singular wedge

pyramids enforce compatibility

This model has brick elements only. However, brick,

Note that FE facets on the cut

Fracture Analysis A typical template

Trimmed patches are divided into triangular sub-

retained cut surface meshes

An advancing front meshing algorithm* is used to generate a tetrahedral volume

It can be difficult to mesh a thin section

Step 1: Selecting Cracks from FRANC3D Menu

Step 2: Selecting Crack Type

Step 3: Specify the Crack Size

Step 4: Specify Crack Location and Orientation

Step 5: Specify Crack Front Template

Step 6: Surface and Volume Meshing of Local Model after

Step 1: Select Static

Step 2: Select FE Solver

z,w z,w z,w

Mode I Mode II Mode III

M-Integral (Interaction Integral):

SIFs are computed with the M-integral for isotropic and

For plane strain case:

Substituting crack-tip stress and displacement fields yields

The contour J-Integral can be recast as an equivalent area (volume in 3D)

W (1,2) ij(1) ij( 2) ij( 2) ij(1)

(1) ui(1) q ( 2) ui( 2) q

for small scale yielding

1 2 (1) ( 2) 1 2 (1) ( 2) 1 (1) ( 2)

A definition of M in terms of Ks and material properties.

equating the two definitions for the M-Integral

(1) ui( 2) u (1) q

1 2 (1) ( 2) 1 2 (1) ( 2) 1 (1) ( 2)

We select three simple auxiliary solutions a 1.0 0.0 0.0

1.2 crack front

1.15 The oscillations arise because different

corner node mid-side node

FRANC3D includes an M-Integral

local kink angle

Stress Intensity Factors are used to predict the

after 21 steps of automatic crack growth

non-planar crack growth

meshed extended crack

Where Keff is a function of six principal toughnesses and crack

kink such that ( ) max

kink such that

kink such that

c 30 Transition Mode I only: