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Investigation of a crack at an interface between
two dissimilar materials.
Lecturer: Ing. Csar Sebastin Silva Proao
Study Program: Mechatronics Master
Tutor: Dr. Natalia Konchakova
1.
discussion from a scientific point of view because of the properties that can be
studied in the field of the materials resistance.
The personal motivation for this seminar is the previous formation as
mechanical engineer where the study of the materials resistance was one of
the most passionate and important fields that motivated me into this major.
The expectative after this seminar is the amplification of the present
knowledge regarding the materials resistance and the crack properties.
2. Important notation
An important notation must be considered. In the next Figure 1 the stress
components on an infinitesimal element are presented.
The stresses are noted as ij where the first subscript i refers to the
direction of outward facing normal, and the second one j to the direction of
the component of the force.
5
(1)
(2)
xx yy a 2 xx yy 3a 4
3a 4
1 2
1 4 cos 2 xy 1 4 sin 2 (5)
2
r
2
r
r
xx yy 3a 4 2a 2
3a 4 2a 2
3a 4
r
1 4 2 sin 2 xy 1 4 2 cos 2 xy 1 4 cos 2 8 (6)
2
r
r
r
r
r
KI
22
K II limr 0, 0 2 r 12
K
III
23
Where
K, I
, II
K
(7)
KIII are
10
1) First Intensity Factor Opening Mode, I: In this case the two crack surfaces are pulled apart in the
y direction, but the deformations are symmetric about the x z and z y planes.
2) Second Intensity Factor Shearing Mode, II: Here the two crack surfaces slide over each other in
the x direction, but the deformations are symmetric about the x y plane and skew symmetric about the
xz plane.
3)
Third Intensity Factor Tearing Mode, III: In this case the crack surfaces slide over each other in
the z direction, but the deformations are skew symmetric about the x y and x z planes.
11
12
5.
a
1 0.256
W
2
3
a
a
1.152 12.2
W
W
(8)
KI a
sec
a
1
W
(9)
13
2)
a
a
a
a
1.12 0.23 10.56 21.74 30.42
W
W
W
W
(10)
KI a
a
1 (11)
W
14
3)
a
1.12 0.43
W
2
3
a
a
4.79 15.46
W
W
(12)
KI a
15
16
6. Stresses and Displacements in Homogeneous Cracked Solids for the pure mode I loading.
In Cartesian Coordinates:
In Polar Coordinates:
r
KI
2 r
(17)
1
2
cos 1 sin 2
2
2
(18)
KI
2 r
1
2
sin cos 2
2
2
3
cos 1 sin sin
2
2
2
(14)
1
2
3
sin cos cos
2
2
2
(15)
2 r
KI
2 r
zz X Y
(19)
K r 2
u I cos 1 2sin 2
2 2
2
2
(20)
K r 2
I cos 1 2sin 2
2 2
2
2
w0
(21)
(16)
cos 1 sin
2
2
KI
2 r
1
2
KI
1
2
(13)
2 r
yy
xy
1
2
3
cos 1 sin sin
2
2
2
KI
xx
(21)
(23) 17
1
1) https://en.wikipedia.org/wiki/Plane_stress
2) https://en.wikipedia.org/wiki/Infinitesimal_strain_theory#Plane_strain
18
19
7.
20
1) Preconfiguration
First we should define the number of theta angles from 0 to 360 degrees that we
are going to use for our analysis.
Second and one of the most important things we need to define the important
physical properties of the two materials:
Youngs Modulus
Shear Modulus
Poissons Ratio
1 Material 1
2 Material 2
E1 , E2
1 , 2
1, 2
(24)
k which is defined as
material _1
k
material _ 2
(25)
2k 1 2 2 1 1 k 1
2k 1 2 2 1 1
(26)
21
2)
The calculation of
The factor
is a term that appears for the calculation of the final stresses. Two
r n 0,1, 2,3,...
First Solution:
j coth
(27)
2n 1
n 0,1, 2,3,...
2
Second Solution:
1
1
1
j tanh 1
log
2
1
Assumption n = 0
(28)
22
3)
f cosh j
(29)
3
g a sin sin b 3cos cos
2
2
2
2
23
4)
Stresses Calculation
1
2
1
2
1
2
3
3 j
2
j cos j log r
2 2
4
1
2
Recall:
F f g
Where :
f cosh j
3
g a sin sin b 3cos cos
2
2
2
2
Assume:
Appendix 1
a 10 mm
b 0,1 mm
24
25
8.
Interface Cracks
1) Crack Tip Fields
The objective of this part is the calculation of the near-tip normal and shear
stresses
yy
and
x and y. x and y
for extension of the crack along the interface, given for plain
strain.
26
2) Procedure of Calculation
1. The total intensity factor
K K1 iK2
L
i
K1 iK 2 r i
yy i xy
(33)
2 r
(34)
1 1 2v2 2 1 2v1
2 1 1 v2 2 1 v1
1 1
(36)
ln
2 1
(35)
Recall:
E
E
1 v2
(37)
27
E1 E2
E1 E2
(38)
1
1
K1 iK2
_
_
(39)
4 E1 E2
y i x
r r i
2 1 2i cosh
8. The energy release rate
1
1
K12 K 2 2
_
_
E
E
2
G 1
2cosh 2
(40)
28
29
9.
Material Data:
A36 Steel
Aluminum
200e+09
119e+09
75e+09
48e+09
0.26
0.34
Poissons ratio
30
31
10.
r1 = 0,1 mm
r2 = 1 mm
r3 = 2 mm
Recall:
Assume:
a 10 mm
b 0,1 mm
45
90
135
180
225
270
315
360
Figure 13. Two dissimilar materials stress distribution Steel with Aluminum
32
45
90
135
180
225
270
315
360
45
90
135
180
225
270
315
360
33
45
90
135
180
225
270
315
360
45
90
135
180
225
270
315
360
34
4. Simulation 4: Homogeneous material, Steel, Opening mode I, Selection 2: Single Edge Notch
Panel
A 36 Steel
10 MPa
r1 = 1 mm
r2 = 2 mm
r3 = 5 mm
a 10 mm
w 50 mm
Plane Stress
Selection 1
Selection2
Selection 3
35
45
90
135
180
225
270
315
360
45
90
135
180
225
270
315
360
37
3) Boundary Conditions
5) Simulation
Figure 20. FEM Analysis Procedure
38
39
40
xx
45
90
135
180
225
270
315
Figure 22. Simulation and Calculated Results A36 Steel Stress Sigma xx
360
41
2) Stress
yy
FEM: MAX = 29 MPa at the minimum r
CALCULATION: MAX 35 MPa at r = 1 mm
45
90
135
180
225
270
315
Figure 23. Simulation and Calculated Results A36 Steel Stress Sigma yy
360
42
3) Stress
xy
FEM: MAX 14 - 15 MPa at
45 deg.
45
90
135
180
225
270
315
360
Figure 24. Simulation and Calculated Results A36 Steel Stress Tau xy
43
4) Displacement in X
FEM: MAX 0,0013 0,0015 mm
CALCULATION: MAX 0,0008 mm at r = 1 mm
45
90
135
180
225
270
315
360
5) Displacement in Y
FEM: MAX = 0,0001631 mm
CALCULATION: MAX 0,0014 mm at r = 1 mm
45
90
135
180
225
270
315
360
45
7) Simulation of Stress
xx
46
8) Simulation of Stress
yy
47
9) Simulation of Stress
xy
48
49
When the radius approaches to zero, the value of the stress increases
significantly.
51
14. References
http://www.fracturemechanics.org/fm/westergaard.html
(1898): http://www.fracturemechanics.org/fm/hole.html
Lempidaki, D., O'Dowd, N., & Busso, E. (s.f.). Crack Tip Stress Fields for Anisotropic
Cambridge: ASME.
Saouma, V. (2000). Lecture Notes in: Fracture Mechanics. Colorado: Dept. of Civil
Sih, G., & Rice, J. (1964). The Bending of Plates of Dissimilar Materials with Cracks.
53
QUESTIONS ?
54