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Documenti di Professioni
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Examples Applications
Fatigue cracking in fuselage structure
Ductile tearing in fuselage structure
Fatigue cracking in transmission gear
2
The Lay of the Land In Computational Fracture Mechanics
Cracks are either explicitly represented in the geometry model of the structure, or
they are implicitly acknowledged in the numerical model of the structure.
GEOMETRICAL NON-GEOMETRICAL
REPRESENTATION REPRESENTATION
Atomistic Methods
3
FRANC2D: A Crack Propagation Simulator
for Plane and Axisymmetric Structures
Finite-element-based, mixed-mode, LEFM, stress intensity factor calculator.
Interactive, menu-driven, integrated pre/post processing and FEM analysis.
Automatic re-meshing to accommodate arbitrary crack growth:
-- no limit on number of cracks, automatic propagation under LEFM.
Interface and contact mechanics.
Nonlinear fracture mechanics via cohesive zone models.
Newton and dynamic relaxation solvers.
Mid-80s origin with continuous development to present.
30
20 KI
15
10
5 KII
0
0 0.5 1 1.5 2 2.5
-5
Crack Length (in.)
4
FRANC2D/L: A Crack Propagation
Simulator for Plane Layered Structures
Finite-element-based, mixed-mode, LEFM, stress intensity factor calculator.
Interactive, menu-driven, integrated pre/post processing and FEM analysis.
Automatic re-meshing to accommodate arbitrary crack growth:
-- no limit on number of cracks, automatic propagation under LEFM.
Interface and contact mechanics.
Nonlinear fracture mechanics via cohesive zone models.
Newton and dynamic relaxation solvers.
Mid-90s major variant of FRANC2D, continued development to present.
PLUS
Layering of plane regions, using adhesive and/or riveted connections.
Any number of cracks in any layer.
Out-of-plane loads for plate bending analysis.
EPFM/CTOA with state mapping for tearing simulations.
5
FRANC2D/L 2-Layer Analysis of Effect of Patch on
Crack Growth from Hole
45000
40000
FRANC2D/L: No Patch
35000 ANALYTIC: No Patch
5000
4.0"
0
0 0.2 0.4 0.6 0.8 1 1.2
By way of a simple,
2D simulation
of crack growth in
a gear
7
FRANC3D: A Crack Propagation Simulation
System for 3D Shell and Solid Structures
Designed as a value-added crack growth simulation environment for use
with your FEM/BEM analysis engine.
Interactive, windows-driven, integrated pre/post processing.
Automatic re-meshing to accommodate arbitrary crack growth:
-- no limit on number of cracks, automatic propagation under LEFM.
Late 80s origin, with continuous evolution to present.
8
Overview of Manual Input
finite element
the Simulation model:
OSM
ANSYS,
Process with PATRAN,
NASTRAN,
FE
Translation
IDEAS,
FRANC3D BLADE-GT, or
ABAQUS Solid
Model
Boundary
Rep. File
format
FRANC3D
Boundary
Crack Conditions
Finite element model Propagation
translation using OSM is
Fracture Introduce Mesh
described in the Analysis Flaw(s)
documentation on the CFG yes no
web site: Existing Superposition
Flaw? yes ?
www.cfg.cornell.edu no
Life Crack Face
Prediction Loads
BES
FEM/BEM
Results (Stress Analysis
Analysis
Analysis)
File File
9
Outline of Presentation
Computational Fracture Mechanics (CFM) 2004
A Taxonomy of Approaches
Examples Applications
Fatigue cracking in fuselage structure
Ductile tearing in fuselage structure
Fatigue cracking in transmission gear
10
Fuselage Fatigue
Crack Growth
Simulation
Global-Local
Hierarchical Modeling
11
Predicted Curvilinear Fatigue Crack Growth:FRANC3D/STAGS
Potyondy, Wawrzynek, Ingraffea, Int. J. Num. Meth. Engr., 38, 1611-1633 1995.
12
Plastic Zone Evolution in KC-135 Fuselage Panel:FRANC3D/STAGS
20 in.
10 in.
60 yld
53
46
39
Chen, C.-S., Wawrzynek, P. A., Ingraffea, A. R., AIAA Journal, 40, 566-575, 2002.
Chen, C.-S., Wawrzynek, P. A., Ingraffea, A. R., AIAA Journal, 40, 1644-1652, 2002.
13
Mesh Model of SH 60 Seahawk
Power Transmission Spiral Bevel Gear
Teeth Hub
JMESH Application
14
Initial Flaw Size and Location
Problem Demands
214,000 -
ELEMENTS 327,000
920,000 -
DOF 1,400,000
15
Comparison: Simulated versus Observed
Observed
Simulated
16
Comparison: Simulated versus Observed
Fracture Surfaces
Simulated
Observed
17
Comparison: Simulated vs Observed
Crack Trace on Gear Hub
Observed
Crack
Simulated
1 cm
18
Mesh Detail on Tooth Surface
Initial Flaw/Mesh
19
Outline of Presentation
Computational Fracture Mechanics (CFM) 2004
A Taxonomy of Approaches
Examples Applications
Fatigue cracking in fuselage structure
Ductile tearing in fuselage structure
Fatigue cracking in transmission gear
20
Current Research in the CFG
Continuing advances in computational power (eg. //HPC) and laboratory
observations (eg. EBSP) are enabling progress in two main thrust areas:
1 mm
~1 m
~1 mm
Meso-Scale:
Polycrystal
~1 nm
Atomic Scale:
Grain/Particle Boundaries
22
Cyclic Loading Simulation in FRANC2D/L
n
Elastic-plastic
0.5 mm
orthotropic
grains; cohesive
grain boundaries y
x
yy (MPa)
Average applied strain
6.9e-3
500
100
Time, Cycle 23
Scaling Tests of 3D Polycrystal
24
Detail of Meshing of Grains
25
Simple Scaling Test on a Target Polycrystal
Geometry:
50 m cube
100 Grains
6,271,419 DOF
1,519,816 10-noded
tetrahedra
Solution:
64 Dell 1550 servers
Using 1 CPU each
3669.28 s (61 minutes)
1 GHz PIII CPUs
2GB RAM
Giganet interconnect
Windows 2000 Advanced
Server
Wireframe displaced shape
MPI Pro 1.6.3 Displacement contour - ||u||
26
Illustrative, Small 3D Problem
1 mm cube
5 grains
Elastic grains
E = 72 GPa
= 0.3
CCZM
c = 500 MPa
c = 10 m
k0 = 200 MPa
2% applied xx
Mesh:
3174 Tetrahedral elements
201 Interface elements
932 Nodes
15,744 DOF
27
3D Polycrystal: xx Contours
(GPa)
28
3D Polycrystal: Grain Boundary Separation
Cracked
Decohering
Closed
29
3D Polycrystal: Interface Normal Traction
on Grain Boundaries
(GPa)
30
Summary
therefore
Fracture mechanics does not apply to composite materials, Single, dominant cracks
do not occur in composites: damage is diffuse and multi-phenomenal: in my opinion,
these are no longer meaningful or useful statements.
31
FRANC2D/L 2-Layer Analysis of Effect of Patch on
Crack Growth from Hole
10 m
14
required residual strength (12.5 psi)
12 MSD = 0.025 in. (RS = 11.3 psi)
10
MSD = 0.025 in., Corrosion (RS = 10.8 psi)
8
0 1 2 3 4
Total Crack Extension (inch) 34
Fatigue Loading Simulation
0.7
Cycle
Simulations
discretely and statistically
represent particles
Perform simulations to
investigate the influence of
inclusions on fatigue crack
initiation and propagation.
100 m 36
y, 0.5 GPa
debonded
Interface elements
debonded,
void left behind
Not
debonded
at 0.4% applied strain
38
Major Issues in 3D Meso-Scale
Creating grain geometry
Meshing for FEM
simulations
Assigning individual
material properties for
each grain
Determining appropriate
boundary conditions
Selecting solution
techniques
Determining necessary
computational power
39
Validation Study #1
Crack
Tip 1 .508"
A
Crack
2.412" 2" Tip 2
side view
a1 a3
A
12"
0.25R" EDM
view 2 flaw a2
initial notch
view 1 45 angle
bottom view crack
40
Initial Boundary Element Mesh
Geometric Model
Flaw Mouth
Initial Flaw
Full Beam
41
Predicted and Observed Crack Fronts
a b
b Observed Fatigue Crack Shape
42
Final Predicted Crack Shape
Deformed solid
Experiment
FRANC3D
Comparison of computed initial
crack
and observed crack trace
on the surface
side bottom face side
43
Computed SIF History and Comparison to Observations
a1 a2
46
Deformed Solid During Simulated Crack Growth
initial after 10
steps
after 20
steps
47
Deformed Solid During Simulated Crack Growth (cont.)
48
Comparison Among
Observed and
Simulated Crack
Trajectories
BEM
FEM
observed
BEM
FEM
observed
49
The Current Cost of Realism
Item FRANC3D
Computer power 128 processors
PC-cluster, 2.4 GHz
Number of unknowns ~ 1 to 3 million
Max. solution time per load cycle ~ 2 hours
(1 load cycle=15 load steps)
Typical time for one crack step ~ 5 hours
50