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1 Introduction
Structural components have inherent flaws or defects which serve as initial cracks. The
analysis of cracks within structures is an important application if the damage tolerance and
durability of structures and components are to be predicted. As part of the engineering design
process, engineers have to asses not only how well the design satisfies the performance
requirements but also how durable the product will be over its life cycle. Often cracks cannot be
avoided in structures; however the fatigue life of the structure depends on the location and size of
these cracks. In order to predict the fatigue life for any component, a fatigue life crack growth
study needs to be performed. [2]
Cracks frequently initiate and grow at stress concentration zones such as notches, holes,
re-entrant corners and welded joints in structural components. These initial cracks propagate to
larger sizes and eventually fracture under cyclic fatigue loading. Because such elements occur
frequently in structural components, understanding the severity of cracks is important in the
development of static strength, fatigue crack growth and fatigue life prediction methodologies.
The stress intensity factor (SIF) is the key parameter in linear elastic fracture mechanics
(LEFM) for quantifying the severity of cracks [1]. It reflects the effect of loading; crack size,
crack shape and component geometry in life and strength prediction methods. An accurate
knowledge of the stress intensity factor is essential for the prevention of brittle fractures arising
from cracks; in particular, the use of the LEFM principles in preventing the fracture of
engineering components depends largely on the availability of accurate SIFs. As a result,
analytical, numerical and experimental methods for SIF determination in cracked bodies have
been developed for several decades. Analytical methods are limited to simple configurations due
to mathematical difficulties, and one must resort to numerical or experimental methods for more
complex situations. The experimental determination of stress intensity factors is also needed as a
way to validate theoretical and numerical results, and provides a valuable aid to their application.
The investigation of fatigue crack behavior using fracture mechanics has been largely
focused on Mode I loading. However, engineering components or structures are often subjected
to both normal and shear loading (Modes II and III).
When it comes to high performance jet engines, discs are regarded as the most critical
structural components. The bore of the disc experiences highest net section stresses and requires
high yield and ultimate tensile strengths. Due to the growth of fatigue cracks from small intrinsic
or processing defects, the bore may be of limited life. For this reason, the compressor disc is
chosen for the study of stress intensity factor under mixed mode loading.
The present thesis is focused to study the mixed mode stress intensity factor of surface
cracks in compressor disc of a gas turbine engine. Firstly, the mode I and mode II SIF of surface
cracks on a standard geometry will be found using finite element analysis and they will be
evaluated using classical approach. After validating the finite element analysis approach, it will
be extended to calculate the multi-mode stress intensity factor of surface cracks and the crack
growth rate due to multi-mode stress intensity factor in a compressor disc.
Chapter-2
Fig. 2. 1 Relation between applied stress, fracture toughness and flaw size [1]
For ductile materials, the milestone did not come about until Irwin developed the concept
of strain energy release rate, G, in 1950s. ‘G’ is defined as the rate of change in potential
energy near the crack area for a linear elastic material.
d
G≡
dA
When the strain energy release rate reaches the critical value, Gc, the crack will grow.
Later, the strain energy release rate was replaced by the stress intensity factor K with a similar
approach by other researchers.
After the fundamentals of fracture mechanics were established around 1960, scientists
began to concentrate on the plasticity of the crack tips. In 1968, Rice modelled the plastic
deformation as nonlinear elastic behaviour and extended the method of energy release rate to
nonlinear materials. He showed that the energy release rate can be expressed as a path-
independent line integral, called the J integral. In United States Rice’s theory has since
dominated the development of fracture mechanics. Meanwhile, Wells proposed a parameter
called crack tip opening displacement (CTOD), which led the fracture mechanics research in
Europe.
Thereafter, many experiments were conducted to verify the accuracy of the models of
fracture mechanics. Significant efforts were devoted to converting theories of fracture mechanics
to fracture design guidelines.
In linear elastic fracture mechanics, there are three modes of fracture that can be
considered. The first mode is called the opening mode, where the displacements in the Y
direction are symmetric about the X axis. The second mode is the shearing mode, where the
displacements in the X direction are anti-symmetric about the X axis. The third mode is the
tearing mode, where the displacements in the Z direction are anti-symmetric about the X-axis.
Fig. 2. 3 Schematic of the three fracture modes [1]
The stress field near the crack tip may be derived from the airy stress function in the bi-
harmonic equation with the appropriate boundary conditions. For Mode 1, the stress field is
given by:
K1 3
X cos 1 sin sin
2 r 2 2 2
K1 3
Y cos 1 sin sin
2r 2 2 2
K1 3
XY cos sin sin
2 r 2 2 2
The stress fields for Mode II and Mode III are similar. All the three components of stress
vary as 1/ r, which lead to infinite stress at the crack tip. From an analysis standpoint, this is not
very useful information; however, the term KI is a constant and is called the stress intensity factor
or the coefficient of the singularity in mathematical terms, and can be compared to determine
whether the crack will run, which may often lad to catastrophic failure, or arrest. The goal of a
typical finite element analysis for a fracture model is to determine the stress intensity factors K I,
KII, and/or KIII corresponding to the theoretical stress fields at the crack tip. The stress intensity
factor elegantly characterizes a crack, similar to energy release rate G.
2.1.2 Importance of the mixed-mode stress intensity factor calculation.
The investigation of fatigue crack behaviour using fracture mechanics has been largely
focused on mode I loading. However, engineering components or structures are often subjected
to both normal and shear loading (modes II & III). Therefore it is necessary to determine the life
of such components based on mixed-mode stress intensity factor. This type of fatigue problem is
usually referred to either as the multi-axial fatigue problem for classical fatigue analysis (S–N or
e–N curve approach) or the mixed-mode fatigue crack problem within the context of fracture
mechanics.
2.1.3 Why compressor disc of the engine is chosen.
Although rare in occurrence, a disc rupture in an aircraft engine can lead to a catastrophic
failure. In 1989, United Airlines flight 232 crashed during an attempted landing at Sioux
Gateway Airport, Iowa [Anon., 1990]. The separation, fragmentation, and forceful discharge of
the stage one fan rotor from the number two engine led to leaks in all three hydraulic systems,
resulting in loss of flight controls. The failure was due to a fatigue crack in a critical area of the
compressor disc. Here, 111 fatalities occurred. Another example of a catastrophic disc failure was
Delta Air Lines flight 1288 [Anon., 1998]. For this, a crack in the front compressor disc hub
propagated to fracture during takeoff roll at Pensacola Regional Airport, Florida. This caused an
engine burst where debris penetrated the fuselage. Two passengers were killed and two others
were seriously injured. Due to the high speed and high rotational energy in engine discs, cracks
in discs can propagate quickly and lead to uncontained engine failures. When it comes to high
performance jet engines, discs are regarded as the most critical flight safety components. The
bore of the disc experiences the highest net section stresses and requires high yield and ultimate
tensile strengths. The bore may be life limited by the growth of fatigue cracks from small
intrinsic or processing defects. The rim operates under lower stresses but at higher temperatures
and requires adequate creep resistance.
Traditionally, discs have been designed on the basis of a Low-cycle-fatigue (LCF) life
limitation criterion. This "safe life" design philosophy considers the useful life to be exhausted
after a crack initiation phase results in the development of a small fatigue crack of 0.79 mm (1/32
in) in length in 0.1% of the discs. Due to the conservative nature of the "safe life" approach, there
is considerable economic incentive to extend service lives by combining crack initiation and
crack propagation criteria in life prediction. Closed form expression for mixed-mode stress
intensity factor is available for only simple cases and, therefore, determining stress intensity
factor becomes a challenge for many practical cases. By studying cracks in compressor discs
under mixed mode loading, we can predict the life of the components better. Fig.2.5 shows the
picture of a compressor disc, Fig.2.6 shows the direction of crack growth from the disc and
Fig.2.7 shows that the cracks emanating from the bolt holes on the disc.
Engineering components or structures are often subjected to both normal and shear
loading (modes II and III) but their fatigue lives are calculated by considering only mode I stress
intensity factor. Though mode II SIF may be less when compared to mode I SIF, their value
can vary depending on the angle of the cracks with respect to direction of loading. Therefore it
becomes necessary to consider SIF of all the three modes to calculate the crack growth rate of a
structure.
The purpose of this investigation is to calculate the crack growth rate due to mode I stress
intensity factor alone in first stage, mixed mode stress intensity factor in next stage and
to identify the difference in crack growth rates due to these two factors.
4.2. Project Objectives
The entire study will be carried out in order to achieve the following objectives.
To review the literatures on mixed mode crack propagation, analytical and
experimental models related to fatigue analysis of compressor disc, finite element
simulation of mixed mode crack growth and mixed mode stress intensity factor
evaluation.
To derive the mode I and mode II stress intensity factor of bench marked problems
using FEA code and validate the results using classical methods.
To carry out stress analysis at the contact regions to determine stress singular region
leading to crack initiation.
To carry out FEA analysis of the model with a fatigue crack at the identified location
and to determine the mixed mode stress intensity factor at the crack tip.
To compare the crack growth rates due to mode I stress intensity factor alone and
mixed mode stress intensity factor.
4.3. Methodology
Brief description of the methodology followed is given below.
a) Literature on mixed mode stress intensity factor, numerical and experimental analysis of
fatigue in compressor blades reviewed by referring journals, books and related
documents.
b) Developed a plate model (benchmark problem) with a crack and determined the mode I
and mode II Stress intensity factor using ANSYS 12.0. The results were validated using
analytical equations.
Chapter 5
5.1. Introduction-Construction of Model and Solution
The evaluation of mode I and mode II is carried out using 2D plate models. The model
was generated using ANSYS 12.0 and the analysis and post processing were also carried out
using ANSYS 12.0.Detailed description of the various steps followed in geometry modelling and
FE modelling for carrying out the simulations are given below.
5.2 Evaluation of Mode I, mode II stress intensity factor of a crack in a plate
5.2.1 Geometric Modelling
The modelling of the 2D plate was carried out using ANSYS 12.0. The dimensions of the
[13]
2D plate considered for the mode I, mode II estimation is taken from a literature . Fig.5.1
shows the dimensions of the 2D plate. Here length L = 200 mm, breadth B = 200 mm and crack
length 2a = 40 mm.(i.e. “a” = 20 mm)
Crack tip
Fig.5. 2 Finite element model (Quarter model) of the 2d plate with a crack [14]
Crack Tip
Crack Face
Fig.5. 3 Finite element model (Half model) of the 2d plate with a crack
5.2.6 Loads
Individual analysis has been carried out to determine mode I and mode II. Pressure loads are
applied on the plate edges in both the cases. A pressure load of 100MPa is applied on top edge of
the plate.
Case 1 -Quarter plate crack model with boundary conditions
Boundary
Constraints
Fig.5. 5 Loading on the 2d quarter plate to determine the mode I stress intensity factor
Case 2 -Half plate crack model with boundary conditions
A pressure load of 100MPa is applied to both top and bottom edge of the plate which is shown in
the Fig.5.6. with boundary conditions
Boundary
Constraints
Crack tip
Fig.5. 6 Loading on the 2d Half plate to determine the mode I & mode II
Stress Intensity factor (Mixed mode)
5.2.8 Determining the stress intensity factor of the crack in the 2D model
The KCALC command is used to calculate the Stress Intensity Factors K I and KII. The
following procedure has to be followed in order to use the KCALC command.
Define a local co-ordinate system at the crack tip with x-axis parallel to the crack face as
shown in the Fig.5.7. The stress intensity factors have to be extracted with respect to this
co-ordinate system.
Define a path along the crack face. The first node on the path should be the crack tip
node. For a full crack face, both crack faces are required to define the node, two nodes
along the crack face and two along the other face.
Calculate KI and KII using the plane stress option. The plane stress condition is assumed
here as the loading is in-plane to the plate and thus the displacement in the z direction
will not vary.
Local
Co-ordinate
system
Crack Path
1
a 2
plate is given by , K1 a Sec
W
1
a 2
plate is given by , K1 a Sec
W
Finite element solution to to determine mode I stress intensity factors KI by using KCALC
command. From the analysis KI =26.669 MPa m and KII=0.35914E-02 MPa m
REFERENCES
[1] Ted L. Anderson, Fracture mechanics: fundamentals and applications, 3rd edition,
CRC Press, 2005
[3] John M. Barsom, Stanley T. Rolfe Fracture and Fatigue Control in Structures:
Applications of Fracture Mechanics, Third edition, British Library Cataloguing-in-
Publication Data, Butterwor th-Heinemann,225 Wildwood Avenue,Woburn, MA 01801-
2041
[4] Jeong-Ho Kim and Glaucio H. Paulino, “Finite element evaluation of mixed mode stress
intensity factors in functionally graded materials”, Department of Civil and Environmental
Engineering; University of Illinois at Urbana-Champaign, 2002.
[5] H.S. Hedia and S.M. Aldousari, “Three-Dimensional Finite Element Model for Evaluation
the Stress Intensity Factors for Different Fracture Modes of Homogeneous Bimaterial”, King
Abdulaziz University, Jeddah, Saudi Arabia.
[6] M.A. Meggiolaro, A.C.O. Miranda, J.T.P. Castro, L.F. Martha, “Stress Intensity Factor
Equations for Branched Crack Growth”, Engineering Fracture Mechanics, V 72, 2005, pp
2647–2671.
[7] M.Y. He and J.W. Hutchinson, “Surface Crack Subject To Mixed Mode Loading”,
Engineering Fracture Mechanics, V 65, 2000, pp 1-14.
[8] S. Ma, X.B. Zhang and N. Recho, “The Mixed-Mode Experimental Investigation of the
Fatigue Crack in CTS Metallic Specimen”, Blaise Pascal University of Clermont II, 03100,
France.
[9] Yongming Liu, Sankaran Mahadevan, “Threshold Stress Intensity Factor and Crack
Growth Rate Prediction Under Mixed-Mode Loading”, Vanderbilt University, Nashville, TN
37235, USA, 9 June 2006.
[10] Rajiv A.Naik and John H. Crews, Jr., “Determination of Stress Intensity Factors for
Interface Cracks under Mixed-Mode Loading”, NASA Technical Memorandum 107624,
Langley Research Center, 1992.
[11] Stress intensity factor calculations for cracks emanating from bolt holes in a jet engine
Compressor disc, W. Beres, A.K. Koul, ICAS2002 congress Institute for Aerospace Research,
National Research Council Canada, Ottawa, Canada,.
[12] Introduction to Fracture Mechanics C.H. Wang Airframes and Engines Division
Aeronautical and Maritime Research Laboratory.CODE;- DSTO-GD-0103
[15] Lingaiah, K., Machine Design Data Handbook of Machine Design, 2nd edition, P 49-1
McGraw-Hill Publishing Company, New York, 1996).
Appendix
Case 1: ANSYS output of KI, KII and KIII for plate with tensile loading for
quarter plate crack model
**** CALCULATE MIXED-MODE STRESS INTENSITY FACTORS ****
ASSUME PLANE STRESS CONDITIONS.
ASSUME A HALF-CRACK MODEL WITH SYMMETRY BOUNDARY CONDITIONS
(USE 3 NODES).
EXTRAPOLATION PATH IS DEFINED BY NODES: 1 62 61
WITH NODE 1 AS THE CRACK-TIP NODE.
USE MATERIAL PROPERTIES FOR MATERIAL NUMBER 1
EX = 0.20000E+06 NUXY = 0.30000 AT TEMP = 0.0000.
Case 2: ANSYS output of KI, KII and KIII for plate with tensile loading for
half plate crack model
**** CALCULATE MIXED-MODE STRESS INTENSITY FACTORS ****