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CONTENTS:
Similitude in fatigue
Empirical Fatigue Crack Growth Equations
Crack Closure Effect and Fatigue Threshold
Variable Amplitude Loading and Retardation
Fatigue Crack Growth of short cracks
Experimental Measurement of Fatigue Crack Growth
Damage Tolerance Design Methodology
SOURCE:
T. L. Anderson, Fracture Mechanics : Fundamentals and Applications, 2/e,
CRC Press, 1995.
“One of the most successful applications of the theory of fracture mechanics is the
characterization of fatigue crack propagation” - Suresh.
Fatigue Crack Propagation
FATIGUE CRACK PROPAGATION : FRACTURE
MECHANICS APPROACH
Random loading
--------------------(1)
da C.(K ) m
dN (1 R ) K crit K
------------------- (2)
OR
da C.(K ) m 1
dN K crit
K 1 -------------------(3)
max
Weertman’s Semiempirical equation for regions II and III :
da C.(K ) 4
-------------------(4)
dN K crit K max
Both the Forman and weertman’s equations do not account for the
threshold.
Klesnil and Lukas equation: Accounts for the threshold
da
C (K m K Thm )
dN -------------------(5)
da K K Th
C -----------------(6)
dN K crit K max
da 2 K
C K K Th 1
dN K K ------------------(7)
crit max
Some Useful Remarks
All the equations are strictly valid only for constant amplitude
loading.
Example: Derive an expression for the number of stress cycles required
to grow a semicircular surface crack from an initial radius a0 to a final
size of af, assuming Paris Law describes the FCG rate. Assume that af is
small compared to plate dimensions (width, length, thickness) and the
stress amplitude Δσ is constant.
The SIF Solution:
K 0.663 a
( max min )
da
C 0.663 . a
m m/ 2
dN
m m
1 1
2
a a 2
0 f
for m 2
m
C 1 0.663 . m
2
da
C. J
m
dN
K eff K max K op
U
K K max K min
C. K eff
da m
dN
Prior to the overload, the crack tip plastic zone would have reached
a steady state size, but the overload cycle produces a significantly
larger plastic zone. When the load drops to the original Kmax and
Kmin, the RESIDUAL STRESSES that result from the overload
plastic zone are likely to influence subsequent FCG behavior.
Fig. 10.12. A single overload during cyclic loading
• Figure 10.13, shows experimental data, where a single overload is
For FCG analysis under Variable Amplitude Loading, the stress input
consists of two components. The spectrum and the sequence. The
spectrum is a statistical distribution of stress amplitudes, which
quantifies the relative frequency of LOW, MEDIUM and HIGH
stress cycles. The sequence, which defines the order of the various
stress amplitudes, can be wither RANDOM or a REGULAR pattern.
FCG analysis under Variable Amplitude Loading must first be Performed
on the experiment to determine the adjustable parameters that gives the
best prediction of measured crack growth. The model can then be applied
to structure / component life predictions. If a structure / component with
a different stress spectrum is to be analyzed, the FCG analysis model
must be recalibrated with a new experiment.
Summary:
da C K eff
m
dN
K eff K max K op , if Kmin < Kop
K max K min
, if Kmin Kop
da C K rms
m
dN
where C and m are material constants.
and
n
i
K
i 1
2
K rms
n
Here, Δki is the SIF range in the ith cycle in a sequence consisting of
n stress cycles. ΔKrms = ΔK for constant amplitude fatigue loading.
Although empirical, this approach is used in a number of fatigue critical
applications.
Short cracks grow typically much faster than longer cracks at the
same ΔK particularly near the threshold (Fig. 10.18).
Some researchers have proposed adjusting the data for crack tip
plasticity by characterizing da / dN with ΔJ rather than ΔK. Note ΔJ
computations includes crack tip plasticity effects.
Short cracks exhibit different crack closure behavior than longer cracks,
and the FCG data [ da/dN (m / cycle) Vs ΔK (Mpa √m)] for different
crack length can be rationalized through Δkeff. Figure 10.19 (a), shows
Kop measurement for the short and long crack FCG data presented in
Fig 10.18. The closure loads are significantly higher in the longer
cracks, particularly at low ΔK levels. Fig. 10.19 (b) shows the short and
long crack FCG data lie on a common curve when da / dN (m/cycle) is
plotted against Δkeff, thereby lending credibility to the crack closure
theory of short crack behavior.
(a) Crack closure data for short and long
cracks
All specimens must be fatigue pre cracked prior to the actual fatigue
test. The Kmax at the end of fatigue precracking should not exceed
the initial Kmax in the FCG test, otherwise retardation effects any
influence the measured FCG rate.
During the test the crack length must be measured periodically. Crack length
measurement techniques include optical, unloading compliance and
potential drop. Optical crack length measurements require a traveling
microscope. One obvious disadvantage of the optical method is that it can
only measure growth on the surface, in thick specimens, the crack length
measurements must therefore be corrected for tunneling, which cannot be
done until the test specimen is broken open after the test!. Another
disadvantage of the optical technique is that the crack length measurement
are recorded manually. It may be possible to automate optical crack length
measurements with Image Analysis hardware and software, but most
Material Testing Labs do not have this facility. The unloading compliance
technique requires that the fatigue test be interrupted for each crack length
measurement.
The ASTM standard E647 outlines two types of Fatigue Tests:
(1) Constant Load Amplitude Tests where K increases
(2) K - decreasing test in which the load amplitude decreases
during the test to achieve a negative K gradient.
1 dK 1 d K 1 dK min 1 dK max
G
K da K da K min da K max da
da a j 1 a j
dN a a N j 1 N j
where
a a j 1 a j 2
Fig 10.24 Schematic fatigue crack growth curves. da
/ dN is inferred from numerical differentiation of
these curves.
• The derivative at a given point on the a Vs N curve can also
be found by fitting several neighboring points to a quadratic
polynomial (i.e., a Parabola)
Since Retardation effects are not considered, the DTA is simpler and
will tend to overestimate FCG rates!
EXAMPLE: An edge crack of length 3.1 mm is detected in a large plate
made out of ferrite - pearlite steel with KIC = 165 Mpa m^½ and
subjected to constant amplitude cyclic loading having σmax = 310 Mpa and
σmin = 172 Mpa. Determine (i) Propagation life up to failure and
(ii) propagation life of the crack length is not allowed to exceed 25 mm.
SOLUTION: a
K I f a
SIF: w
a
f 1.12
w
a0 0.0031m
2
K IC
(i) Critical Crack Length, ac
1.12 * max 2
0.0719m a f
da
C K
m
dN
C 6.8 *10 12
m3
m m
1 1
a 2
0 a 2
f
Life: N P
m m a0
1C. f w . . 2
m m
2
3 3
NP
0.0031 2 0.0719
1 1
2
*
1
3 6.8 *1012 * 1.12 138 * 2
3 3 3
1
2
= 203.6*103 cycles