Books/References Engg Fracture Mechanics - NPTEL Lectures by Dr Ramesh Prashant Kumar. Elements of Fracture Mechanics, Wheeler Publishing, 1999. Broek, D. Elementary Engineering Fracture Mechanics, Kluwer Academic Publishers, Dordrecht, 4th ed., 1986. Broek, D. The Practical Use of Fracture Mechanics, Kluwer Academic Publishers, Dordrecht, 1993. Anderson T.L. Fracture Mechanics - Fundamentals and Applications, 3rd Edition, Taylor and Francis, 2005.Historical Development Study of elliptical holes in a tension strip by Inglis (1913) has brought into focus the severity of a crack in a structure. Griffith in 1920 considered the propagation of cracks in glass and developed right ideas for crack growth. He formulated that an existing crack will grow provided the total energy of the system is lowered by its growth. His work was not noticed at that time due to the exigencies of the World War and the following depression worldwide. Griffith was not able to coin a convenient parameter for predicting the failure load of a component through the growth of a crack.Fracture Mechanics is a Broad Area Covering Several Disciplines. * Stress field ® Fracture evaluation Material * Fracture process * =Damage tolerant a Science design ‘ Fracture toughness ® Safe life design ® Fail safe design — Multiple load path *® Crack detection ) — Design for crack arrest — Leak before break (LBB) %* Crack growth monitoringFracture Mechanics is a Broad Area Covering Several Disciplines «Contd ® Fracture mechanics attempts to account for the existence of inherent flaws in structures and thus is closer to reality in modeling engineering problems. ® Ituses stress analysis to determine the stress intensity factors, material (Non penne Testing) science to determine the fracture sh toughness and NDT to determine the initial flaw size. © Design for a given safe life is possible if the above mentione three inputs are available. ®eLEFM and EPFM ® Structures made of ductile high strength alloys failing ina brittle fashion prompted the birth of fracture mechanics. ® Linear Elastic Fracture Mechanics (LEFM) * Extension of Griffith's ideas for brittle solids to ductile high strength materials was done by Irwin in 1948. * The main focus of Irwin's theory is on the crack tip rather than the crack; by moving the analysis to the crack-tip, Irwin devised workable parameters like stress intensity factor and energy release rate. * LEFM accounts only for small scale yielding (SSY) near the crack-tip. ®eLEFM and EPFM s.Contd © Elasto-Plastic Fracture Mechanics (EPFM) * Role of plastic deformation near the crack-tip is better accounted in EPFM. * For situations where material behaviour is non-linear such as in nuclear applications, EPFM is essential. © Typical materials for which LEFM is applicable (at room temperature) are %* High strength steel, precipitation hardened aluminium, polymers below glass transition temperature, ceramics, ceramic composites. ® Typical materials for which EPFM/Non-linear Fracture Mechanics is applicable are * Low and medium-strength steel, metals at high temperatures or high strain rates, polymers above glass transition temperature, ceramics at high temperatures,Range of LEFM / EPFM ® The plastic zone is very small and is highly localized. CO o o (@) (b) High strength material in plane strainRange of LEFM/ EPFM ® The plastic zone is very small and is highly localized. os o (a) (b) High strength material High strength material in in plane strain plane stress LEFMRange of LEFM / EPFM Plastic Collapse Sa) So o Ss mt o o o (c) (d) ©) Ductile material More ductile material Ductile material with spread fully plastic in plane stress or plane strain of plasticity EPFMFracture Mechanics should be Able to Answer the Following Questions: 2 @ @ What is the critical length of a crack? For a given crack length what is the residual strength? What is the time that would take for a crack to grow? How to decide the NDT schedule? What causes the crack to branch? What are the energy dissipating mechanisms?A center-cracked plate made of 7075-T651 aluminum alloy had dimensions, as defined in Fig. 8.12(a), of b = 19.05, t = 6.60mm, and large h. A zero-to-maximum (R = 0) cyclic force of P = 18.8KN was applied, causing the crack to grow. Crack growth rates measured at various crack lengths are given in Table P11.3. (a) Calculate AK for each crack length and then make ada/dN versus AK plot of these data. Then obtain approximate values for constants C and m for Eq. 11.10. (b) Use a log-log least-squares fit to obtain refined values of C and m. Table P11.3 da/aN, mmn/feyele 1.76 x 10-4 — 1 O50 +0326 x7 5.08 x 10-4 Fe= 1.27 x 103 VI= A) 3.18 x 10-3New Test for Fracture Mechanics LUtrasonic Probe AP3 AP2 ‘ al AP: J ® AP;> AP2 > APs N da lon de ie : aN —=C(AR) dNSchematic Representation of the Fatigue Life Showing the Relative Proportion of Life for Crack Initiation and Propagation _ crack propagation period crack initiation period Ac= Fatigue limit Alternating stress range, Ac log Fatigue lifeResidual Strength Diagram @p — Permissible crack length Design ac — Critical crack length strength Be No where N- — Crack length safety factor ap Service load ap Crack size —> Residual strength diagramResidual Strength Diagram Crack growth Design Amin — Minimum crack length strength identifiable by the inspection system 4 Total Life | Time available for inspection Onax 8 t 3 ap x g 8 $ 5 5 g nin ap Crack size —> Residual strength diagram r tr Time >Fracture Mechanics — a Holistic Methodology In many aspects, fracture mechanics draws parallels from the practice of homeopathy. Homeopathy does not treat symptoms but addresses the root cause of a disease through the symptoms. Likewise fracture mechanics starts with the premise that any structure can have internal flaws and it attempts to account for this in the design. Homeopathy is holistic and for similar symptoms it has different medicines for men/women, tall/short person etc. In fracture mechanics one finds different recommendation for handling thin structures (plane stress) and thick structures (plane strain). Further, process induced anisotropy is accounted for in fracture testing and design.Fracture Parameters — a Summary Energy release rate or crack driving force K (MPaJm) Stress intensity factor J(Nimm) J-integral CTOD COD (mm) Stress based Energy based Displacement based Parameter Basis Symbol Named of development | in Honour of pea Energy based Griffith Keis — collaborator lof Irwin JR. Rice CTOD - Crack-tip opening displacement COD — Crack opening displacement Applicable for LEFM Applicable for EPFMTypical Failures Initiated by a Crack Helicopter blade retaining bolt hole fracture Fracture surface Crack surface Reprinted From: NJ. Lourerce, C.F, Von Dotinger MLA. Graca and P,P. de Campos, Failure analysis ofthe main rotor ip ofa cil helicopter Engineering Failure Analysis, vol 12(1), 2005, pp 43-47__ Fig? & 4a with permission trom Essevier Crack originated at a corrosion pitTypical Failures Initiated by a Crack ...Contd ® Kidney shaped crack or detail crack has initiated fracture of a rail section. © This has been a topic of study for the last 20 years. Fracture surface © Usually the older rail sections are found to fail by this. Simulated Detail Crack Photoelastic study of detail crackTypical Failures Initiated by a Crack 4 ® Failure of a bolt due to Hydrogen embrittlement. ® Cracks have initiated due to Stress Corrosion Cracking (SCC) at two sides. ® In fatigue failure, normally the first or the second thread fails —here the failure has occurred a few threads below due to scc. Arrow head indicate crack originating sites Courtesy:www. hghouston come Hem, The Henarx Group Ine.Typical Failures Initiated by a Crack ....Contd Ee | @ Inherent flaw in an aircraft a % engine crank shaft. * ; — ‘ ®@ The flaw shape could be modeled as an elliptical crack.Typical Failures Initiated by a Crack s.Contd Crack propagation from a circumferential groove of a shaft under torsion. Crack growth pattem ina shaft subjected to low amplitude Made itl cyclic stress intensity factor. Repirted From! ‘A Vaai and H. Nayeb-Hasherl The ellect of crack surface mloractlon onthe siress inten facor ade il rack growth in round sha, Enaineering Fracture Mechanics, wo! 72/4), 2008, pp 617628. with permission fom Eleevi Crack growth pattem ina shaft subjected to high amplitude Mode III cyclic stress intensity factor.Photoelastic Visualisation of Crack-tip Stress Fields — Mode | Mode | Isochromatics (Medium cracks) Crack Length 15 mm.Photoelastic Visualisation of Crack-tip Stress Fields — Mode II Mode I! Mode II Inplane Shear Mode Crack surface Sliding Mode Mode II Isochromatics (Medium cracks)Photoelastic Visualisation of Crack-tip Stress Fields — Mixed-mode o Crack Length 5 mm. Orientation 45° Mixed-mode Isochromatics (Medium cracks)Cracks emanating from inner boundary ® In pressure vessels, radial cracks emanate from the inner boundary. © In order to increase the maximum pressure the vessel can bear, techniques such as autofrettage have been developed to induce residual compressive stress at the internal boundary. Photoelastic study of eight cracks emanating from inner boundary subjected to internal pressureCracks emanating from outer boundary © Radial cracks have been found to occur in mechanical components such a bladed disk assemblies, fly wheels, railway wheels, clutch plates etc. ® In these, centrifugal loading as well as thermal loading contribute to the formation of cracks. Pavers of Related Inerest 2K Ramesh, S Shula, P.M Dist, and N. Karuppaah, Numerical! evaluation of SIF for radial cars in ties annular Photoelastic study of multiple cracks emanating (i.9 ising cycic symmetry Encinaering Froviere Miechane, from outer boundary subjected to internal CS A pressure. Note that the cracks are of different lengths. The radial cracks are at different angular Positions.Interfacial crack © The plane problem of a crack lying along the interface of two dissimilar media in linear elasticity is one of great importance. ® The solution to such a problem could find application in the study of * Geological investigations dealing with fault lines along the interface between two layers of rock strata. * Debonding of fibre-reinforced composites. * Welded joints in which two dissimilar metallic materials are welded together with flaws or cracks developed along the original weld line owing to faulty joining techniques etc.Crack-tip stress fields in fibre-reinforced composites ® Extension of photoelasticity to the study of fibre-reinforced composites is photo-orthotropic elasticity. ® One of the challenges in model making is that the refractive index of the fibre material and the matrix must match. © The data interpretation is quite complex and further details can be seen in the reference: K. Ramesh and N.Tiwari, A brief review of photo-orthotropic elasticity theories, Sadhana, 18(6), 985 - 997, 1993. © lsochromatics obtained for a E-glass fibre reinforced polyester composite of 35% volume fraction is shown for various modes of loading and also for situations wherein crack is parallel/ perpendicular direction to the fibre direction.Crack-tip stress fields in fibre-reinforced composites lsochromatics obtained for a E-glass fibre reinforced polyester composite of 35% volume fraction is shown for various modes of loading and also for situations wherein crack is parallel/ perpendicular direction to the fibre direction.Crack-tip stress fields in fibre-reinforced composites lsochromatics obtained for a E-glass fibre reinforced polyester composite of 35% volume fraction is shown for various modes of loading and also for situations wherein crack is parallel/ perpendicular direction to the fibre direction. Mode IICrack-tip stress fields in fibre-reinforced composites lsochromatics obtained for a E-glass fibre reinforced polyester composite of 35% volume fraction is shown for various modes of loading and also for situations wherein crack is parallel/ perpendicular direction to the fibre direction. Mixed ModeCrack-tip stress fields in fibre-reinforced composites Mixed Mode For further deta: K. Ramesh. AK. Yadav and Viay A. Parithawela, Cassiicaton cof creck-lp lsochromates in orholropc composites, Engineering Fraciue Mechanics, 53(1), 1» 16, 1986 In composites, the volume fraction of the fibres do play a role on the value of the SIF.THANK YOU