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a
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Worked Example 1
Answer:
(1) Critical crack length acrit at max = 310 MPa can be found from fracture criterion KI
= KIC; Hence acrit = 0.072 m
(2) Using the Paris law, crack growth life can be found from the numerical integration
procedure (see table below). Alternatively, the direct integration method can be used
because is a constant.
da/dN
mean 1
a (m)
0.0075
0.0050
1.12
285
48.99688
2.56193E-07
0.0125
0.0050
1.12
285
63.25470
4.49366E-07
3.52779E-07
0.0175
0.0050
1.12
285
74.84397
6.50641E-07
0.0225
0.0050
1.12
285
84.86509
0.0275
0.0050
1.12
285
0.0325
0.0050
1.12
0.0375
0.0050
0.0425
da/dN
da/dN
mean 2
N1
N2
N=
N2
3.393E-07
14173
14736
14736
5.50003E-07
5.40718E-07
9091
9247
23983
8.57828E-07
7.54234E-07
7.47086E-07
6629
6693
30676
93.82189
1.06971E-06
9.63768E-07
9.57928E-07
5188
5220
35895
285
101.99514
1.2855E-06
1.1776E-06
1.17265E-06
4246
4264
40159
1.12
285
109.56036
1.50464E-06
1.39507E-06
1.39076E-06
3584
3595
43754
0.0050
1.12
285
116.63591
1.72674E-06
1.61569E-06
1.61187E-06
3095
3102
46856
0.0475
0.0050
1.12
285
123.30612
1.95147E-06
1.83911E-06
1.83567E-06
2719
2724
49580
0.0525
0.0050
1.12
285
129.63357
2.17859E-06
2.06503E-06
2.0619E-06
2421
2425
52005
0.0575
0.0050
1.12
285
135.66623
2.40787E-06
2.29323E-06
2.29036E-06
2180
2183
54188
0.0625
0.0050
1.12
285
141.44182
2.63917E-06
2.52352E-06
2.52087E-06
1981
1983
56172
0.0675
0.0045
1.12
285
146.99065
2.87232E-06
2.75575E-06
2.75328E-06
1814
1816
57988
1.12
285
151.81129
3.08365E-06
2.97799E-06
2.97611E-06
1511
1680
59668
0.0720
Therefore the crack growth life from initial crack of 7.5 mm to final crack
length 72 mm is approximately 59,668 cycles.
Crack growth curve is presented by plotting crack length (a) against
the cycles (N).
Fatigue crack growth curve
80.0
70.0
60.0
50.0
40.0
30.0
20.0
10.0
0.0
0
10000
20000
30000
40000
50000
60000
70000
(1) Increase the critical crack size at failure (acrit) by using a material
with a higher KIC value. However, this may not provide significant
life increment since crack growth rate will be much higher at the
longer crack length (i.e. when KI is close to KIC). Nevertheless, a
longer critical crack length could help with inspection.
(2) Lower the design stress (max) to increase the critical crack size at
failure (acrit).
(3) Lower the stress range () to decrease the rate of crack growth,
thereby increasing the crack growth life. Note that because crack
growth rate is a power function of , or actually , lowering the
stress range slightly has a significant effect on the life.
(4) Improve the inspection capability so that the initial flaw size (ao) is
reduced. It is clear from the result presented in the Table and Figure
above that most of the life is taken up in the early stages of crack
propagation. In this example, if ao were only 5 mm instead of 7.5
mm, then the number of cycles to grow the crack from 5 to 7.5 mm
is about 12,150 giving a total life of 72,150 cycles (from 5 to 72
mm), which is a 20% improvement of the fatigue life. Therefore
any decrease in initial crack size has a very significant effect on the
fatigue life of a structural member.
Worked Example 2
A stiffened skin panel with stringers at 200 mm pitch is subjected to a
constant amplitude stress varying from 0 to 120 N/mm2. Using Figure Q2 to
determine the number of cycles required to grow a mid-bay crack (2a)
initially 100 mm long to a length of 300 mm.
Take S = E2A/(E1bt) = 0.111, da/dN = C(K)n, where C = 2 x 10-11, n = 3.5.
Unit: where da/dN is in m/cycle and K is in MN, m units.
KI for a crack between two stiffeners in a periodically stiffened sheet subjected to a uniform uniaxial tensile
stress [DP Rooke & DJ Cartwright, Compendium of Stress Intensity Factors, HMSO, London, 1976.]
Answer:
Choose a = 0.01 m
da/dN (mean 1) = 0.5(da/dN1 + da/dN2),
da/dN (mean 2) = (da/dN1 x da/dN2)1/2
N1 = a / [da/dN mean]
a
(m)
a/b
da/dN
da/dn
mean1
0.05
0.25
0.985
120
46.84653
1.40735E-05
0.06
0.30
0.980
120
51.05730
1.9021E-05
1.65472E-05
0.07
0.35
0.965
120
54.30409
2.36017E-05
0.08
0.40
0.945
120
56.85033
0.09
0.45
0.910
120
0.10
0.50
0.850
0.11
0.55
0.12
da/dN
mean2
N 1
N 2
1.63613E-05
604.3313
611.1998
2.13113E-05
2.11879E-05
469.2336
471.9672
2.77074E-05
2.56546E-05
2.55723E-05
389.7944
391.0483
58.06559
2.98364E-05
2.87719E-05
2.87522E-05
347.5617
347.7998
120
57.17091
2.82581E-05
2.90472E-05
2.90365E-05
344.2669
344.3940
0.780
120
55.02336
2.47141E-05
2.64861E-05
2.64268E-05
377.5565
378.4043
0.60
0.750
120
55.25964
2.50875E-05
2.49008E-05
2.49001E-05
401.5931
401.6044
0.13
0.65
0.735
120
56.36574
2.68895E-05
2.59885E-05
2.59729E-05
384.7850
385.0165
0.14
0.70
0.725
120
57.69766
2.91799E-05
2.80347E-05
2.80113E-05
356.7007
356.9986
0.15
0.75
0.720
120
59.31087
3.21366E-05
3.06583E-05
3.06226E-05
326.1764
326.5563
4002
4015