2 Static Strength and Fracture

Static Strength and Fracture
Stress Concentration Factors

Professor Darrell F. Socie
Department of Mechanical Science and Engineering
University of Illinois at Urbana-Champaign
2011 Darrell Socie, All Rights Reserved
Fatigue and Fracture
( Basic Course )
Static Strength and Fracture 2011 Darrell Socie, All Rights Reserved 1 of 106
Fracture Mechanics
Approximate Stress Intensity Factors
Ductile vs. Brittle Fracture
Stress Concentration
Load flow lines
Circular Notch
o
o
o
o
u
a
r
o
r
t
ru
o
u
o
r
o
u
t
ru
Stresses
u
|
|
.
|
\
|
|
.
|
\
|
|
.
|
\
|
+

+
|
|
.
|
\
|
|
.
|
\
|
+
=
o
o
2 cos 4 3 1
2
1
1
2
1
2 4 2
a
r
a
r
a
r
r
u
|
|
.
|
\
|
|
.
|
\
|
+

|
|
.
|
\
|
|
.
|
\
|
+
+
=
o
o
u
2 cos 3 1
2
1
1
2
1
4 2
a
r
a
r
u
|
|
.
|
\
|
|
.
|
\
|
+
|
.
|
\
|

=
o
t
u
2 sin 2 3 1
2
1
2 4
a
r
a
r
r
Independent of size, dependant only on r/a
Stress Distribution
For tension = 0 and u = 90
0
1
2
3
0 1 2 3 4
s
t
r
e
s
s
o
o
r
o
o
u
o
o
o o u
a
r
r
a
Stress Ratio Effects
-4
-3
-2
-1
0
1
2
3
4
30 60 90 120 150 180
Angle
o
u
o
= 1
= 0
= -1
o
o
o
o
stresses around the circumference of a hole
Elliptical Notches
a
b a
K
T
2
2 1 =
+ =
2a
2b
Sharp Notch:
high K
T
high gradient
Blunt Notch:
low K
T
low gradient
s
t
r
e
s
s
K
T
K
T
Plane Stress Plane Strain
thick plate
thin plate
plane stress o
z
= 0 c
z
= 0 plane strain o
z
= 0 c
z
= 0
Thick or Thin ?
Plane strain
Plane stress
Transverse Strains
Longitudinal Tensile Strain
T
r
a
n
s
v
e
r
s
e

C
o
m
p
r
e
s
s
i
o
n

S
t
r
a
i
n
0 0.002 0.004 0.006 0.008 0.010 0.012
0.001
0.002
0.003
0.004
0.005
40 mm
20 mm
10 mm
5 mm
Thickness
100
x
z
y
v = 0.3
v = 0.5
25 D
Notch Stresses
t c
x
c
z
o
x
o
z
7 0.01 -0.005 63.5 0
15 0.01 -0.003 70.6 14.1
30 0.01 -0.002 73.0 21.8
50 0.01 -0.001 75.1 29.3
x
z
y
Fracture Surfaces
Fracture Surfaces
Stress or Strain Control?
elastic
material
plastic
zone
Elastic material surrounding
the plastic zone forces the
displacements to be compatible,
I.e. no gaps form in the structure.
Boundary conditions acting on the
plastic zone boundary are
displacements. Strains are the
first derivative of displacement
Define K
o
and K
c
S , e
o , c
Define: nominal stress, S
nominal strain, e
notch stress, o
notch strain, c
Stress concentration
Strain concentration
S
K
o
=
o
e
K
c
=
c
K
o
and K
c
S
t
r
e
s
s

(
M
P
a
)
Strain
K
T
S
K
T
e
o
c
S
K
o
=
o
e
K
c
=
c
Stress and Strain Concentration
K
T
Nominal Stress
S
t
r
e
s
s
/
S
t
r
a
i
n

C
o
n
c
e
n
t
r
a
t
i
o
n
1 K
o
2
T
K K
c
First yielding
Notched Plate Experiments
1
2
1
1
2
1
10
1
4
1
2
1
2
Materials:
1018 Hot Rolled Steel
7075-T6 Aluminum
1/4 thick
1018 Stress-Strain Curve
0
100
200
300
400
500
0 0.1 0.2 0.3 0.4 0.5
Strain
true fracture strain, c
f
= 0.86
true fracture stress, o
f
= 770 MPa
7075-T6 Stress-Strain Curve
0
100
200
300
400
500
600
700
0 0.05 0.1 0.15 0.2
Strain
true fracture strain, c
f
= 0.23
true fracture stress, o
f
= 720 MPa
1018 Steel Test Data
0
20
40
60
80
100
0 2 4 6 8 10
l
o
a
d
,

k
N
displacement, mm
edge
diamond
slot
hole
0
20
40
60
80
100
0 2 4 6 8 10
7075-T6 Test Data
displacement, mm
l
o
a
d
,

k
N
edge
diamond
slot
hole
Failure of a Notched Plate
Failures from Stress Concentrations
Net section stresses
must be below the
flow stress
Notch strains must be
below the fracture strain
2D vs 3D
Plates and shells
2D stress state
Solids
3D stress state
Stress Concentration in a Bar
1
2
3
4
5
r
Axial, o
z
Tangential, o
u
Radial, o
r

o
o
o
Bridgeman Analysis (1943)
r
o
z
a
o
r
r
o
z
a
o
r
Elastic stress distribution Plastic stress distribution
o
ys
o
ys
t tan cons
2
r z
=
o o
= t
Stresses
(
|
|
.
|
\
|
+
+ o = o
a 2
r a 2 a
ln 1
2 2
o z
}
o t =
a
0
z z
dr r 2 P
|
|
.
|
\
|
+
|
.
|
\
|

+ o t =
2
a
1 ln
a
2
1 a P
flow
2
max
P
max
= A
net
o
flow
CF
CF constraint factor
Constraint Factors
0 1
1 1.21
2 1.38
4 1.64
8 1.73
20 2.63
2.96
CF a /
P
max
= A
net
o
flow
CF
Effect of Constraint
S
t
r
e
s
s
,

o
z
Strain, c
z
Increasing constraint
Higher strength and lower ductility
1
4
1
4
1
2
1
4
1
8
R
1
4
1
16
R 1 R
V notch
6
Notched Bars
0
5
10
15
20
25
30
0 1 2 3 4 5
1018 Steel Test Data
displacement, mm
V
1.6
3.2
25.4
7075-T6 Test Data
0
5
10
15
20
25
30
0 1 2 3 4 5
displacement, mm
V
1.6
3.2
25.4
Conclusion
Net section area, state of stress and material strength
control the failure load in a structure only in ductile
materials. In brittle materials, cracks will form before the
maximum load capacity of the structure is reached.
Fracture Mechanics
Fractures
1943 1972
Stress Concentration
2 a
+ =
a
2 1 K
T
a ~ 10
-3
for a crack
~ 10
-9
K
T
~ 2000
Fracture Mechanics Parameters
G strain energy release rate
K stress intensity factor
J J-integral
R crack growth resistance
Strain Energy Release Rate
o
o
2a
U = 0
o
o
Aa
AU = AI
strain energy surface energy
Plastic Energy Term
o
o
Aa
AU = AI + AP
strain energy surface energy + plastic energy
Strain Energy Release Rate, G
a
U
G
c
c
=
F x
internal strain energy = external work
x F
2
1
U=
F
x
a
Strain Energy Release Rate, G
a
U
t
1
G
A
A
=
F x
F
x
a + Aa
a + Aa
a
AU
t
G is the energy per unit crack area
needed to extend a crack
Stress Intensity Factor, K
r
u
(
u u
u
t
= o
2
3
sin
2
sin 1
2
cos
r 2
K
x
(
u u
+
u
t
= o
2
3
sin
2
sin 1
2
cos
r 2
K
y
2
3
cos
2
sin
2
cos
r 2
K
xy
u u u
t
= t
(
u
+
v +
v u
t
=
2
sin 2 1
1
3
2
cos
2
r
G 2
K
u
2
(
u
+
v +
v u
t
=
2
cos 2 1
1
3
2
sin
2
r
G 2
K
v
2
x
u
x
c
c
= c
x
v
y
c
c
= c
x
v
y
u
xy
c
c
+
c
c
=
Design Philosophy
Stress < Strength
Stress Intensity < Fracture Toughness
o < o
y
K < K
Ic
Two cracks with the same K will have the same behavior
Fracture Toughness
|
.
|
\
|
t o =
w
a
f a K
IC
fracture toughness
operating stresses
flaw size
flaw shape
K and G
E
K
G
2
=
( )
E
K 1
G
2 2
v
=
plane stress
plane strain
Elastic-Plastic Stress Field
o
y
small scale yielding
plastic zone
2r
p
(
u u
+
u
t
= o
2
3
sin
2
sin 1
2
cos
* r 2
K
y
r
r*
Critical Crack Sizes
2
f
IC
critical
K 1
a
|
|
.
|
\
|
o t
=
What would the critical crack size be in a
standard tensile test ?
Fracture Toughness
From M F Ashby, Materials Selection in Mechanical Design, 1999, pg 431
Measuring Fracture Toughness
displacement
f
o
r
c
e
www.enduratec.com
Thickness Effects
From Wilhem Fracture Mechanics Guidelines for Aircraft Structural Applications AFFDL-TR-69-111
Plastic Zone Size
plane stress
plane strain
2
ys
p
K
2
1
r
|
|
.
|
\
|
o t
=
2
ys
p
K
6
1
r
|
|
.
|
\
|
o t
=
3D Plastic Zone
plane stress
plane strain
Fracture Surfaces
Thickness Requirements
0
20
40
60
80
100
0 5 10 15 20 25
thickness, mm
f
r
a
c
t
u
r
e

t
o
u
g
h
n
e
s
s
,

M
P
a

\
m
K
Ic
2
ys
c
K
5 . 2 t
|
|
.
|
\
|
o
>
Size Requirements
p
2
ys
r 50
K
5 . 2 a , a W , t ~
|
|
.
|
\
|
o
>
o
ys
K
Ic
t, mm
2024- T3 345 44 40.7
7075 -T6 495 25 6.4
Ti-6Al-4V 910 105 33.3
Ti-6Al-4V 1035 55 7.1
4340 860 99 33.1
4340 1510 60 3.9
17-7 PH 1435 77 7.2
52100 2070 14 0.1
Strength, Toughness, Flaw Size
0
10
20
30
40
50
60
70
80
1400 1500 1600 1700 1800 1900 2000 2100
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Yield Strength, MPa
F
r
a
c
t
u
r
e

T
o
u
g
h
n
e
s
s
,

M
P
a

\
m
F
l
a
w

S
i
z
e
,

m
m
0.5C-Ni-Cr-Mo steel
0.4
0.8
1.2
1.6
2.0
2.4
2.8
3.2
y s
o = o
2
ys
o
= o
Silver Bridge
Collapse, Wearne, P. TV Books, NY 1999
Source
Eyebar
12 wide
2 thickness
12
6
Material Properties
o
u
= 100 ksi
o
y
= 75 ksi
Working stress 50 ksi
CVN = 2.6 ft-lb at 32 F
CVN = 8.6 ft-lb at 165 F
Fracture Toughness
) lb ft , in psi ( ) CVN ( 2
E
K
2
3
2
IC
=
Barsom-Rolfe
) lb ft ( CVN 5 . 15 K
IC
= Corten-Sailors
) lb ft ( CVN 35 . 9 K
65 . 1
IC
=
Roberts-Newton
Barsom-Rolfe
in ksi 9 . 15 K
IC
=
Corten-Sailors
in ksi 0 . 25 K
IC
=
Roberts-Newton in ksi 2 . 45 K
IC
=
Average 28.7
Critical Crack Size
Assume a corner crack
( ) a
2
12 . 1 K
2
IC
t
t
o =
Let o = o
y
a ~ 0.073 inches
Let o = 50 a ~ 0.163 inches
Modern Aircraft Materials
Bucci et. al., Need for New Materials in Aging Aircraft Structures Journa of Aircraft, Vol. 37, 2000, 122-129
Summary
Both stress and flaw size govern fracture
|
.
|
\
|
t o >
W
a
f a K
Ic
Fracture Mechanics
Stress Intensity Factors
Analytical
Theory of elasticity
Numerical
Finite element
Experimental
Compliance
Handbook
Approximate
a
M M
K
t s
t o
u
=
M
s
free surface effects
M
t
back surface effects
u crack shape effects
M
s
free surface effects
M
s
= 1.12
a
b
2a
c
0
1
2
3
4
5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
M
t
back surface effects
a
b
b 2
a
tan
a
b 2
M
t
t
t
=
M
t
a / b
u crack shape effects
0
1
2
3
0 0.1 0.2 0.3 0.4 0.5
Q
c 2
a
2
2
|
.
|
\
|
t
Q = u
2
2
2 /
0
2 2
c
a
1 k
d sin k 1 Q
|
.
|
\
|
=
| | =
}
t
2c
a
c a
c
a
464 . 1 1 Q
65 . 1
s
|
.
|
\
|
+ ~
Edge Cracked Plate in Tension
|
|
|
|
.
|
\
|
t
t
+ +
t
t
=
|
.
|
\
|
b 2
a
cos
)
b 2
a
sin 1 ( 37 . 0
b
a
02 . 2 752 . 0
b 2
a
tan
a
b 2
b
a
F
3
Edge Cracked Plate in Bending
|
|
|
|
.
|
\
|
t
t
+
t
t
=
|
.
|
\
|
b 2
a
cos
)
b 2
a
sin 1 ( 199 . 0 923 . 0
b 2
a
tan
a
b 2
b
a
F
4
Tension and Bending
0
2
4
6
8
10
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
|
.
|
\
|
b
a
F
a / b
bending
tension
Boundary Conditions
0
1
2
3
4
0 0.2 0.4 0.6 0.8 1
uniform stress
uniform displacement
|
.
|
\
|
b
a
F
a / b
Handbook
Handbook
Stress Intensity Factors Handbook
Y. Murakami Editor, Pergamon Press
Useful approximations
a
2
) 12 . 1 ( K
2
t
t
o =
Two free edges
Semicircular shape
Corner crack
a
a
Crack Shape
a
a 71 . 0 a
2
12 . 1 K t o = t
t
o =
a 12 . 1 K t o =
Through crack
Semielliptical crack
Superposition
tension + bending
( ) ( )
( ) ( )
bending tension total
ij
total
ij
bending tension
ij
ij
bending
ij
tension
ij
K K K
f
r 2
K
f
r 2
K K
f
r 2
K
f
r 2
K
+ =
u
t
= u
t
+
= o
u
t
+ u
t
= o
Crack tip stresses:
Stress Gradients
N
o
m
i
n
a
l

S
t
r
e
s
s
x
a
3
2
3
1
12 . 1 K
tip crack average
t
|
.
|
\
|
o + o ~
Pressure Vessel
P
t
r P
= o
t
r P
= o
a 1
t
r
P K t
|
.
|
\
|
+ =
a P a
t
r P
K t + t =
Cracks at Notches
D
a
a D + a
K
t
S
S
S
a << D a >> D
0 0.1 0.2 0.3 0.4 0.5 0.6
1.0
0
3.0
2.0
D
a
D S
K
a S K K
t
t =
( ) a D S K + t =
Cracks at Holes
20 1 1
22
Once a crack reaches 10% of the hole radius,
it behaves as if the hole was part of the crack
Summary
|
.
|
\
|
t o >
W
a
f a K
Ic
o ~ o
ys
/
2
a ~ 0.1 mm - 100 mm
2 1 ~
W
a
f
|
.
|
\
|
Fracture Mechanics
Fracture Behavior
LEFM
EPFM
Collapse
Failure Analysis Diagram
Ic
K
K
f low
o
o
1
1
LEFM
EPFM
Collapse
Plastic Collapse
2W
2a
B
P
P
f low
B ) a W ( 2
P
o <
B W 2
P
S=
Nominal stress
|
.
|
\
|
o =
W
a
1 S
flow
Fracture
Ic
K
W
a
f a S =
|
.
|
\
|
t
2W
2a
B
S
B W 2
P
S=
|
.
|
\
|
t
=
W
a
f W
W
a
K
S
Ic
Fracture vs. Collapse
|
.
|
\
|
t
=
|
.
|
\
|
o
W
a
f W
w
a
K
W
a
1
Ic
flow
|
.
|
\
|
t
|
.
|
\
|
=
o W
a
f W
w
a
W
a
1
K
flow
Ic
Fracture and collapse equally likely
Material Properties
o
ys
K
Ic
1020 250 200 0.800
2024-T3 345 44 0.128
7075-T6 495 25 0.051
Ti-6Al-4V 910 105 0.115
Ti-6Al-4V 1035 55 0.053
4340 860 99 0.115
4340 1510 60 0.040
17-7 PH 1435 77 0.054
52100 2070 14 0.007
o
ys
K
Ic
Fracture Diagram
0
0.5
1
1.5
2
0 0.2 0.4 0.6 0.8 1
W = 1m
m 1
K
f low
Ic
=
o
m 1 . 0
K
f low
Ic
=
o
m 5 . 0
K
f low
Ic
=
o
a / W
f low
S
o
Fracture Diagram
0
0.5
1
1.5
2
0 0.2 0.4 0.6 0.8 1
W = 1m
m 5 . 0
K
f low
Ic
=
o
W = 0.1m
a / W
f low
S
o
Fracture vs. Collapse
W 2
a
tan
a
W 2
W
a
W
a
1
W
K
flow
Ic
t
t
t
|
.
|
\
|
=
o
Fracture Diagram
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
Plastic Collapse
Fracture
W
K
f low
c
o
a / W
small flaws
high stresses
large flaws
low stresses
Typical Stress Concentration
2
T
K
T
K
Stress distribution Strain distribution
elastic
failure
Stress and Strain Concentration
K
T
Nominal Stress
S
t
r
e
s
s
/
S
t
r
a
i
n

C
o
n
c
e
n
t
r
a
t
i
o
n
1 K
o
2
T
K K
c
First yielding
Failure Diagram Ductile Material
0 1
a/w
ys
2
T f
K c = c
2
T
f net
max
K
E A
P
c
=
fully plastic
c
f
is large
net flow max
A P o =
strength limited
Strength limit is reached before cracking at the notch
Failure Diagram Brittle Material
0 1
a/w
ductility limited
ys T f
K c = c
T
f net
max
K
E A
P
c
=
elastic
c
f
is small
net flow max
A P o =
Cracks form at the notch before the limit load is reached
Cracks at Notches
D
a
a D + a
K
t
S
S
S
a << D a >> D
Cracks at Holes
20 1 1
22
Once a crack reaches 10% of the hole radius,
it behaves as if the hole was part of the crack
Notch Fracture
r 1 . 0 K 12 . 1 K
T ys c
t o =
For K
T
= 3 and r = 10 mm
18 . 0
K
ys
c
>
o
to avoid fracture from the notch
What ratio of strength to toughness is
needed to avoid fracture?
Material Properties
o
ys
K
Ic
1020 250 200 0.800
2024-T3 345 44 0.128
7075-T6 495 25 0.051
Ti-6Al-4V 910 105 0.115
Ti-6Al-4V 1035 55 0.053
4340 860 99 0.115
4340 1510 60 0.040
17-7 PH 1435 77 0.054
52100 2070 14 0.007
o
ys
K
Ic
Summary
Fracture is a likely failure mode for all higher
strength materials
Fracture is even more likely at stress concentrators
Fatigue and Fracture
( Basic Course )

2 Static Strength and Fracture

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2 Static Strength and Fracture

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Static Strength and Fracture

Stress Concentration Factors

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