Engineering Fracture Mechanics 72 (2005) 2174–2185

www.elsevier.com/locate/engfracmech

Advantages of the J-integral approach for calculating

stress intensity factors when using the commercial
finite element software ABAQUS
S. Courtin a, C. Gardin a,*
, G. Bézine a, H. Ben Hadj Hamouda b

a
LMPM, UMR CNRS 6617, ENSMA, BP 40109, F-86961 Futuroscope-Chasseneuil Cedex, France
b
RENAULT, DM, CTR, 67 rue des Bons Raisins, F-92508 Rueil Malmaison Cedex, France

Received 19 July 2004; received in revised form 2 November 2004; accepted 7 February 2005
Available online 27 April 2005

Abstract

A predictive method for remaining component lifetime evaluation consists in integrating the crack growth law of the
material considered in a finite element step-by-step process. So, as part of a linear elastic fracture mechanics analysis,
the determination of the stress intensity factor distribution is a crucial point. The aim of the present work is to test sev-
eral existing numerical techniques reported in the literature. Both the crack opening displacement extrapolation method
and the J-integral approach are applied in 2D and 3D ABAQUS finite element models. The results obtained by these
various means on CT specimens and cracked round bars are in good agreement with those found in the literature. Nev-
ertheless, since the knowledge of the field near the crack tip is not required in the energetic method, the J-integral cal-
culations seem to be a good technique to deal with the fatigue growth of general cracks.

2005 Elsevier Ltd. All rights reserved.

Keywords: Fatigue crack growth; Finite element method; Stress intensity factor; J-integral; Round bar

1. Introduction

The major source of failure of structural components is fatigue crack growth. In the past, the S–N curves
were the only engineering tools, and crack propagation was not considered to predict lifetime. Nevertheless,

*
Corresponding author. Tel.: +33 5 49 49 82 35; fax: +33 5 49 49 82 38.
E-mail address: catherine.gardin@lmpm.ensma.fr (C. Gardin).

0013-7944/$ - see front matter
2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.engfracmech.2005.02.003
 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185 2175

at present, studying crack growth behaviour has been made possible by the linear elastic fracture mechanics
(LEFM) and the prediction of remaining lifetime of components is accessible. This is of great practical
importance in order to know if a part can be still used or must be replaced.
A predictive method consists in integrating the crack growth law. Two kinds of data are required: first,
the experimental Paris crack growth law of the considered material and second, the stress intensity factor
(SIF) distribution along the crack front. The Paris relation is quite easy to obtain on the contrary to SIF.
Many numerical methods using finite element analysis have been developed to obtain SIF values [1].
The most investigated case deals with cylindrical components such as shafts, because they have many
engineering applications. Most failures are experimentally due to surface cracks. Therefore, many numer-
ical investigations on surface cracks in round bars subjected to tension and bending are reported in the lit-
erature [2–11]. The opening mechanism (Mode I) is the favourite subject, and we also study this case in the
present work. In order to reduce the calculations, the authors, in the literature, prefer to assume that
the crack front shape does not change during the fatigue growth process. Thus, circular or elliptical arcs
are the most frequently used shapes [2–7].
To sum up, using the commercial finite element code ABAQUS, the present work aims to test several
existing numerical techniques for SIF evaluation in order to determine the most adequate one to study
the fatigue growth of general cracks. First, literature work are reported and some numerical methods devel-
oped. Then, we focus on a CT specimen and a cracked round bar.

2. Numerical simulation techniques

2.1. Crack growth simulation process

The LEFM allows studying crack growth behaviour. The predictive method is based on the Paris crack
growth law which gives the expression between the fatigue crack growth rate da/dN and the range of the
SIF, DK, during the cyclic load
da m
¼ CðDKÞ ð1Þ
dN
where the two values of C and m can be obtained experimentally. Therefore, the fatigue crack growth rate
da/dN is a function of the single parameter DK. As a consequence, many authors use this kind of numerical
crack growth simulation process [5,12]

• The specimen with an initial crack is simulated in a finite element model. Assumptions are made con-
cerning the crack shape and dimensions. Then, the SIF distribution is calculated along this first crack
front.
• Where this parameter is the highest, the value of the maximum incremented crack growth da is chosen.
Thus, the only unknown quantity to calculate in the Paris law becomes the number of cycles dN asso-
ciated with the crack growth da.
• Then, on the whole initial crack front, dN being known, the crack growth da can be calculated using the
Paris law again. Thus, a new crack front is entirely redesigned (see Fig. 1). One can notice that the
growth is chosen perpendicular to the initial front.
• On this new crack front, similar steps can be performed again and the crack growth can be studied with a
step-by-step process.

It is obvious that the SIF is the essential parameter of the predictive method. Its determination is crucial.
That is why many methods have been developed in order to obtain this quantity.
2176 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185

new crack front

dai

initial crack front

Fig. 1. Crack growth simulation process.

2.2. Numerical methods for stress intensity factor evaluation

The most common method consists in the extrapolation of the displacements in the vicinity of the crack
tip, and uses analytical expressions given by the LEFM [1]. Let us consider a two dimensional meshed body
in a cylindrical reference centred on the crack tip (see Fig. 2).
Then, it can be shown that
8 9
> h 3h rffiffiffiffiffiffi

< ð2j  1Þ cos  cos > = 2p ur
KI 2 2 ¼ 4G ð2Þ
> h
: ð2j þ 1Þ sin  sin 3h >
; r uh
2 2
E 3t
where G ¼ 2ð1þtÞ is the shear modulus and j ¼ 1þt in plane stress state, j = 3  4t in plane strain state.
Therefore, the SIF values can be obtained with a finite element analysis giving the displacement field in
the vicinity of the crack. The expressions (2) can be used at any node along a radial line emanating from the
crack tip. In the literature, many authors prefer to work on the crack faces [5–12]. In the heart of the body,
as one can assume a plane strain state, the expression (2) on the crack lips (h = p) is the following:
rffiffiffiffiffiffi
E 2p
KI ¼ 2
uh ð3Þ
4ð1  t Þ r
Thus, it is possible to plot the K-values against the radial distance r from the crack tip (see Fig. 3). Then, by
discarding the results for nodal points close to the crack tip, the solution can be extrapolated to r = 0.

Fig. 2. 2D crack tip in a cylindrical reference [1].

 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185 2177

Fig. 3. Obtaining K by the displacement extrapolation method [1].

A way to improve the numerical results in the vicinity of the crack tip is to use singular finite elements
introduced by Barsoum [13]. One side of the element must be collapsed in order to have its three nodes just
in one geometric point. Then, by shifting the mid-side nodes to quarter-positions, the square-root stress
singularity predicted by the LEFM is exactly simulated (see Fig. 4).
Thus, many authors apply the relationship (3) just on the first node on the crack face and, by using fine
meshes, consider that the distance r is very close to 0 and obtain the value of the SIF [5–12].
However, this method may be quite difficult and costly to use. Indeed, this kind of elements is not always
in the library of the finite element codes. ANSYS has this possibility [4] but ABAQUS, which is used in this
paper, has not. The user must, manually, collapse the finite elements and relocate the mid-side nodes. This
task may be easy in 2D. Unfortunately, with 3D models, when the crack front is curved, for instance, and
subjected to great changes during the fatigue growth process, lots of problems occur. Besides, Lin and Smith
have also shown that this method requires necessarily an orthogonal mesh in the vicinity of the crack [12].
Taking these difficulties into account, it could be interesting to study other possibilities to obtain the SIF
distribution. The second kind of methods reported in the literature is an energetic one. It consists in deter-
mining the J-integral values. This quantity, introduced by Rice [14], is originally a two-dimensional line
integral. Considering a path C which encloses the crack tip and with initial and final points which lie on
the two crack faces, this integral can characterize the energy release associated with the crack growth [1]
Z 
od
J¼ U dy  t ds ð4Þ
C ox
where U is the strain energy density, t the traction vector on a plane defined by the outward normal, d the
displacement vector and ds the element of arc along the path C.
Using the divergence theorem, the J-integral can also be generalized to 3D by considering a tubular sur-
face around the crack front. This domain integral method is used to evaluate contour integrals automatically

Fig. 4. Quarter-point finite elements in 2D (a) and 3D (b) [9].

2178 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185

in the finite element code ABAQUS [15]. Therefore, the SIF distribution is accessible by determining the J-
integral values along the crack front since, as part of a linear analysis, J-integral can be directly related to the
SIF [1]
1=2
8GJ
KI ¼ ð5Þ
1þj
Let us note that there is also considerable work reported in the literature on the equivalent domain integral
(EDI) method to calculate the strain energy release and hence the stress intensity factors [16,17].
Further, one can notice that, theoretically, this integral quantity is path independent. As a consequence,
the J-integral values can be obtained quite far from the crack tip. Fine meshes and collapsed quarter-point
finite elements are not necessarily required in order to exactly simulate the singularity. Besides, non-ortho-
gonal meshes have no effect on the results [12].
To sum up, two kinds of methods are reported in the literature. The most widely used is the displacement
extrapolation technique with collapsed quarter-point finite elements. However, using the code ABAQUS,
another one seems to be attractive: the J-integral approach. The present work is the opportunity to evaluate
these both techniques.

3. Numerical calculations of stress intensity factors in CT specimens

Now, a CT specimen is examined since there exist different empirical expressions giving K. For example
[18]
P a
K ¼ pffiffiffiffi f ð6Þ
B w w
with
a a  a 2  a 3  a 4  a 5  a 6
f ¼ 4.55  40.32 þ 414.7  1698 þ 3781  4287 þ 2017
w w w w w w w
where P is the applied load, B and w are the CT specimen thickness and characteristic length and a is the
crack length.
The coefficients in these various K-expressions may differ a little bit according to the authors. Neverthe-
less, the obtained results remain very similar.
p In the present work, with the values chosen for P, B, w and a,
the SIF ranges from 985 to 1015 MPa mm. In order to check the validity of the finite element method
results, these empirical values of SIF are considered as a reference.

3.1. The use of singular Barsoum elements

As is discussed previously, most authors use singular finite elements to exactly simulate the displacement
field at the crack tip. In the present work, such finite elements are used in a simplified 2D approach, with the
assumption of plane strain state (see Fig. 5). Then, the displacements are calculated by the FEM and, p by
considering the first free node on the crack face, the use of the expression (3) leads to K = 1015 MPa mm.

3.2. Displacement extrapolation method

For more general studies (3D ones for example) with the ABAQUS software, it would be very difficult
and costly to use singular finite elements at the crack tip. Then, it is necessary to choose methods that
do not require the knowledge of the displacement fields near the crack tip. Therefore, the displacement
 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185 2179

Fig. 5. Mesh of the CT specimen, including singular finite elements at the crack tip.

extrapolation method is tested here in both 2D (under plane strain state) and 3D approaches, and with two
different mesh refinements (see Fig. 6).
An example of the obtained curve representing the stress intensity factor K versus the distance r from the
crack tip is given in Fig. 7. It can be observed that, in the singularity zone at the crack tip, the obtained K-
values are far from the reference ones, as no Barsoum element has been introduced. However, for values of

Fig. 6. Various meshes of the CT specimen: 2D and 3D, and two different mesh refinements.
2180 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185

1100

stress intensity factor (MPa.mm1/2)

1050

1000 y = 41.64x + 998.94

950

900

K calculations
850
domain interpolated
800
linear interpolation
750
0 0.2 0.4 0.6 0.8 1 1.2
distance to the crack tip r (mm)

Fig. 7. Extrapolation curve of the stress intensity factor, in the fine two-dimensional mesh.

Fig. 8. Various nodes taken into account for SIF evaluation.

p
r higher than 0.4 mm, SIF can be obtained with a linear extrapolation: 999 MPa mm. Similar calculations
have been performed on the 3D finite element model with the two mesh refinements. The results are dis-
cussed later.
At present, let us remember that this method can be applied to any radial line emanating from the crack
tip. In order to derive maximum benefit from the possibilities of this technique, the K-values have been also
evaluated, with the 3D coarse mesh, for nodes perpendicular to the crack face (see Fig. 8). In this new con-
figuration, the expressions (2) give
pffiffiffi rffiffiffiffiffiffi
2E 2p
KI ¼ ur ð7Þ
ð3  4tÞð1 þ tÞ r
The obtained curves are given in Fig. 9. Again, a linear domain can be easily highlighted and
p an extrapo-
lation to r = 0 can be done. For this coarse mesh, the calculatedpK-values are 1048 MPa mm when the
nodes on the crack face are taken into account, and 1057 MPa mm when the nodes perpendicular to
the crack face are considered.

3.3. J-integral approach

Now, the J-integral technique is tested with the 3D coarse mesh (see Fig. 6). Here, the aim is to find the
way to study general cracks where the meshes can not be always very fine.
 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185 2181

1200

stress intensity factor (MPa.mm1/2)

y = 25.75x + 1057.2
1100

y = 22.11x + 1047.6
1000

900

800

on the crack face

700
perpendicular to the crack face
600
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
distance to the crack tip r (mm)

Fig. 9. Extrapolation curves of K in the 3D model, for the coarse mesh.

These calculations have been performed with the finite element code ABAQUS. Provided that the user
has defined the nodes of the crack front, the software automatically finds the contours in order to carry out
the energetic analysis (see Fig. 10), and then returns a SIF value for each contour. This integral is theoret-
ically path independent. However, it is widely accepted that the first contour does not provide good results
because of numerical singularities [15]. Therefore, the SIFs have been obtained from the second contour or
even further from the crack tip, in order to get a convergent value. The results are discussed in next section.

3.4. Comparison of the various methods

To sum up, in the present work, we have calculated the SIF in the symmetry plane of a CT specimen,
where a plane strain state can be assumed. 2D and 3D meshes have been modelled and various techniques
have been used. All the results are reported in Table 1.
Like in the literature, singular finite elements exhibit good results. Nevertheless, as is discussed previ-
ously, their use by employing ABAQUS may require manual changes in the mesh and seems to be quite
difficult and costly in the case of general 3D cracks. Further, one can notice that the displacement extrap-
olation method provides also excellent results. A 3D effect is observed since the plane strain assumption is
not exactly simulated in the 3D model but the K-values are very close. Besides, this technique could be eas-
ily adapted since it can be used both in the crack plane and in the plane perpendicular to the crack plane.
Moreover, it does not require an excessive mesh refinement since the results obtained with the 3D coarse
mesh are pin good agreement. The J-integral method has the same advantages since it provides
1060 MPa mm as K-value with the 3D coarse mesh.

Fig. 10. Various contours for the calculation of the J-integral with the 3D coarse mesh.
2182 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185

Table 1
p
Comparison of the K-values (in MPa mm) obtained with the various method
Empirical 2D 3D 3D coarse mesh
expressions
Singular Displacement Displacement Displacement extrapolation J-integral
elements extrapolation extrapolation In the crack plane Perpendicular to the
crack plane
985–1015 1015 999 1045 1046 1057 1060

As a conclusion, the various methods of displacement extrapolation and J-integral analysis have pro-
vided excellent results. This enables us to get free from the singular finite elements which could be difficult
to use in a 3D context with the finite element code ABAQUS. In next section, these techniques are tested in
a more complex problem: a cracked round bar.

4. Numerical calculations of stress intensity factors in round bars

The aim of the present work is to determine the most adequate method for SIF evaluation in the case of
general crack shapes. However, to check the validity of the reported techniques, examples which have been
already investigated in the literature are considered. Let us assume that the crack is semi-elliptical (see Fig.
11). The crack shape is defined by the lengths a and b which are, respectively, 6.282 and 10.118 mm.
The cracked round bar is numerically loaded under three point bending. To be able to compare the pres-
ent results with the bibliographical ones, a dimensionless SIF is introduced
KI
K I ¼ pffiffiffiffiffiffi ð8Þ
r pa
where KI is the real SIF, r the applied stress and a the depth of the crack.
Most authors report the SIF values only at two characteristic points: M and E (see Fig. 11). M corre-
sponds to the centre of the crack front, on the symmetry plane of the sample, and E is the intersection be-
tween the crack front and the external surface. However, it is well known that near this second region, the
SIF calculations are made difficult by numerical problems [2,3,5,11]. That is why, in the present work, as in
the literature, the results given at the external surface actually refer to a point very close to it and the plane
strain state is assumed.
The finite element analysis is carried out by using 20-node quadratic brick finite elements using reduced
integration (see Fig. 12). Both extrapolation techniques and J-integral method have been applied to calculate
the SIF distribution along the crack front. However, as is discussed previously, no singular finite element has
been introduced in the mesh because this task is particularly complex with the tools at our disposal.

340 mm

d = 48 mm
a
M E

Fig. 11. Geometry of the semi-elliptical cracked round bar.

 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185 2183

Fig. 12. Three-dimensional model of the semi-elliptical cracked round bar.

The centre of the crack front (point M) is here chosen to compare the results of the various methods. The
results are reported in Table 2, and show that the obtained values are very close to each other. Nevertheless,
the J-integral approach is less difficult to perform by employing ABAQUS code.
Thus, the J-integral method results enable to valid the present work by the comparison with the litera-
ture results (see Table 3). The differences observed show the difficulty of getting SIF distribution. Using
ABAQUS, the energetic approach reveals a good efficiency. With great practical simplifications since no

Table 2
Comparison of the K I -values obtained with the various methods at the centre of the crack front
J-integral Displacement extrapolation Displacement extrapolation
method in the crack plane in the plane perpendicular
to the crack
K I at M 0.699 0.678 0.687

Table 3
Comparison between the present work and the literature for the semi-elliptical cracked shaft
Present Carpinteri and Shih and Couroneau and da Fonte and Raju and Shiratori et al.
work Brighenti [3] Chen [4] Royer [6] de Freitas [7] Newman [19] [20]
K I at M 0.699 0.748 0.718 0.700 0.734 0.750 0.690
K I at E 0.664 0.706 0.681 0.649 0.647 0.670 0.635

1
adimensional stress intensity factor

0.9
0.8
0.7
0.6
present work
0.5 Carpinteri & Brighenti [3]
0.4 Shih & Chen [4]
0.3 Couroneau & Royer [6]

0.2 da Fonte & de Freitas [7]

Raju & Newman [19]
0.1
Shiratori & al. [20]
0
0 1 2 3 4 5 6 7 8 9 10
distance from the middle of the crack front (mm)

Fig. 13. Profile of the SIF along the semi-elliptical crack front.
2184 S. Courtin et al. / Engineering Fracture Mechanics 72 (2005) 2174–2185

singular element and orthogonal mesh are required, the obtained K-values are in the range of those re-
ported in the literature. Then, the profile of the SIF along the crack front is also easily accessible (see
Fig. 13).
One can note that the K-distribution is uniform along the crack front. The crack always attempts to
propagate towards an iso-K configuration [9]. Therefore, the crack shape chosen here may correspond to
experimental observations.

5. Conclusions

In order to predict component remaining lifetime, the determination of the SIF distribution is a crucial
point. Thanks to the development of finite element techniques, this task is now accessible by a LEFM anal-
ysis. The present work has discussed the major methods reported in the literature. Most of the authors use
the extrapolation of the displacements in the vicinity of the crack tip and model the latter with singular
Barsoum elements. Semi-elliptical or circular crack shapes are often considered, and the SIF calculations
are carried out at two or three characteristic points. However, this technique may be complex in the case
of the fatigue growth of general cracks. The displacement extrapolation technique requires, for instance,
orthogonal meshes, and singular elements are not automatically accessible in all finite element codes.
Using ABAQUS, the present work has highlighted another possibility to determine the SIF distribution:
the energetic method which consists in calculating the J-integral values on rings surrounding the crack tip.
CT specimens in 2D and 3D models have been herein considered. The comparison between different meth-
ods with or without the singular elements has shown good agreement. The case of cracked round bars has
also been treated and again, the various methods have provided nearly the same results in good agreement
with the ones reported in the literature. Therefore, the validity of the energetic approach is checked.
Moreover, the J-integral method shows some advantages compared to the displacement extrapolation
one. First of all, this method may be applied automatically with the ABAQUS code. Then, the knowledge
of the exact displacement field in the vicinity of the crack tip is not required, and the use of singular finite
elements is not essential anymore. Besides, non-orthogonal meshes are without effect on the SIF calcula-
tions. The user has just to be sure that a convergent value is obtained on the different rings.
As a consequence, this approach seems to be particularly suitable to deal with the fatigue growth of gen-
eral cracks. It will be the way, for the present authors, to study notched round bars and to evaluate the
influence of superficial compressive residual stresses in the fillet of these shafts.

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