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FEA-Crack Software
Ted L Anderson, Ph.D., P.E.March 7, 2007
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Company Overview
Structural Reliability Technology (SRT) founded in 1995.SRT acquired by Quest Reliability, LLC on January 1, 2007.Approximately 50 engineers worldwide, including 15 with Ph.D. degrees.Office locations:• Boulder, CO• Houston, TX• Wellington, New Zealand• Brisbane, Australia
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Company Overview(cont.)
Broad range of services:• Fitness-for-service & fracture mechanics• Stress analysis• Failure analysis• Software development
Diverse group of clients• Power• Chemical, petroleum, petrochemical• Pipeline• Rail transportation• Defense• Aerospace
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FEA-Crack Overview
Pre- and post-processor for 3D crack problems.Front end to Abaqus, ANSYS, and Warp3D.Drop-down list of component/geometry choices (20 & counting).User-defined geometry option for cases not covered in list.Crack growth modeling• Re-meshing• Element deletion• Node release• Cohesive elements
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Partial List of FEA-Crack Customers
NASA Marshall Space Flight CenterLos Alamos National LaboratoryExxonMobilShellBPChevronWestinghouseSouthwest Research InstituteRolls RoyceBoeingDominion Engineering
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Crack Meshing
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Crack Tip Region
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Crack Front Profile
Straight line crack front
“Thumbnail” custom crack front
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Meshing Controls
Coarse mesh
Refined Mesh
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Variable Crack Dimensions
Shallow Crack
Deep Crack
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Post ProcessingJ-Integral Plot
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Post ProcessingStress Intensity Results
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The J-IntegralPath-Independent Line Integral
i ij jT nσ=
ii
uJ wdy T dsxΓ
∂⎛ ⎞= −⎜ ⎟∂⎝ ⎠∫
Where Γ is an arbitrary counter-clockwise path around the crack tip and:
0
ij
ij ijw dε
σ ε= ∫
Γds
x
y
For 2D problems, the line integral can be converted to an area integral for evaluation with finite element analysis.
In 3D, a surface integral is converted to a volume integral.
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The J-IntegralNonlinear Energy Release Rate
dU
Displacement
Load P
∆
( )21IKJ
Eν−
=
In the limit of linear elastic material behavior, J = G and:
assuming plane strain conditions.
1 dUJB da ∆
⎛ ⎞= − ⎜ ⎟⎝ ⎠
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KI from J Example 1Griffith Plate
0.96
0.98
1
1.02
1.04
1 2 3 4 5
1/4 - Point Node inFirst Element Ring
Mid-Point Node inFirst Element Ring
Contour #
Through Thickness Crack in Flat PlateSubject to a Uniform Crack Face Pressure
2D Plane Strain Analysis
JKaσ π∞
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KI from J Example 23D Griffith Plate
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KI from Crack Opening Displacement
Similar expressions exist for Modes II and II
( )20
21 limI y
r
EK urπ θ π
ν →
⎡ ⎤= =⎢ ⎥− ⎣ ⎦
x
y r
θuy
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Displacement Extrapolation
θ = π
KI
r
2
21
yEurπ
ν−
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Displacement Method ExampleGriffith Plate
0.9
0.95
1
1.05
0 0.02 0.04 0.06 0.08 0.1
Baseline Model2x Refinement8x Refinement
( )uIK
aσ π∞
Through Thickness Crack in Flat PlateUniform Crack Face Pressure
2D Plane Strain Analysisθ = π
r/a
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FEA-Crack Validation Methods
Compare results to known cases (e.g. buried crack in infinite solid).Compare results from 2 different methods (e.g. K from J versus K from displacement).Compare results with published solutions.Compare results from different finite element solvers (e.g. Abaqus versus ANSYS).Perform mesh refinement convergence study.
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Benchmark Example
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Incorporation of Weld Residual StressesMap Residual Stresses with Crack Closed
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Incorporating Weld Residual StressesAllow Crack to Open
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User-Defined GeometryInitial Uncracked Mesh
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User-Defined GeometryRemove 6-Sided Primitive
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User-Defined GeometryInsert New 6-Sided Primitive with Crack
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User-Defined GeometryFEA Results
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Crack Growth in a Finite Element ModelExamples of Available Methods
Re-Meshing (Elastic Only)Element Deletion (e.g. Gurson-TvergaardPlasticity)Node ReleaseCohesive Elements
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Crack Growth in a Finite Element ModelMesh Types
Focused Mesh• Remeshing
Cell Mesh• Element Deletion• Node Release• Cohesive Elements
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Cell Mesh for Crack Growth Analysis
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Remeshing ExampleSurface Crack in Wind Turbine Rotor
Small Initial Surface Crack
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Dynamic Simulation of Charpy Test
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Collision/Fracture Simulation
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New FEA-Crack DevelopmentFunded by EPRI
Add custom-shape surface crack with K-driven crack growth,where da/dt (or da/dN) is computed at each node point along the crack front.Impose non-uniform temperature distribution in weld to mimic residual stresses.Add rigid contact surface to crack symmetry plane to model crack closure.Add additional functionality to custom through crack.Add “nozzle to safe end” geometry to drop-down list.
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Custom Surface Crack Input
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Custom Surface Crack Mesh