Finite Element Study of Structural Discontinuities

Finite Element Study of
Structural Discontinuities
Presentation Objectives
Discuss background of structural

discontinuities
Introduce the finite element method
Explain how to generate a finite element
model
Review previous work
Present new work
Discuss possibilities for future work
Answer questions
What is a Structural
Discontinuity?
A break or gap within a structural

component that alters its behavior
under load
Examples of Structural
Discontinuities
Holes: Often used to lighten an

aerospace structure or to rivet
components together
Cracks: Usually a result of material
imperfections or areas of high
stress
Concerns
Uniform loading of a square plate results in

a uniform stress distribution
Concerns
Holes alter the

stress distribution
and induce stress
concentrations.
Study of Mesh Refinement

EM 360 Fall 2002
Concerns
Stress concentrations at crack tips
Crack propagation
Possible Consequences
Stress fields around discontinuities can

interact with each other and cause
failure.
Cessna 402C Mishap Investigation, 1999
Solution Method
Structural discontinuity problems are

often very difficult to solve analytically,
sometimes impossible.
Our method is to use ABAQUS, a finite
element program.
The Finite Element Method

(FEM)
General technique
for constructing
approximate
solutions to
boundary value
problems

EM 360 Fall 2002
How to Generate a Finite

Element Model
An input file must be written

containing the following two parts:
Model Data: This portion defines the

geometry of the model and
material properties.
History Data: This portion defines how the
model will be loaded and what
values should be outputted.
Some Important Factors to

Consider
Boundary
Conditions
Load Type and
Directions
Mesh Refinement
EM 360, Fall 2002

Consider : Mesh Refinement
Petersons Stress Concentration Factors, 1997
11 Elements
1 Second
K=4.342
max
K= ____
Finite Element Study of Structural Discontinuities, 2003

67 Elements
1 second
K=4.41

211 Elements
1 second
K=4.47

823 Elements
2 seconds
K=4.512

Approx. 3000 Elements
4 seconds
K=4.517

Approx. 19000 Elements
21 seconds
K=4.520
Mesh Convergence Curve

4.54
4.52
4.5
4.48
4.46
Ktg
4.44
4.42
4.4
4.38
4.36
4.34
4.32
0
2000
4000
6000
8000
10000
12000
14000
16000
Number of Elements
Mesh Convergence
18000
20000
Computation Time
25
Computation Time (sec)
20
15
10
0
0
2000
4000
6000
8000
10000
12000
14000
16000
Number of Elements
Effect of Number of Elements on Compuation Time
18000
20000
Mesh Convergence
Refining a coarse finite element mesh

will result in a more accurate solution
at the cost of computation time.
Caveat and Approach
Just because a solution is obtained does not

necessarily mean it is correct. Therefore, it
is important to study the results and
compare your solution with a known,
correct solution.
Previous Work
Model 1
Previous Work
Model 1 (continued)
5
4.5
4
Ktg = max /
3.5
3
Ktg
2.5
2
1.5
ABAQUS
Peterson
0.5
0
0
0.1
0.2
0.3
0.4
0.5
d/H
Stress Concentration Factor (Model 1)
0.6
Previous Work
Model 2
Previous Work
Model 2 (continued)
3.5
Ktg = max / 1
2.5
Ktg
1.5
ABAQUS
0.5
Peterson
0
0
0.1
0.2
0.3
0.4
0.5
d/l
Stress Concentration Factor (Model 3)
0.6
0.7
New Work
Reduction of stress concentrations

from edges of holes
Finite element modeling of cracks
Reduction of crack stress intensity
factor
Reducing Stress
Concentrations from Holes
Method:
Add another hole to alleviate the stress
concentration.
Constant: Radius of original hole = 2 in

Tensile Load = 1 psi in horizontal
direction
Variables: R = radius of added hole

L = distance between
centers of holes
Reducing Stress
Reducing Stress
Reducing Stress
Reducing Stress
Reducing Stress
Conclusion:
Adding holes in a plane perpendicular
to the loading direction does not
reduce the stress concentration factor.
Reducing Stress
Reducing Stress
Reducing Stress
Reducing Stress
3.1
2.9
2.7
SCF
2.5
2.3
2.1
1.9
1.7
1.5
0
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1.8
R (in)
Variation of Stress Concentration Factor with Second Hole Radius

(L = 4 in)
Reducing Stress
3.2
3
SCF
2.8
2.6
2.4
2.2
2
0
0.5
1.5
R (in)

(L = 5 in)
2.5
Reducing Stress
2.9
2.7
SFC
2.5
2.3
2.1
1.9
1.7
1.5
0
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1.8
R (in)

(L = 7.50 in)
Reducing Stress
2.6
Optimal SFC
2.55
2.5
2.45
2.4
2.35
0
L (in)
Effect of Hole Spacing on Stress Concentration Factor
Reducing Stress
Conclusion:
Adding holes in a plane parallel to the
loading direction does reduce the
stress concentration factor.
Finite Element Analysis of

Cracks
Crack configuration models:
Tada The Stress Analysis of
Cracks Handbook
Model 1
Model 2
Model 3

Cracks
Crack Model 1 (Center Cracked Plate)

Cracks
Crack Model 2 (Edge Cracked Plate)

Cracks
Crack Model 3

Cracks
Tada, The Stress Analysis of Cracks Handbook
Crack Model 3

Crack Repair
Crack repair models:

Cracks
Center Cracked Plate with Stop Holes

Cracks
Center Cracked Plate with an Array of Holes Near the Crack Tip

Cracks
Patch Repair of Center Cracked Plate

Cracks
Arrester Repair of Center Cracked Plate

Cracks
2.9
2.8
2.7
K (psi-in
0.5
2.6
2.5
2.4
2.3
2.2
2.1
2
0
L (in)
Variation in Stress Intensity Factor with Arrester Strip Distance
Summary of Work
Completed This Semester
Used the FEM to determine how holes

and cracks affect stress distributions.
Devised a method to alleviate stress
concentrations around holes.
Investigated crack repair methods.
Possibilities for Future Work
Finite element modeling of structural

discontinuities under cyclic loading
Finite element modeling of structural
discontinuities in more complex structures
Adaptation of scripting feature in ABAQUS

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Finite Element Study of

Discuss background of structural

A break or gap within a structural

Holes: Often used to lighten an

Uniform loading of a square plate results in

Holes alter the

Study of Mesh Refinement

Stress concentrations at crack tips

Stress fields around discontinuities can

Cessna 402C Mishap Investigation, 1999

Structural discontinuity problems are

The Finite Element Method

Study of Mesh Refinement

How to Generate a Finite

An input file must be written

Model Data: This portion defines the

Some Important Factors to

Some Important Factors to

Petersons Stress Concentration Factors, 1997