Stress Intensity Factor

Stress Intensity Factor
• Key parameter for crack growth analysis

• Fracture failure related to Kc
• Fatigue crack growth rate related to cyclic SIF ∆K
da/dN ~ F(∆K)
• Stress corrosion crack growth rate related to SIF
da/dt ~ F(K)
• Many K solutions publically available
• Well established techniques available for obtaining
new results
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1
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Crack Tip Stress Field
Can prove elastic stresses at crack tip

•
are square root singular

2
Determination of K
• In theory, any method capable of resolving crack
tip stresses or displacement can be used to obtain
K
At ϴ = 0
Find dimensionless β factor

3
Corner, Surface and Embedded Cracks
• Crack plane perpendicular to remote stress
W
Remote Stress
Corner crack Surface crack Embedded crack
Crack plane
W
Surface crack
Remote Stress
2R (Hole) Corner crack
4
Embedded Elliptical Crack
• Stress intensity factor is of three-dimensional nature
• Cracks may start from internal material defects or
from external surfaces
• K varies along crack perimeter
• Cracks may grow faster at certain locations than
others -> result in change in shape

5
Embedded Elliptical Crack y
Remote Stress
ϕ
2a
x
2c
Remote Stress

6
Embedded Elliptical Crack β
2a
x
2c
empirical equation available for a/c ≤ 1

7
Circular Crack
•a=c
• Note K is constant for all angles, so circular cracks

are “stable” shape for embedded cracks loaded in
remote tension
8
Noncircular Crack
• a < c for ϕ = 0,

9
Various Methods to Develop SIF
• Engineering estimates of K (8.3)
• Linear superposition (8.4)
• Experimental methods (8.5)
• Analytical and numerical methods (8.6)

10
Example – Estimate K
• It is often possible to estimate or bound K with existing
solution for similar problems
• Can existing short crack and long crack stress intensity
factor solutions estimate cracked hole problem?
2R

11
Estimate K
• Edge crack
σ
• Center crack
2a

12
• Assume edge crack model apply to short crack
• Assume center crack model apply to long crack
• Compare with exact solution
Kt = 3σ0
σ0
Short crack
W a
2R
a
2aeffective (2R+a)
Long crack
σ0
13
Short crack
Estimated beta = 3.36
Long crack
3.5
2.5
• SIF can be reasonably
Beta
2 Exact Beta solution
1.5 Est. Short Crack Beta estimated using correct

1
Est. Long Crack Beta
assumptions
0.5
0
0 2 4 6
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14
Superposition of Bending & Tension SIF
M M
P P
P P
= +
P P
M M

15
Superposition Open & Loaded Holes
P
Hole with bypass

+ = and bearing loads

16
Sum of Crack Face Pressure Solutions
p(x/R)
• If stress status is known at crack face, use Section 8

Table 8.2 to calculate SIF
17
Example 8.3
•

18
Example 8.4 Coldworked Hole
•

19
Hole Cold-working
• Residual hoop stresses next to bore of hole
counteract stresses due to remote loading
Residual hoop stress

Sleeve in hole bore
Tensio
Tapered n
mandrel
Compression
Plastically
deformed hole

20
Cold-worked Holes
• Compressive residual hoop
stresses counteract remote
Residual hoop stress

applied loading
Original
• Significantly extended
fatigue life Final
• Increased hole expansion

lead to longer life
Compression
Plastically
deformed hole

21
Fatigue Life Improvement by Hole
Coldworking
• Residual stress produced by coldworking increases

fatigue life
• Reference: FTI product brochure
22
Experimental Methods
• Compliance calibration
• Crack Tip Opening measurement
• Fatigue crack growth rate calibration
• Fracture toughness calibration

23
Compliance Calibration
• G: strain energy release rate
• P: applied load
• a: crack length
• B: specimen thickness
• C: compliance
Plane strain Plane stress

24
Compliance Calibration
P
a=a1
Displacement ∆ a=a2
a=a3
a=a4
a=a5
C5
Displacement ∆
Compliance C
G
C4 G4
C3 G3
C2 dC/da G2
C1 G1
Crack length a AE 542 - C. Park - Copyright Material - Do Not Crack length a

25
Crack Tip Opening Measurement
• Measure crack tip displacements at point (r, ϴ)
• Interferometry
• Microscope
• Compute K from displacement relations
ϴ=π
2Uy
r

26
Fracture Toughness Method
• Fracture specimens with desired geometry
• Measure fracture stress and crack length
• Compute β with known fracture toughness Kc
• Kc from standard baseline tests with same material
thickness
• Problems
• Multiple specimens required
• Accuracy limited by crack tip plasticity

27
Fatigue Crack Growth Rate Method
• Conduct fatigue crack growth tests
• Measure da/dN in new geometry
• Back calculate ∆K using known da/dN ~ ∆K for
material
• Simple procedure
• Often significant scatter
• Crack closure may affect results

28
Fatigue Crack Growth Rate Method
Log da/dN
C
∆KThreshold
Log ∆K

29
Analytical & Numerical Methods
• Weight function
• Finite Element Methods
• Other numerical Methods

30
Weight Function Method
• General term calculated from known stress
intensity factor and displacement solution for one
loading
• Weight function then determines K for any other
loading of same geometry
Weight
Function
Case 1 Case 2

31
Finite Element Methods
• Most popular method for K analysis
• Many commercial codes to solve crack problems
• Most have special crack tip elements with built-in
singularity
• Various strategies to relate FEM data to K

32
SIF Development using FEM
•
r1 r2 r3 r4
KI
Obtained SIF
x x
x
x
x
x
Location r/a

33
SIF Development using FEM
•
Plane strain Plane stress

34
SIF Development using FEM (VCCT)
• Crack Closure Technique
• Run two FE analysis cases
(1) Before extension
(2) After extension
• Work ∆E required to close

the crack along one
element side can be
calculated as:
Reference: “Virtual crack closure technique: History, approach, and

applications”, Appl Mech Rev vol 57, no 2, March 2004
35
• “Modified” Crack Closure
Technique or “Virtual” Crack
Closure Technique
• Run only one FE analysis case
• Assume crack extension does not
significantly alter the state at the
crack tip
• Displacements behind the crack tip
at node on initial state are
approximately equal to the
displacements behind the crack tip
at propagated state
• Work ∆E required to close the
crack along one element side can
be calculated as:

36

37

38
Four node
Eight node

39

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41

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Stress Intensity Factor

• Key parameter for crack growth analysis

AE 542 - C. Park - Copyright Material - Do Not

Can prove elastic stresses at crack tip

AE 542 - C. Park - Copyright Material - Do Not

Find dimensionless β factor

AE 542 - C. Park - Copyright Material - Do Not

Corner crack Surface crack Embedded crack

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AE 542 - C. Park - Copyright Material - Do Not

empirical equation available for a/c ≤ 1

AE 542 - C. Park - Copyright Material - Do Not

• Note K is constant for all angles, so circular cracks

AE 542 - C. Park - Copyright Material - Do Not

AE 542 - C. Park - Copyright Material - Do Not

AE 542 - C. Park - Copyright Material - Do Not

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Estimated beta = 3.36

2 Exact Beta solution

1.5 Est. Short Crack Beta estimated using correct

AE 542 - C. Park - Copyright Material - Do Not

Hole with bypass

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• If stress status is known at crack face, use Section 8

AE 542 - C. Park - Copyright Material - Do Not

AE 542 - C. Park - Copyright Material - Do Not

Residual hoop stress

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Residual hoop stress

• Increased hole expansion

AE 542 - C. Park - Copyright Material - Do Not

• Residual stress produced by coldworking increases

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Plane strain Plane stress

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Crack length a AE 542 - C. Park - Copyright Material - Do Not Crack length a

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AE 542 - C. Park - Copyright Material - Do Not

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AE 542 - C. Park - Copyright Material - Do Not

AE 542 - C. Park - Copyright Material - Do Not

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• Work ∆E required to close

Reference: “Virtual crack closure technique: History, approach, and

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AE 542 - C. Park - Copyright Material - Do Not

AE 542 - C. Park - Copyright Material - Do Not

AE 542 - C. Park - Copyright Material - Do Not

AE 542 - C. Park - Copyright Material - Do Not

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