Chapter-2 Linear Elastic Fracture Mechanics INTRODUCTION TO LEFM • • • • Concepts of fracture mechanics before 1960; applicable only to materials that obey Hooke’s law Since 1960; fracture mechanics theories developed to account for various types of nonlinear material behavior (plasticity and viscoplasticity) as well as dynamic effects All of these more recent results; extensions of Linear Elastic Fracture Mechanics (LEFM) This chapter • • • Energy, and stress intensity approaches to linear fracture mechanics Early work of Inglis and Griffith Introduction to energy release rate and stress intensity parameters. • Later chapters about LEFM • • • • Chapter 7 and Chapter 8; laboratory testing of linear elastic materials Chapter 9; application of LEFM to structures Chapter 10 and chapter 11; apply LEFM to fatigue crack propagation and environmental cracking, Chapter 12; numerical methods for computing stress intensity factor and energy release rate. ATOMIC VIEW OF FRACTURE • • • • • A material fractures when sufficient stress and work are applied at atomic level to break bonds that hold atoms together Bond strength is supplied by attractive forces between atoms Figure 2.1; schematic plots of potential energy and force vs separation distance between atoms Equilibrium spacing occurs where potential energy is at a minimum A tensile force is required to increase separation distance from the equilibrium value • This force must exceed the cohesive force to sever the bond completely Figure 2.1 Potential energy and force as a function of atomic separation. At equilibrium separation xo potential energy is minimized, and attractive and repelling forces are balanced • It is of interest to estimate cohesive strength at the atomic level; it can be shown that cohesive stress σ0 is given by E : Young’s modulus or x0: atomic spacing (approximately) • • Surface energy can be estimated as Surface energy per unit area γs is equal to one-half of fracture energy because two surfaces are created when a material fractures. Therefore STRESS CONCENTRATION EFFECT OF FLAWS • • • • Previous section; theoretical cohesive strength of a material is approximately E / π However; experimental fracture strengths for brittle materials are typically three or four orders of magnitude below this value Experiments by Leonardo da Vinci, Griffith, and others; discrepancy between actual strengths of brittle materials and theoretical estimates was due to flaws in these materials Fracture cannot occur unless stress at atomic level exceeds cohesive strength of material • • • First quantitative evidence for stress concentration effect of flaws; Inglis who analyzed elliptical holes in flat plates Elliptical hole 2a long by 2b wide with an applied stress perpendicular to major axis of ellipse; Fig 2.2 He assumed that hole was not influenced by plate boundary • Plate width >> 2a, and plate height >> 2b • Stress at tip of major axis (Point A) is given by • Ratio σA/σ defined as stress concentration factor kt • When a >> b, hole is circular and kt = 3.0; well-known result in most strength-of-materials textbooks Figure 2.2 Potential energy and force as a function of atomic separation. At equilibrium separation xo potential energy is minimized, and attractive and repelling forces are balanced • • • As major axis a increases relative to minor axis b, elliptical hole begins to take on the appearance of a sharp crack; better to use radius of curvature ρ When a >> b Good approximation for stress concentration due to a notch that is not elliptical except at the tip • • • • • • • Previous equation; infinite stress at tip of sharp crack; ρ = 0 Major concern; no material can withstand infinite stress Material with sharp crack should theoretically fail even at near-zero load This paradox motivated Griffith to develop fracture theory based on stress rather than local stress Infinitely sharp crack is not possible in real materials Metals deform plastically; blunting of sharp crack In the absence of plastic deformation, minimum crack tip radius is of the order of atomic radius Substituting ρ = 0 in previous equation • • Assuming that fracture occurs when σA = σc, and combining previous equations • • Last equation; rough estimate of failure stress Continuum assumption of Inglis is not valid at atomic level Gehlen and Kanninen; similar result from numerical simulation of a crack in a 2D lattice; discrete atoms connected by nonlinear springs • α is a constant of the order of unity, based on atomic forcedisplacement law. GRIFFITH ENERGY BALANCE • • • • • • First law of thermodynamics System goes from non-equilibrium to equilibrium state; decrease in energy 1920; Griffith applied this idea to crack formation Plate with crack of length 2a, subjected to constant stress σ (Fig) Assume that plate width >> 2a; with plane stress valid Note that, plates are same if a >> b For crack to grow, sufficient potential energy needed in plate to overcome surface energy of material Griffith energy balance for incremental increase in crack area dA under equilibrium conditions: • • • • • • Serious distinction between crack area and surface area Crack area; projected area of crack; 2aB in current example Crack includes two matching surfaces; so crack area is 2A • Griffith approach also applicable to other crack shapes Fracture stress for penny-shaped flaw (circular) embedded in material: a is crack radius and υ is Poisson’s ratio Comparison with Critical Stress Criterion • • • • • Griffith model based on global energy balance For fracture to occur, energy stored in structure must be sufficient to overcome surface energy of material. Fracture involves breaking of bonds Stress on atomic level must be equal to cohesive stress This local stress intensification can be provided by flaws in material Similarity between stress-concentration and energy-balance equations for is obvious • • Predictions of global fracture stress from Griffith approach and local stress criterion differ by less than 40%. The two approaches are consistent with one another for the case of sharp crack in an ideally brittle solid • • Apparent contradiction when the crack-tip radius is significantly greater than atomic spacing. Griffith model implies that fracture stress is insensitive to ρ Inglis stress analysis; σf must vary with 1/√ρ for σc to be attained at notch tip Consider a crack with ρ = 5x10-6 m Crack would appear sharp under a light microscope, but ρ would be 4 orders of magnitude larger than atomic spacing in a typical crystalline solid Local stress approach would predict global fracture strength 100 times larger than Griffith equation Actual material behavior is somewhere between these extremes • • • • • • • This apparent discrepancy can be resolved by viewing fracture as a nucleation and growth process When global stress and crack size satisfy Griffith energy criterion, there is sufficient thermodynamic driving force for crack growth, but fracture must first be nucleated Nucleation of fracture can come from a number of sources, eg Microscopic surface roughness at tip of flaw could produce sufficient local stress concentration to nucleate failure Another possibility; Fig 2.5; sharp microcrack near tip of a macroscopic flaw with a finite notch radius Macroscopic crack magnifies stress in the vicinity of microcrack, which propagates when it satisfies Griffith equation Microcrack links with large flaw, which then propagates if Griffith criterion is satisfied globally This type of mechanism controls cleavage fracture in ferritic steels; Chapter 5 • • • • • • • Figure 2.5 A sharp microcrack at the tip of a macroscopic crack Modified Griffith Equation • Griffith equation is valid only for ideally brittle solids Griffith obtained good agreement with experimental fracture strength of glass However, Griffith equation severely underestimates fracture strength of metals Irwin and Orowan independently modified Griffith expression to account for materials that are capable of plastic flow • • • γp is plastic work per unit area of surface created and is typically much larger than γs. • • • Although Irwin and Orowan originally derived their equation for metals, it is possible to generalize Griffith model for any type of energy dissipation wf is fracture energy, which could include plastic, viscoelastic, or viscoplastic effects, depending on the material Fig 2.6; various types of material behavior and corresponding fracture energy Word of caution in the case of materials that exhibit nonlinear deformation Griffith model applies only to linear elastic material behavior; global behavior of structure must be elastic Any nonlinear effects, such as plasticity, must be confined to a small region near crack tip. • • Figure 2.6 Crack propagation in various types of materials, with corresponding fracture energy: (a) ideally brittle material (b) quasi-brittle elastic-plastic material (c) brittle material with crack meandering and branching Example 2.1 A flat plate made from a brittle material contains a macroscopic throughthickness crack with half length a1 and notch tip radius ρ. A sharp penny-shaped microcrack with radius a2 is located near tip of the larger flaw; Fig 2.5. Estimate minimum size of microcrack required to cause failure in the plate when Griffith equation is satisfied by the global stress and a1. Example 2.1 A flat plate made from a brittle material contains a macroscopic throughthickness crack with half length a1 and notch tip radius ρ. A sharp penny-shaped microcrack with radius a2 is located near tip of the larger flaw; Fig 2.5. Estimate minimum size of microcrack required to cause failure in the plate when Griffith equation is satisfied by the global stress and a1. Solution Nominal stress at failure is obtained by substituting a1 into Eq 2.19. Stress in the vicinity of the microcrack can be estimated from Eq 2.11, which is set equal to Griffith criterion for the penny-shaped microcrack (Eq 2.20) Solving for a2 gives ENERGY RELEASE RATE • • • • 1956; Irwin energy approach for fracture; essentially equivalent to Griffith model, but more convenient for solving engineering problems Energy release rate G; measure of energy available for an increment of crack extension G is rate of change in potential energy with crack area; Also called crack extension force or crack driving force Energy release rate for a wide plate in plane stress with a crack of length 2a (Fig 2.3) is given by • • Crack extension occurs when G reaches a critical value • where G c is a measure of fracture toughness of the material • It is convenient at this point to introduce compliance; inverse of plate stiffness • It can be shown that • where P is applied load, and B is plate thickness Example 2.2 Determine the energy release rate for a double cantilever beam (DCB) specimen; Fig 2.9 Figure 2.9 Double cantilever beam (DCB) specimen INSTABILITY AND R CURVE • • • • • • Crack extension occurs when G = 2wf This crack growth may be stable or unstable, depending on how G and wf vary with crack size Convenient to replace 2wf with R, material resistance to crack extension Plot of R vs crack extension; resistance curve or R curve Corresponding plot of G vs crack extension; driving force curve Wide plate with through crack of initial length 2a0 (Fig 2.3) At a fixed remote stress σ, energy release rate varies linearly with crack size Fig 2.10; schematic driving force vs R curves for two types of material behavior • • INSTABILITY AND R CURVE • • • • • • Crack extension occurs when G = 2wf This crack growth may be stable or unstable, depending on how G and wf vary with crack size Convenient to replace 2wf with R, material resistance to crack extension Plot of R vs crack extension; resistance curve or R curve Corresponding plot of G vs crack extension; driving force curve Wide plate with through crack of initial length 2a0 (Fig 2.3) At a fixed remote stress σ, energy release rate varies linearly with crack size Fig 2.10; schematic driving force vs R curves for two types of material behavior • • Figure 2.10 Schematic driving force vs R curve diagrams (a) flat R curve and (b) rising R curve • • First case, Fig 2.10(a); flat R curve Material resistance is constant with crack growth Crack is stable when stress is σ1 Fracture occurs when stress reaches σ2; crack propagation is unstable because driving force increases with crack growth, but material resistance remains constant Fig 2.10(b); material with a rising R curve Crack grows a small amount when stress reaches σ2, but cannot grow further unless stress increases When stress is fixed at σ2, driving force increases at a slower rate than R Stable crack growth continues as stress increases to σ3 Finally, when stress reaches σ4, driving force curve is tangent to the R curve; plate is unstable with further crack growth because rate of change in driving force exceeds slope of the R curve • • • • • • • • Conditions for stable crack growth: and • Unstable crack growth occurs when Reasons for R Curve Shape • • • Shape of R curve depends on material behavior and, to a lesser extent, on configuration of cracked structure R curve for an ideally brittle material is flat When nonlinear material behavior accompanies fracture, R curve can take on a variety of shapes Ductile fracture in metals usually results in a rising R curve If cracked body is infinite (plastic zone is small compared to relevant dimensions of the body), R curve becomes flat with further growth Some materials can display a falling R curve When a metal fails by cleavage, R curve would be relatively flat if crack growth were stable However, cleavage propagation is normally unstable • • • • • Load Control vs Displacement Control • • Stability of crack growth depends on the rate of change in G; second derivative of potential energy Driving force G is the same for both load control and displacement control However, rate of change of driving force curve depends on how the structure is loaded Displacement control tends to be more stable than load control With some configurations, driving force actually decreases with crack growth in displacement control When R curve is determined experimentally, specimen is usually tested in displacement control, Since most of the common test specimen geometries exhibit falling driving force curves in displacement control, it is possible to obtain a significant amount of stable crack growth • • • • • Example 2.3 Evaluate the relative stability of a DCB specimen (Fig 2.9) in load control and displacement control STRESS ANALYSIS OF CRACKS Figure 2.13 Definition of coordinate axis ahead of a crack tip. The z direction is normal to the page Stress Intensity Factor • • • Each mode of loading produces singularity at the crack tip It is convenient to represent it by the stress intensity factor K There are three types of loading that a crack can experience; Fig 2.14 Mode I loading; principal load is applied normal to crack plane; tends to open the crack Mode II; in-plane shear loading; tends to slide one crack face with respect to the other Mode III; out-of-plane shear A cracked body can be loaded in any one of these modes, or a combination of two or three modes It is usually given a subscript to denote the mode of loading; Fig 2.14; KI, KII, KIII • • • • • Figure 2.14 The three modes of loading that can be applied to a crack Relationship between K and Global Behavior • • • • • Consider a through crack in an infinite plate subjected to a remote tensile stress; Fig 2.3 Remote stress σ is perpendicular to the crack plane; loading is pure Mode I Linear elastic bodies must undergo proportional stressing Thus crack-tip stresses must be proportional to remote stress It can be shown that relationship between KI and global conditions has the form • Amplitude of crack-tip singularity for this configuration is proportional to the remote stress and square root of crack size Figure 2.3 • A related solution is that for a semi-infinite plate with an edge crack; Fig 2.16; infinite height, finite width This configuration can be obtained by slicing the plate in Fig 2.3 through the middle of the crack Stress intensity factor for edge crack can be shown to be given by • • • 12% increase for edge crack is caused by different boundary conditions at the free edge Figure 2.16 Edge crack in a semi-infinite plate subjected to a remote tensile stress • • Penny-shaped crack in an infinite medium (Fig 2.4) is another configuration for which a closed-form solution for KI exists: where a is the crack radius More general case of an elliptical or semielliptical flaw is illustrated in Fig 2.19 Two length dimensions are needed to characterize the crack size: 2c and 2a, major and minor axes of the ellipse • Figure 2.4 A penny-shaped (circular) crack embedded in a solid object subjected to a remote tensile stress Figure 2.19 Mode I stress intensity factors for elliptical and semielliptical cracks. These solutions are valid only as long as crack is small compared to plate dimensions and a << c Q: flaw shape parameter s: surface correction factor Effect of Finite Size • • • Closed-form K solution generally for crack of simple shape (rectangle or ellipse) in infinite plate Crack dimensions are small compared to plate size As crack size increases, or as plate dimensions decrease, outer boundaries begin to exert an influence on crack tip Closed-form K solution is usually not possible Cracked plate subject to remote tensile stress; Fig 2.20 Effect of finite width on crack tip stress distribution, represented by lines of force Local stress is proportional to spacing between lines of force Infinite plate; line of force at a distance W from crack centerline has force components in x and y directions If plate width is restricted to 2W, force must be zero on free edge; this boundary condition causes the lines of force to be compressed; higher stress intensification at crack tip • • • • • • Figure 2.20 Stress concentration effects due to a through crack in finite and infinite width plates: (a) infinite plate and (b) finite plate. • Mode I stress intensity factor for finite width is given by K I a f (a / W ) • • • • Stress intensity approaches infinite-plate value as a/W approaches zero More accurate solutions for through crack in finite plate have been obtained from finite-element analysis; one such solution is Table 2.4 lists stress intensity solutions for several common configurations These KI solutions are plotted in Fig 2.23 Several handbooks are devoted solely to stress intensity solutions • Figure 2.23 Plot of stress intensity solutions from Table 2.4 • Although stress intensity solutions are given in a variety of forms, K can always be related to the through crack using an appropriate correction factor σ: characteristic stress a: characteristic crack dimension Y: dimensionless constant that depends on crack and plate geometry and mode of loading Example 2.4 Show that KI solution for the single edge notched tensile (SENT) panel reduces to Equation (2.42) when a << W. Example 2.4 Show that KI solution for the single edge notched tensile (SENT) panel reduces to Equation (2.42) when a << W. Solution Equation 2.42 All of the KI expressions in Table 2.4 are of the form P: applied force B: plate thickness f(a/W): dimensionless function Principle of Superposition • • • Linear elastic materials; similar individual components of stress, strain, and displacement are additive Similarly, stress intensity factors are additive as long as mode of loading is consistent Principle of superposition allows stress intensity solutions for complex configurations to be built from simple cases for which solutions are well established Example An edge-cracked panel (Table 2.4) subject to combined membrane (axial) loading Pm and three-point bending Pb Solution Both types of loading impose pure Mode I conditions, so KI values can be added where fm and fb are geometry correction factors for membrane and bending loading, respectively Listed in Table 2.4 and plotted in Fig 2.23 RELATIONSHIP BETWEEN K AND G • Two parameters that describe the behavior of cracks Energy release rate G: quantifies net change in potential energy that accompanies an increment of crack extension Stress intensity factor K: characterizes stresses, strains, and displacements near the crack tip Energy release rate describes global behavior, while K is a local parameter For linear elastic materials, K and G are uniquely related • • • • • • • • Through crack in an infinite plate subject to a uniform tensile stress (Fig 2.3), G and KI are given by Equation (2.24) and (2.41) Combining these two equations leads to the following relationship between G and KI for plane stress For plane strain conditions, E must be replaced by E/(1-ν2). Notation in this book CRACK-TIP PLASTICITY • • • • • • Linear elastic stress analysis of sharp cracks predicts infinite stresses at the crack tip In real materials; stresses at crack tip are finite because crack-tip radius must be finite Elastic stress analysis becomes increasingly inaccurate as inelastic region at crack tip grows Simple corrections to linear elastic fracture mechanics (LEFM) are available for moderate crack-tip yielding Size of crack-tip-yielding zone can be estimated by two methods Irwin approach; elastic stress analysis is used to estimate elasticplastic boundary Strip-yield model Both approaches lead to simple corrections for crack-tip yielding • • Figure Examination of crack tip plasticity using Thermoelastic Stress Analysis (TSA); phase difference may be used to size the plastic zone Figure Maps of (a)TSA signal and (b) phase difference, and (c) line plots through the crack tip of an Aluminium 2024 CT specimen of fatigue crack length = 31.2 mm with mean load = 1000N; load amplitude = 500N; frequency 30Hz. (d) Shape of the plastic zone found using the phase difference map is superimposed on the line plot Irwin Approach • • • • Fig 2.13; on the crack plane (θ = 0), normal stress σyy in a linear elastic material is given by As a first approximation, we can assume that boundary between elastic and plastic behavior occurs when above stresses satisfy a yield criterion Plane stress conditions; yielding occurs when σyy = σYS, uniaxial yield strength of material Substituting into above equation and solving for r gives a first-order estimate of plastic zone size YS KI 2r • • • • This simple analysis is not strictly correct It is based on an elastic crack-tip solution When yielding occurs, plastic zone must increase in size A simple force balance leads to a second-order estimate of plastic zone size which is twice as large as the first-order estimate; Fig 2.29 • Irwin accounted for softer material in the plastic zone by defining an effective crack length that is slightly longer than the actual crack size where ry for plane stress is given on previous slide Figure 2.29 First-order and second-order estimates of plastic zone size (ry and rp). Crosshatched area represents load that must be redistributed, resulting in a larger plastic zone. • In plane strain • Effective stress intensity is obtained by • An iterative solution is usually required to solve for Keff K is first determined in the absence of a plasticity correction First-order estimate of aeff is then obtained from equation (2.64) or (2.68) This is used to estimate Keff A new aeff is computed from Keff estimate Process is repeated until successive Keff estimates converge • • • • • • In certain cases, this iterative procedure is unnecessary because a closed-form solution is possible Examples Effective Mode I stress intensity factor for a through crack in an infinite plate in plane stress is given by • • • For embedded elliptical flaw Qeff is the effective flaw shape parameter Not recommend to use Irwin plastic zone adjustment for practical applications; chapter 9 gives recommended approaches for handling plasticity effects Strip Yield Model • • • • • Strip-yield model was first proposed by Dugdale and Barenblatt They assumed a long, slender plastic zone at the crack tip in a nonhardening material in plane stress for a through crack in an infinite plate Assuming a crack of length 2a + 2ρ ρ is length of plastic zone Closure stress equal to σYS applied at each crack tip This strip-yield model is a classical application of the principle of superposition For σ << σYS, it yields • • • Note similarity between this equation (2.79) and earlier eq (2.66) • • 1/π = 0.318, and π/8 = 0.392; Irwin and strip-yield approaches predict similar plastic zone sizes Burdekin and Stone obtained a more realistic estimate of Keff for the strip-yield model Comparison of Plastic Zone Corrections • • • • • • • Figure 2.33; comparison between a pure LEFM analysis (Eq 2.41), Irwin correction for plane stress (Eq 2.70), and strip-yield correction on stress intensity (Eq 2.81) Effective stress intensity, nondimensionalized by σYS√πa, is plotted against normalized stress LEFM analysis predicts a linear relationship between K and stress Both Irwin and strip-yield corrections deviate from LEFM theory at stresses greater than 0.5 σYS The two plasticity corrections agree with each other up to approximately 0.85 σYS In 1970s, strip-yield model was used to derive a practical methodology for assessing fracture in structural components Approach called failure assessment diagram (FAD) Higher course; described in Chapter 9 • Figure 2.33 Comparison of plastic zone corrections for a through crack in plane strain Figure 2.34 Crack-tip plastic zone shapes estimated from elastic solutions (Table 2.1 and Table 2.3) and von Mises yield criterion for Mode I loading End Chapter-2