Task 6 - Safety Review and Licensing

On the Job Training on Stress Analysis

F.M. with Finite Element analysis - Different calculation

techniques + Numerical examples (ANSYS Workbench) 1/2

Davide Mazzini – Ciro Santus

Pisa (Italy)
June 15 – July 14, 2015
 FM parameters with Finite Element method

Content

• Different FE techniques

• ANSYS Workbench
- Crack geometry element mesh preparation

- KI(II,III) and J calculation

- Examples

• ANSYS Apdl
- The quarter point technique

- Examples

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 FM parameters computed with FE

Stress Intensity Factor(s)SIFs: K I , K II , K III

Stress parameters

Energy release rate: G

Energy parameters

Contour integral: J

Crack Mouth Opening Displacement CMOD

Deformation parameters
Crack Tip Opening Displacment CTOD

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 Three different loading modes for a crack

Fracture Mechanic parameters for the three modes

Mode I: Mode II: Mode III:

Opening In-plane shear Out-of-plane shear

K I2  K II2 K II2I
J 
E 2G

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 ANSYS different calculation techniques

ANSYS help:
 ui 
J    w dy  Ti ds 

x 

d
J 
dA
K I , K II , K III
J  K I , K II , K III
J  K I , K II , K III
(only if 2/3are zero, or ratios are known)

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 ANSYS Apdl

KCALC command

Quarter point technique:

The mid-side node is shifted at ¼ of the
element size to reproduce the displacement
derivative singularity.
ANSYS Help
From displacement to (elastic) KI(II,III)
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 ANSYS Apdl

KCALC command

M. Beghini, C. Santus. "An application of the weight function technique to inclined surface cracks under rolling contact fatigue, assessment
and parametric analysis". Engineering Fracture Mechanics. Vol.98, pp.153–168, 2013. DOI: 10.1016/j.engfracmech.2012.10.024

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 ANSYS Workbench

CINT command options

Crack front (ANSYS Wb =>

ANSYS classic)
Mid-side nodes
not shifted at ¼

Overlapped but
distinct nodes
‘Spiderweb’ mesh

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 ANSYS Workbench

CINT command options

Plane elements (not for Workbench)

Workbench default element

thus VCCT is not available

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 ANSYS Workbench

CINT command options

Postprocessing menu: only available CINT for J and CINT for K1(2,3)

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 ANSYS Workbench

CINT command options

CINT,SIFS

Volume (not path) integration, with

the virtual load technique to
distinguish K1, K2 and K3

This way the SIFs are obtained as

integration, rather than point
displacement as KCALC

A coarser mesh is enough for an

accurate solution

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 ANSYS Workbench

How to introduce a crack

Introduce the ‘Fracture’ module

into the Modeler

(this feature is available only

since the 14.5 ANSYS version,
the current version is 16.0)

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 ANSYS Workbench

How to introduce a crack

1. It is possible to (easily) introduce a crack starting from a solid uncracked

body and automatically generate the spiderweb mesh distribution at the
crack front
(Worth noting: this is for a semielliptical crack only)

2. Alternatively a (generic) crack front can be prepared in advance and

introduced as the crack front

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 ANSYS Workbench

How to introduce a crack

Mesh preparation

Usually Hexahedrons are to be preferred than Tetrahedrons

Here Tets are necessary for mesh continuity

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 ANSYS Workbench

Mesh preparation A strong local refinement is required

The Sphere of Influence tool is
recommended

New local Coordinate

System, both for mesh and
for crack position/ orientation

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 ANSYS Workbench

Crack position and orientation

The crack semi-elliptical ‘center’
is coincident with Coordinate
System origin point

X axis has to be inward the

component to be cracked and it
should be perpendicular

If not the crack plane is going to

be perpendicular to the surface
anyway
The Crack is identified X-Z axes define the crack plane,
by its dedicated thus Y is the vertical direction
Coordinate System

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 ANSYS Workbench

Mesh and geometry parameters of the crack

Buffer Zone

Dir. Z
Dir. X

Preview of
the crack to
be introduced

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 ANSYS Workbench

The introduction of the crack is just a matter of mesh

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 ANSYS Workbench

Spiderweb mesh parameters

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 ANSYS Workbench

Half-space surface crack basic example

Same commands
for loads and
constraints

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 ANSYS Workbench

Postprocessing, K1(2,3) and J along the crack front

Curvilinear
coordinate

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 ANSYS Workbench

Tabular values
Contour integration results

Contours
1
23
45
6

2 ≈3 ≈4…
1

Usually the first is the less accurate,

while the others show very similar
results

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 ANSYS Workbench

Validation example 1 (half space)

a  2 mm  t
c  2 mm
 0  100 MPa ( i  0, i  1...5)

a  2 mm  t
c  2 mm
 0  100 MPa
Laham'sSIFs Handbook:
ANSYS Wb:
K I (A)  165 MPa mm  5.22 MPa m
K I (A)  162 MPa mm  5.12 MPa m
(diff.%  1.9 %)
K I (B)  177 MPa mm  5.60 MPa m K I (B)  179MPa mm  5.68 MPa m
(diff.%  1.4 %)
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 ANSYS Workbench

Validation example 2 (pipe)

Ri  50 mm
t  10 mm
a  2 mm
c  4 mm

 0  50 MPa ( i   bg  0, i  1...5)

Laham's SIFs Handbook:

K I (A)  112MPa mm  3.53MPa m
ANSYS Wb:
(diff.%  2.3%)
K I (A)  109 MPa mm
 3.45 MPa m Pisa, June 15 – July 14, 2015 24
 ANSYS Workbench

Exercise 1: Introduce an inclined

Calculate the three SIFs. crack on the specimen
Which on is expected to be zero? surface

Torque
M T  10 N m

45
a  1mm
c  1mm

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 ANSYS Workbench

Exercise 2:
Verify the ASTM standard CT
specimen formula for KI
B
W
P

How to manage a
semi-elliptical crack
  a /W for this case?
P 2 
KI  (0.886  4.64  13.32 2  14.72 3  5.64 4 )
B W (1   )
3/2

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 ANSYS Workbench

Exercise 2:

Corner blends Almost straight

portion of a semi-
elliptical crack

P  10 kN a  22.5 mm, W  60 mm, B  12 mm

P 2 
KI  (0.886  4.64  13.32 2  14.72 3  5.64 4 )  699 MPa mm
B W (1   )
3/2

K I (ANSYS)  782 MPa mm Large percentage

%  12 % difference

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 ANSYS Workbench

How to introduce a crack – Pre-Meshed Crack

1. It is possible to (easily) introduce a crack starting from a solid uncracked

body and automatically generate the spiderweb mesh distribution at the
crack front
(Worth noting: this is for a semielliptical crack only)

2. Alternatively a (generic) crack front can be prepared in advance and

introduced as the crack front

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 ANSYS Workbench

Pre-Meshed Crack, CT specimen example

A crack (almost zero angle) is initially

introduced on the CAD model

Almost crack
geometry Notch
region

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 ANSYS Workbench

Pre-Meshed Crack, CT specimen example

Hexahedrons mesh
is to be preferred in
this case

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 ANSYS Workbench

Pre-Meshed Crack, CT specimen example

Named selection:
Crack front

The edge is then converted

into the nodes

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 ANSYS Workbench

Pre-Meshed Crack, CT specimen example

The associated
coordinate
system is placed
at one edge of
the crack
Crack orientation,
not crack actual
shape and size

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 ANSYS Workbench

Pre-Meshed Crack, CT specimen example

Usual
(self-equilibrated)
loading
Stress distribution
Plane stress

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 ANSYS Workbench

Pre-Meshed Crack, inaccurate results

P  10 kN a  30 mm, W  60 mm, B  12 mm
P 2 
KI  (0.886  4.64  13.32 2  14.72 3  5.64 4 )  971MPa mm
B W (1   )
3/2

K I (ANSYS)  480 MPa mm

J (ANSYS)  negative ??

Maybe this technique is

intended for future
development…

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