Session2FractureControlAnalysisTools,MethodsandLessonsLearned Morfeo/Crack,adedicatedsolutionforindustrialdamagetolerantapproaches Authors: EricWyart(Cenaero),HenkCruyssen(DutchSpace),AmineGhouali(Snecma) Since2002,CenaerohasdevelopedMorfeo/Crackforfatiguecrackgrowthanalysis. Morfeo/CrackisbasedontheeXtendedFiniteElementMethod(XFEM)andthelevelset techniqueswhichallowformodellingcrackpropagationswithouttheneedofspecific remeshingtechniques.Consequently,thetimespendbytheuserisreducedwhilethe computationaltimeremainsessentiallythesame.Morfeo/Crackisalsoavailableasaplugin solutionforgeneralpurposeFEsolversthataremorefamiliartoengineersinthestress office. ForseveralyearsMorfeohasbeensuccessfullyusedforaeronauticalandaerospace applications.Inthiscontribution,someaerospaceapplicationssuchasarocketengines componentandsatelliteswillbeconsideredtoillustratethecapabilitiesofMorfeo/Crackfor damagetolerantassessment.

nt. ************ Computationofstressintensityfactorsandenergyreleaseratecomponentswithinthe frameworkofthepversionofthefiniteelementmethod Authors: RicardoL.ActisandBarnaA.Szabo(ESRDInc.) Prediction of damage propagation events is based on the idea that some parameter, assumedtobethedriverofdamageaccumulation,whichiscomputablefromthesolutionof acontinuummechanicsproblem,canbeconsistentlycorrelatedwithdamageaccumulation observed in physical experiments. In the case of metallic structures, linear elastic fracture mechanics(LEFM)istypicallyusedforthepredictionoftheonsetoffailureinthepresence ofaflaworcrack.ThecharacterizingparameteristheStressIntensityFactor(SIF)whichis denotedbyKIformodeIloading,andthecorrespondinglimitvalueisthefracturetoughness (KIC). The reliable prediction of crack growth and the determination of residual strength require the accurate computation of SIFs for partthrough cracks and through cracks. Analytical solutions of these types of crackgeometry configurations typically are not available; therefore estimates of SIFs have to be obtained by numerical methods, such as finite elementsandboundaryelements. TherearemanyproceduresforextractingSIFsfromfiniteelementsolutions.However,most extractionproceduresarecumbersometouseandrequireagreatdealofexpertiseonthe part of the users, which makes them impractical for everyday applications. A procedure basedontheContourIntegralMethod(CIM)incombinationwiththepversionofthefinite elementmethod[1],makestheextractionoftheSIFssimpleandaccurateatanynumberof pointsalongacrackfront.

A fracture mechanics based approach to assess the damage tolerance of composite structuresisalogicalandnaturalextensionoftheLEFMtocomposites.However,inthecase oflaminatecomposites,theproblemiscomplicatedbytheanisotropyofthematerialandby the coupling between load and deformation modes (i.e., a symmetric loading may lead to asymmetric deformation) due to lack of symmetry in material properties. Mode I (Interlaminar tension), Mode II (interlaminar sliding shear) and Mode III (interlaminar scissoring shear) loading are expected to be present in most cases. Typical failure in the presenceofaninitialdefect,suchasdelamination,appearsunderamixedmodeloading. Modelsbasedontheassumptionthatfailurepropagationcanbecorrelatedwiththestrain energyreleaserate(G)associatedwitheachmodeofdeformationhavebeenproposed[2]. The critical energy release rate (Gc) is defined by a failure surface which depends on the components of the total energy release rate corresponding to each mode, Gc = Gc (GI, GII, GIII).Thereforethestrainenergyreleaserate(ERR)componentsformodeI(GI),modeII(GII) andmodeIII(GIII)mustbedeterminedwithguaranteedaccuracytoformulatemixedmode failure criteria for the determination of onset of instability of interlaminar flaws in componentsmadeofcompositematerials. OneofthemostcommonlyusedprocedurestocomputetheERRcomponentsistheVirtual Crack Closure Technique (VCCT). Numerical implementations of the VCCT within the framework of the hversion of the finite element method (hFEM) has the advantage of utilizingasingleFEsolutiontodeterminethecomponentsoftheenergyreleaserate,butthe resultsarequitesensitivetothesizeoftheelementsaroundthecrackfrontandtoelement distortion[3].TheJintegraldecomposition[45] providesanalternativewaytoaccurately computetheERRcomponentsalongacrackordelaminationfrontfromasingleFEsolution andtheresultscanbeshowntobemeshindependent. ThepresentationaddressestheuseoftheCIMforthecomputationofSIFsandtheJintegral fordeterminingtheERRcomponentsinpostprocessingoperationswithintheframeworkof pversion of the finite element method (pFEM) implemented in the professional software product StressCheck. The main benefit from combining these extraction procedures with the pFEM is the feedback information available to the user regarding the convergence of thedataofinterestwithrespecttoincreasingnumberofdegreesoffreedom,anessential prerequisite of verification and validation procedures. Several examples are presented to illustratethemeritsoftheimplementationandtodemonstratetheefficiencyandaccuracy ofbothextractionprocedures. References 1.Szab,B.A.andBabuska,I.FiniteElementAnalysis,JohnWileyandSons,Inc.NewYork, 1991. 2. R. Krueger, The Virtual Crack Closure Technique: History, Approach and Applications. ICASEReportNo.200210.NASA/CR2002211628,April2002. 3. R. Krueger. An approach for assessing delamination propagation capabilities in commercialfiniteelementcodes.PaperpresentedattheAmericanSocietyofComposites 22nd Annual Technical Conference, University of Washington, Seattle, WA, September 17 19,2007. 4. O. Huber, J. Nickel and G. Kuhn. On the decomposition of the Jintegral for 3D crack problems.InternationalJournalofFracture,Vol.64,pp.339348,1993. 5.R.H.RigbyandM.H.Aliabdi.DecompositionofthemixedmodeJintegralRevisited. Int.J.SolidsStructures,Vol.35,No.17,pp20732099,1998. ************

XFEMandotheradvancedfracture&failuremechanicsinAbaqus Authors: VincentBouwman,JohnWilliam(SimuliaBenelux) Fractureandfailuremodelingallowsforproductdesignsthatmaximizethesafeoperating lifeofstructuralcomponents.Abaqusoffersmanycapabilitiesthatenablefractureand failuremodelinginbothA/StandardandA/Explicit. Thispresentationprovidesanoverviewofthesecapabilitiesandwilldiscussdamagein FiberReinforcedComposites,FastenerFailure,SurfacebasedCohesiveBehavior,VCCT, FatigueanalysisandXFEM. ************ FractureControlDesignRecommendations Author: M.Vorel(ASTRIUMSpaceTransportation) Duringafewthoughnotallpreviousdevelopments,therewasnoformallinkbetween designanddamagetolerance.Thefocalpointofthedesignwasprimarilyoptimizationof stiffness,massandproductioncosts.Thefinaldesignwashowevernotalwayscompatibleto damagetolerancerequirementssothatdamagetolerancecapabilitycouldnotbejustified. Infewcasesthisfinallyresultedinacostlyredesign.Thesituationwasaggravatedbythe factthatadamagetoleranceverificationisbyprincipleperformedattheendofthe developmentchain(wheninputsfromdesign,static,dynamicandproductiondepartments areavailable).Atthattimethedesign,manufacturingprocessesaswellasmassandcost budgetareusuallyalreadyfrozenandanewloopofaredesignmaybecostlybothinterms ofscheduleandbudget. Theobjectiveofthepresentationisthereforetomakeawareofvariousdesignsolutions whichresultinadesignwithinherentdamagetolerantfeatures.Inparticularthisshall facilitate: achievementofdamagetoleranceindevelopment maintainabilityofdamagetoleranceinproduction

Anadvanceddesignthatrespectsdamagetoleranceprinciplesstilldoesnotguaranteethat damagetolerancewilleasilybejustifiable.Nevertheless,suchadesignisabasicassumption forasuccessfuljustificationand,inabroaderview,forasuccessfulcompletionofthe FractureControlprogramme.Withrespecttotheindustrializationofthedesignthepurpose ofthedesignrecommendationsis: keepingthecostsatpossiblylowlevel(avoidingunnecessarydiscussionsandexpensive correctiveactions) maintaininghighlevelofrobustness(reductionofriskofstructuralfailure).

Thepresentationcontentsisbasedontheconsolidationofdesignmethodsforthe developmentoftheA5MEUpperStage,asdocumentedinadedicatedhandbooklike proprietaryreport. ************