Fracture Mechanics Overview & Basics - Parnell Eng
Transcript of Fracture Mechanics Overview & Basics - Parnell Eng
1T. Kim Parnell; May 3, 1999
Fracture MechanicsOverview & Basics
T. Kim Parnell, Ph.D., P.E.
May 3, 1999
2T. Kim Parnell; May 3, 1999
MotivationMotivation• Brittle failure at low stress in low-
strength steels– WWII era Liberty Ships
• Welded structures• Ductile/Brittle transition temperature too high
• The occurrence of failure at low stress in high-strength materials spurred Fracture Mechanics further
• NBS economic study in 1978 estimated the cost of fracture at $119 Billion in the U.S. (about 4% of the GNP)
• Brittle failure at low stress in low-strength steels– WWII era Liberty Ships
• Welded structures• Ductile/Brittle transition temperature too high
• The occurrence of failure at low stress in high-strength materials spurred Fracture Mechanics further
• NBS economic study in 1978 estimated the cost of fracture at $119 Billion in the U.S. (about 4% of the GNP)
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Fracture v Strength CriteriaFracture v Strength Criteria
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Historical DevelopmentHistorical Development
• A.A. Griffith work on brittle fracture• G.R. Irwin extended Griffith’s work to
ductile materials
• A.A. Griffith work on brittle fracture• G.R. Irwin extended Griffith’s work to
ductile materials
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Work of GriffithWork of Griffith• A. A. Griffith started his work in around the 1920s.
At this time, it was accepted that the theoretical strength of a material was taken to be E/10, where E is Young's Modulus for the particular material. He was only considering elastic, brittle materials, in which no plastic deformation took place. However, it was observed that the true values of critical strength was as much as 1000 times less than this predicted value, and Griffith wished to investigate this discrepancy.
• He discovered that there were many microscopic cracks in every material which were present at all times. He hypothesized that these small cracks actually lowered the overall strength of the material because as a load is applied to these cracks, stress concentration is experienced.
• A. A. Griffith started his work in around the 1920s. At this time, it was accepted that the theoretical strength of a material was taken to be E/10, where E is Young's Modulus for the particular material. He was only considering elastic, brittle materials, in which no plastic deformation took place. However, it was observed that the true values of critical strength was as much as 1000 times less than this predicted value, and Griffith wished to investigate this discrepancy.
• He discovered that there were many microscopic cracks in every material which were present at all times. He hypothesized that these small cracks actually lowered the overall strength of the material because as a load is applied to these cracks, stress concentration is experienced.
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Work of IrwinWork of Irwin• G. R. Irwin, in the 1950s, began to see how the
theory outlined by Griffith would apply to ductile materials.
• He determined that there was also a certain energy from plastic deformation that had to be added to the strain energy originally considered by Griffith in order for the theory to work for ductile materials.
• Irwin developed the concept of the strain energy release rate.
• G. R. Irwin, in the 1950s, began to see how the theory outlined by Griffith would apply to ductile materials.
• He determined that there was also a certain energy from plastic deformation that had to be added to the strain energy originally considered by Griffith in order for the theory to work for ductile materials.
• Irwin developed the concept of the strain energy release rate.
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Concepts & PrinciplesConcepts & Principles• Crack tip stress distribution
– 1/√r singularity at the crack tip (LEFM)• Energy Release Rate is related to the
Stress Intensity Factor• Condition at the crack tip is
characterized by the Stress Intensity Factor, KI
• Fracture toughness is a material property, KIc.
• Crack tip stress distribution– 1/√r singularity at the crack tip (LEFM)
• Energy Release Rate is related to the Stress Intensity Factor
• Condition at the crack tip is characterized by the Stress Intensity Factor, KI
• Fracture toughness is a material property, KIc.
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Three Modes of CrackingThree Modes of Cracking
– Mode I - opening mode– Mode II - in-plane
shearing/sliding mode– Mode III - out-of-plane
shearing/tearing mode
– Mode I - opening mode– Mode II - in-plane
shearing/sliding mode– Mode III - out-of-plane
shearing/tearing mode
Deal with Mode I most frequently
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Stress ConcentrationStress Concentration
Maximum Stress
0.120
+==t
m aKρσ
σ
StressConcentrationFactor
002 σρ
σσ +=t
Ma
002 σρ
σσ +=t
Ma
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Crack Tip StressesCrack Tip Stresses];length*stress[ 5.0aCKI πσ= ];length*stress[ 5.0aCKI πσ=
Ex: (ksi-√in, MPa-√m)• Near-tip stress field (LEFM)
⎟⎠⎞
⎜⎝⎛=
⎟⎠⎞
⎜⎝⎛ −=
⎟⎠⎞
⎜⎝⎛ +=
23cos
2cos
2sin
r2
23sin
2sin1
2cos
r2
23sin
2sin1
2cos
r2
θθθπ
τ
θθθπ
σ
θθθπ
σ
K
K
K
xy
x
y
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Some Applications ofFracture Mechanics
Some Applications ofFracture Mechanics
• Remaining life as a function of crack size
• Crack size that can be tolerated (critical crack size)
• Time for a crack to grow from an initial size to the critical size (inspection interval)
• Remaining life as a function of crack size
• Crack size that can be tolerated (critical crack size)
• Time for a crack to grow from an initial size to the critical size (inspection interval)
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Test Techniques forFracture PropertiesTest Techniques forFracture Properties
• Compact Tension (CT) specimen
• Charpy impactspecimen
• Compact Tension (CT) specimen
• Charpy impactspecimen
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Stress Intensity Factors for CTStress Intensity Factors for CT
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Miniature SpecimensMiniature Specimens• Trend:
Development of techniques using miniature specimens
• Example:Small Punch procedure for generating constitutive properties & fracture toughness
• Trend: Development of techniques using miniature specimens
• Example:Small Punch procedure for generating constitutive properties & fracture toughness
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Piping Design:Leak Before Break Criteria
Piping Design:Leak Before Break Criteria
• Desirable for pipe to be able to grow a crack through-wall (leak) without unstable crack growth (break).
• Leak provides an opportunity to detect the crack before it becomes long enough to be critical.
• Desirable for pipe to be able to grow a crack through-wall (leak) without unstable crack growth (break).
• Leak provides an opportunity to detect the crack before it becomes long enough to be critical.
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Pipeline-Unstable Crack GrowthPipeline-Unstable Crack Growth• 16-inch underground natural gas line• 300 psi internal pressure• Poor quality welds (ERW pipe)• Fast fracture of a 40-ft. section after initial weld
defects grew through fatigue to critical size• Resulting fire & explosions demolished the plant
• 16-inch underground natural gas line• 300 psi internal pressure• Poor quality welds (ERW pipe)• Fast fracture of a 40-ft. section after initial weld
defects grew through fatigue to critical size• Resulting fire & explosions demolished the plant
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Fatigue GrowthFatigue Growth• Cyclic stress intensity factor
• Paris law ⇒
• Integrate to get Cycles to failure
• Cyclic stress intensity factor
• Paris law ⇒
• Integrate to get Cycles to failure
aYKKK πσ∆=−=∆ minmax
( )mKAdNda
∆=
( ) ( )2/2/0f f
0
f
0
1a mm
aammm
aa
N
aYda
AYAdadNN ∫
∆=
∆∫=∫=
σππσ
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Fatigue Fracture SurfaceFatigue Fracture Surface
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ConclusionsConclusions• Cracks are everywhere, it is
just a matter of how large!• Fracture design criteria are
required more often in modern design
• More efficient designs with lower factors of safety drive this trend
• Cracks are everywhere, it is just a matter of how large!
• Fracture design criteria are required more often in modern design
• More efficient designs with lower factors of safety drive this trend
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Selected References:Fracture Mechanics
Selected References:Fracture Mechanics
• Broek, David (1982). Elementary Engineering Fracture Mechanics, 3rd Ed., Martinus Nijhoff Publishers.
• Anderson, T.L. (1991). Fracture Mechanics: Fundamentals and Applications, CRC Press.
• Dieter, George, E. (1976). Mechanical Metallurgy, 2nd Ed., McGraw-Hill.
• ASTM E399-83, (1983). “Standard Test Method for Plane-Strain Fracture Toughness of Metallic Materials.”, Philadelphia.
• ASTM E813-87, (1987). “Standard Test Method for JIC, a Measure of Fracture Toughness”, Philadelphia.
• ASTM E1152-87, (1987). “Standard Test Method for Determining J-R Curves”, Philadelphia.
• Broek, David (1982). Elementary Engineering Fracture Mechanics, 3rd Ed., Martinus Nijhoff Publishers.
• Anderson, T.L. (1991). Fracture Mechanics: Fundamentals and Applications, CRC Press.
• Dieter, George, E. (1976). Mechanical Metallurgy, 2nd Ed., McGraw-Hill.
• ASTM E399-83, (1983). “Standard Test Method for Plane-Strain Fracture Toughness of Metallic Materials.”, Philadelphia.
• ASTM E813-87, (1987). “Standard Test Method for JIC, a Measure of Fracture Toughness”, Philadelphia.
• ASTM E1152-87, (1987). “Standard Test Method for Determining J-R Curves”, Philadelphia.