Fatigue Failure of Structural Steel – Analysis Using Fracture Mechanics

Fatigue is the major threat in service of steel structure subjected to fluctuating loads. With the additional effect of corrosion and presence of weld joints the fatigue failure may become more critical in structural steel. One of the apt examples of such structural is the sailing ship. This is experiencing a constant stress due to floating and a pulsating bending load due to the waves. This paper describes an attempt to verify theory of fatigue in fracture mechanics approach with experimentation to determine the constants of crack growth curve. For this, specimen is prepared from the ship building steel and it is subjected to a pulsating bending load with a known defect. Fatigue crack and its nature is observed in this experiment. Application of fracture mechanics approach in fatigue with a simple practical experiment is conducted and constants of crack growth equation are investigated.

The Effect of Stress Biaxiality on Crack Shape Development

The development of shape and size of a crack in a pressure vessel under uniaxial and biaxial loadings is important in fitness-for-service evaluations such as leak-before-break. In this work finite element modelling was used to evaluate the mean stress and the J-integral around a front of a surface-breaking crack. A procedure on the basis of ductile tearing resistance curves of high and low constrained fracture mechanics geometries was developed to estimate the amount of ductile crack extension for surface-breaking cracks and to show the evolution of the initial crack shape. The results showed non-uniform constraint levels and crack driving forces around the crack front at large deformation levels. It was also shown that initially semi-elliptical surface cracks under biaxial load developed higher constraint levels around the crack front than in uniaxial tension. However similar crack shapes were observed with more extensions associated with cracks under biaxial loading.

Obtain the Stress Intensity Factor (SIF) in a Medium Containing a Penny-Shaped Crack by the Ritz Method

In the crack growth analysis, the Stress Intensity Factor (SIF) is a fundamental prerequisite. In the present study, the mode I stress intensity factor (SIF) of three-dimensional penny- Shaped crack is obtained in an isotropic elastic cylindrical medium with arbitrary dimensions under arbitrary loading at the top of the cylinder, by the semi-analytical method based on the Rayleigh-Ritz method. This method that is based on minimizing the potential energy amount of the whole of the system, gives a very close results to the previous studies. Defining the displacements (elastic fields) by hypothetical functions in a defined coordinate system is the base of this research. So for creating the singularity conditions at the tip of the crack the appropriate terms should be found.

An Adaptive Dynamic Fracture for 3D Fatigue Crack Growth Using X-FEM

In recent years, a new numerical method has been developed, the extended finite element method (X-FEM). The objective of this work is to exploit the (X-FEM) for the treatment of the fracture mechanics problems on 3D geometries, where we showed the ability of this method to simulate the fatigue crack growth into two cases: edge and central crack. In the results we compared the six first natural frequencies of mode shapes uncracking with the cracking initiation in the structure, and showed the stress intensity factor (SIF) evolution function as crack size propagation into structure, the analytical validation of (SIF) is presented. For to evidence the aspects of this method, all result is compared between FEA and X-FEM.

Effect of Relative Permeability on Well Testing Behavior of Naturally Fractured Lean Gas Condensate Reservoirs

Gas condensate Reservoirs show complicated thermodynamic behavior when their pressure reduces to under dew point pressure. Condensate blockage around the producing well cause significant reduction of production rate as well bottom-hole pressure drops below saturation pressure. The main objective of this work was to examine the well test analysis of naturally fractured lean gas condensate reservoir and investigate the effect of condensate formed around the well-bore on behavior of single phase pseudo pressure and its derivative curves. In this work a naturally fractured lean gas condensate reservoir is simulated with compositional simulator. Different sensitivity analysis done on Corry parameters and result of simulator is feed to analytical well testing software. For consideration of these phenomena eighteen compositional models with Capillary number effect are constructed. Matrix relative permeability obeys Corry relative permeability and relative permeability in fracture is linear. Well testing behavior of these models are studied and interpreted. Results show different sensitivity analysis on relative permeability of matrix does not have strong effect on well testing behavior even most part of the matrix around the well is occupied with condensate.

Hydrogen Embrittlement in a Coupled Mass Diffusion with Stress near a Blunting Crack Tip for AISI 4135 Pressure Vessel

In pressure vessels contain hydrogen, the role of hydrogen will be important because of hydrogen cracking problem. It is difficult to predict what is happened in metallurgical field spite of a lot of studies have been searched. The main role in controlling the mass diffusion as driving force is related to stress. In this study, finite element analysis is implemented to estimate material-s behavior associated with hydrogen embrittlement. For this purpose, one model of a pressure vessel is introduced that it has definite boundary and initial conditions. In fact, finite element is employed to solve the sequentially coupled mass diffusion with stress near a crack front in a pressure vessel. Modeling simulation intergrarnular fracture of AISI 4135 steel due to hydrogen is investigated. So, distribution of hydrogen and stress are obtained and they indicate that their maximum amounts occur near the crack front. This phenomenon is happened exactly the region between elastic and plastic field. Therefore, hydrogen is highly mobile and can diffuse through crystal lattice so that this zone is potential to trap high volume of hydrogen. Consequently, crack growth and fast fracture will be happened.

Stress Analysis of Non-persistent Rock Joints under Biaxial Loading

Two-dimensional finite element model was created in this work to investigate the stresses distribution within rock-like samples with offset open non-persistent joints under biaxial loading. The results of this study have explained the fracture mechanisms observed in tests on rock-like material with open non-persistent offset joints [1]. Finite element code SAP2000 was used to study the stresses distribution within the specimens. Four-nodded isoperimetric plain strain element with two degree of freedom per node, and the three-nodded constant strain triangular element with two degree of freedom per node were used in the present study.The results of the present study explained the formation of wing cracks at the tip of the joints for low confining stress as well as the formation of wing cracks at the middle of the joint for the higher confining stress. High shear stresses found in the numerical study at the tip of the joints explained the formation of secondary cracks at the tip of the joints in the experimental study. The study results coincide with the experimental observations which showed that for bridge inclination of 0o, the coalescence occurred due to shear failure and for bridge inclination of 90o the coalescence occurred due to tensile failure while for the other bridge inclinations coalescence occurred due to mixed tensile and shear failure.

Stress Intensity Factors for Plates with Collinear and Non-Aligned Straight Cracks

Multi-site damage (MSD) has been a challenge to aircraft, civil and power plant structures. In real life components are subjected to cracking at many vulnerable locations such as the bolt holes. However, we do not consider for the presence of multiple cracks. Unlike components with a single crack, these components are difficult to predict. When two cracks approach one another, their stress fields influence each other and produce enhancing or shielding effect depending on the position of the cracks. In the present study, numerical studies on fracture analysis have been conducted by using the developed code based on the modified virtual crack closure integral (MVCCI) technique and finite element analysis (FEA) software ABAQUS for computing SIF of plates with multiple cracks. Various parametric studies have been carried out and the results have been compared with literature where ever available and also with the solution, obtained by using ABAQUS. By conducting extensive numerical studies expressions for SIF have been obtained for collinear cracks and non-aligned cracks.

New Ways for Designing External Fixators Applied in Treatment of Open and Unstable Fractures

This paper deals with a new way for designing external fixators applied in traumatology and orthopaedics. These fixators can be applied in the treatment of open and unstable fractures or for lengthening human or animal bones etc. The new design is based on the development of Ilizarov and other techniques (i.e. shape and weight optimalization based on composite materials, application of smart materials, nanotechnology, low x-ray absorption, antibacterial protection, patient's comfort, reduction in the duration of the surgical treatment, and cost).

Analysis of Explosive Shock Wave and its Application in Snow Avalanche Release

Avalanche velocity (from start to track zone) has been estimated in the present model for an avalanche which is triggered artificially by an explosive devise. The initial development of the model has been from the concept of micro-continuum theories [1], underwater explosions [2] and from fracture mechanics [3] with appropriate changes to the present model. The model has been computed for different slab depth R, slope angle θ, snow density ¤ü, viscosity μ, eddy viscosity η*and couple stress parameter η. The applicability of the present model in the avalanche forecasting has been highlighted.

Study on Damage Tolerance Behavior of Integrally Stiffened Panel and Conventional Stiffened Panel

The damage tolerance behavior of integrally and conventional stiffened panel is investigated based on the fracture mechanics and finite element analysis. The load bearing capability and crack growth characteristic of both types of the stiffened panels having same configuration subjected to distributed tensile load is examined in this paper. A fourteen-stringer stiffened panel is analyzed for a central skin crack propagating towards the adjacent stringers. Stress intensity factors and fatigue crack propagation rates of both types of the stiffened panels are then compared. The analysis results show that integral stiffening causes higher stress intensity factor than conventional stiffened panel as the crack tip passes through the stringer and the integrally stiffened panel has less load bearing capability than the riveted stiffened panel.

Tool Wear of Titanium/Tungsten/Silicon/Aluminum-based-coated end Mill Cutters in Millin Hardened Steel

In turning hardened steel, polycrystalline cubic boron nitride (cBN) compacts are widely used, due to their higher hardness and higher thermal conductivity. However, in milling hardened steel, fracture of cBN cutting tools readily occurs because they have poor fracture toughness. Therefore, coated cemented carbide tools, which have good fracture toughness and wear resistance, are generally widely used. In this study, hardened steel (ASTM D2, JIS SKD11, 60HRC) was milled with three physical vapor deposition (PVD)-coated cemented carbide end mill cutters in order to determine effective tool materials for cutting hardened steel at high cutting speeds. The coating films used were (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating films. (Ti,W,Si,Al)N is a new type of coating film. The inner layer of the (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating system is (Ti,W)N coating film, and the outer layer is (Ti,W,Si)N and (Ti,W,Si,Al)N coating films, respectively. Furthermore, commercial (Ti,Al)N-based coating film was also used. The following results were obtained: (1) In milling hardened steel at a cutting speed of 3.33 m/s, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,W)N/(Ti,W,Si)N-coated tool. And, compared with the commercial (Ti,Al)N, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,Al)N-coated tool. (2) The tool wear of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool increased with an increase in cutting speed. (3) The (Ti,W)N/(Ti,W,Si,Al)N-coated cemented carbide was an effective tool material for high-speed cutting below a cutting speed of 3.33 m/s.

Fatigue Analysis of Crack Growing Rate and Stress Intensity Factor for Stress Corrosion Cracking in a Pipeline System

Environment-assisted cracking (EAC) is one of the most serious causes of structural failure over a broad range of industrial applications including offshore structures. In EAC condition there is not a definite relation such as Paris equation in Linear Elastic Fracture Mechanics (LEFM). According to studying and searching a lot what the researchers said either a material has contact with hydrogen or any other corrosive environment, phenomenon of electrical and chemical reactions of material with its environment will be happened. In the literature, there are many different works to consider fatigue crack growing and solve it but they are experimental works. Thus, in this paper, authors have an aim to evaluate mathematically the pervious works in LEFM. Obviously, if an environment is more sour and corrosive, the changes of stress intensity factor is more and the calculation of stress intensity factor is difficult. A mathematical relation to deal with the stress intensity factor during the diffusion of sour environment especially hydrogen in a marine pipeline is presented. By using this relation having and some experimental relation an analytical formulation will be presented which enables the fatigue crack growth and critical crack length under cyclic loading to be predicted. In addition, we can calculate KSCC and stress intensity factor in the pipeline caused by EAC.

Mechanical Properties of Ultra High Performance Concrete

A research program is conducted to evaluate the mechanical properties of Ultra High Performance Concrete, target compressive strength at the age of 28 days being more than 150 MPa. The methodology to develop such mix has been explained. The material properties, mix design and curing regime are determined. The material attributes are understood by studying the stress strain behaviour of UHPC cylinders under uniaxial compressive loading. The load –crack mouth opening displacement (cmod) of UHPC beams, flexural strength and fracture energy was evaluated using third point loading test. Compressive strength and Split tensile strength results are determined to find out the compressive and tensile behaviour. Residual strength parameters are presented vividly explaining the flexural performance, toughness of concrete.Durability studies were also done to compare the effect of fibre to that of a control mix For all the studies the Mechanical properties were evaluated by varying the percentage and aspect ratio of steel fibres The results reflected that higher aspect ratio and fibre volume produced drastic changes in the cube strength, cylinder strength, post peak response, load-cmod, fracture energy flexural strength, split tensile strength, residual strength and durability. In regards to null application of UHPC in India, an initiative is undertaken to comprehend the mechanical behaviour of UHPC, which will be vital for longer run in commercialization for structural applications.

Post-Cracking Behaviour of High Strength Fiber Concrete Prediction and Validation

Fracture process in mechanically loaded steel fiber reinforced high-strength (SFRHSC) concrete is characterized by fibers bridging the crack providing resistance to its opening. Structural SFRHSC fracture model was created; material fracture process was modeled, based on single fiber pull-out laws, which were determined experimentally (for straight fibers, fibers with end hooks (Dramix), and corrugated fibers (Tabix)) as well as obtained numerically ( using FEM simulations). For this purpose experimental program was realized and pull-out force versus pull-out fiber length was obtained (for fibers embedded into concrete at different depth and under different angle). Model predictions were validated by 15x15x60cm prisms 4 point bending tests. Fracture surfaces analysis was realized for broken prisms with the goal to improve elaborated model assumptions. Optimal SFRHSC structures were recognized.