Cracks in Metal Components
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Transcript of Cracks in Metal Components
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Mechanical design – Static design
Tópicos/Outline
Introduction to Fracture Mechanics 5.12
- Concept (idea)
- Crack propagation modes
- Stress intensity factor (SIF) – K
- Fracture Toughness
- SIF applied to design
- Validity of the project concerning LEFM
Failure theories (Tresca; von Mises; MNS, Coulomb-Mohr) vs
Linear elastic fracture mechanics 5.13
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Concept of Fracture Mechanics
It is based on the assumption that all materials contain defects or these
ones are introduced during the manufacturing process or appear in
service by a process of fatigue or corrosion
Mechanical design – Static design
Idea is that cracks exist in parts even before service begin and
those cracks can grow during service
The focus of this philosophy is on crack growth until it
becomes critical, and the part is removed from service
![Page 3: Cracks in Metal Components](https://reader034.fdocuments.us/reader034/viewer/2022042718/563db817550346aa9a907996/html5/thumbnails/3.jpg)
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Fracture Mechanics
Linear elastic
fracture mechanics
(LEFM)
Elasto-Plastic fracture
mechanics (EPFM)
Defect ?
Pore/void
crack
Inclusion/flaw
Unfavorable shape of the grain (rolling)
Mechanical design – Static design
![Page 4: Cracks in Metal Components](https://reader034.fdocuments.us/reader034/viewer/2022042718/563db817550346aa9a907996/html5/thumbnails/4.jpg)
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Fracture Mechanics
Stress concentration factors are limited to structures for which all
dimensions are precisely known no longer valid for FM k
t
Mechanical design – Static design
![Page 5: Cracks in Metal Components](https://reader034.fdocuments.us/reader034/viewer/2022042718/563db817550346aa9a907996/html5/thumbnails/5.jpg)
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Stress Intensity Factor (SIF) - K
Controls the crack propagation conditions
a – dimension´s defect (m)
KI – Stress Intensity Factor (MPa.m^0.5)
- Stress Intensity modification Factor
- nominal stress (MPa)
Is function of: geometry of component (plate; shell; tube),
geometry of crack (elliptic; circular; corner) and crack
propagation modes (mode I, II or III)
Mechanical design – Static design
KI=a
![Page 6: Cracks in Metal Components](https://reader034.fdocuments.us/reader034/viewer/2022042718/563db817550346aa9a907996/html5/thumbnails/6.jpg)
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For the analytical model consisting
of an infinite plate uniformly
tensioned
= Y = 1
Mechanical design – Static design
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Crack propagation modes
Mechanical design – Static design
Opening crack propagation
mode – the most common in
practice – most dangerous
Sliding mode
In plane shear Tearing mode
Out of plane shear
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Mix mode opening crack
Slant cracks
Consider mix mode opening crack:
?
Mechanical design – Static design
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Opening crack propagation mode I- KI
Mode I – the most
dangerous!!!
Survey of SIF:
-Rooke and Cartwright, “Compendium
of stress intensity factors”
-Y. Murakami, “Stress intensity factors
Handbook”, Pergamon Press
Mechanical design – Static design
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Mechanical design – Static design
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Mechanical design – Static design
Fig. 5-26
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Mechanical design – Static design
Beams of
rectangular cross
section having an
edge crack
-Pure bending
- 3PB
Fig. 5-27
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Mechanical design – Static design
Fig. 5-28: Plate in tension containing a circular hole with 2 cracks
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Fig. 5-29: Cylinder loading in axial tension having a radial
crack of a depth a around the circumference
Mechanical design – Static design
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Internal pressure p
& radial crack
Mechanical design – Static design
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Fracture Toughness – KIC ?
Mechanical design – Static design
Is a material property that dependes on the material, crack
mode, processing of the material, temperature, loading rate,
and the state of stress at the crack tip site.
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Apllying SIF to design
Known KIC and the solution KI=a for a specific case,
we can compute:
1. The critical fracture stress of the component
a
kICcr
2
1
IC
cr
ka
ICI kak
2. The critical crack length
3. The fracture toughness which should be specified for a
material
ICI kak
Mechanical design – Static design
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Design concerning
fracture: n = KIC / KI
yieldIC
cra
k
Fracture design vs Yielding design
Yielding controls
the design!!!!
Mechanical design – Static design
Apllying SIF to design
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Yield stress, Sy corresponds to yield design (von Mises)
As fracture toughness, KIC, corresponds to Linear Elastic Fracture
design (LEFM)
Mechanical design – Static design
Apllying SIF to design
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The zone of plastic deformation in the front of the crack is
small or large?
- There is very little plasticity max. brittleness
Specimen fracture in a state of plane strain (SPS)
tri axial stress state
Condition to check: Tick.min. ≥ 2.5 (KIC / C)^2
Mechanical design – Static design
Validity of the project concerning LEFM
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In the case of cracks in reservoirs of pressure two
possibilities of ruin exist:
- Leakage before fracture:
- Unexpected and brittle fracture,
without leakage aC
?
Mechanical design – Static design
Fracture design vs Yielding design
crack reaches a length
superior to the thickness, leading to leakage
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PROJECTO MECANICO
EXERCISES FROM BOOK
Static Loading exercises: 5-19;5-36; 5-63; 5-76
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Mechanical design – Static design
Fig. 5-26