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CALCULATION OF FATIGUE LIMITS FOR FINITE SIZED COMPONENTS USING A HYBRID FEM AND DDT METHOD

N. Larrosa, A. Navarro y V. Chaves Dpto. Ing. Mec nica y de los Materiales. Escuela Superior de Ingenieros. Universidad de Sevilla. a Avda. Camino de los Descubrimientos, s/n. 41092. Sevilla. E-mail: navarro@us.es RESUMEN En este trabajo se presenta una herramienta hbrida iterativa (FEMIS) del m todo de los elementos nitos (MEF) e y el m todo de las dislocaciones distribuidas (DD), que hace uso de un modelo microstructural (Modelo NR) e para analizar microgrietas sometidas a carga cclica creciendo en s lidos bidimensionales nitos, i.e., donde las o dimensiones de la grieta y el propio s lido son del mismo orden. La principal ventaja del m todo desarrollado es o e la generalidad de su formulaci n, en la que no se necesita implementar n cleos de deformaci n especiales para o u o describir la geometra del s lido a analizar. El modelo microstructural implementado tiene en cuenta la interacci n o o de la microgrieta con las sucesivas barreras microestructurales. Se describe la formulaci n del m todo FEMIS y o e su aplicaci n a problemas cuya soluci n es conocida, lo que permite validar la herramienta. o o ABSTRACT This work presents an iterative hybrid technique (FEMIS) of the nite element method (FEM) and the distributed dislocation technique (DDT), that makes use of a microstructural model to analyze the growth of fatigue microcracks in plane nite bodies. The main advantage of the method is that it does not make use of any special kernels to represent the stresses generated by the dislocations in the component, making the method general and practical. The microstructural approach implemented (NR model) accounts for the interaction of the crack with the microstructural barriers. The FEMIS method formulation is described and its application to well-known problems is shown to ascertain its potential usefulness. Keywords: Dislocations, Cracks, Finite Bodies, FEM, DDT 1 Introduction Engineering components and structures, to be safe and of reliable use, should permit users to know with a certain degree of approximation their behavior under wellknown prescribed boundary conditions. Cyclic loading often is the main reason for the appearance of cracks. It is well known that in fatigue of metals, the short crack regime corresponds to the greatest part of the components total life, so it is of great importance the development of models that takes the short crack regime into account. Most fatigue theories, such as those of Neuber and Peterson are based on the W hler curve concept o and are, therefore, phenomenological in nature: they do not consider any crack in the analysis, and are thus unable to account for the full physics of the problem. On the other hand, Micromechanical models extend fracture mechanics down to the regime where the cracks have the size of the material microstructure. These models describe the interaction of the crack with microstructural barriers and are of great use for predicting fatigue life. Based on the pioneering ideas of Bilby, Cottrell and Swinden [4] on the representation of a crack and its associated plastic zones by means of dislocations, Navarro and de los Rios [1], [3] developed a model for fatigue microcracks growing in plain innite bodies. The NR model is the foundation of the present work. Finite bodies behave differently from innite bodies when the relation between the microstructual length (e.g, grain size D) and a geometrical parameter (e.g, specimen width W) increases, and the boundary effects become more appreciable. This is the case of microelectromecanical devices (MEMS) and medical stents, with an average diameter of 100 micras. Indeed, the study of the behaviour of medical stents under cyclic load is the main driving force behind the development of the current technique. Many works focus their efforts on the calculation of stress intensity factors or T-stress in nite bodies [13], [12], [15], [16]. Iterative hybrid techniques are used in these cases. They all employ a combination of the Boundary Element Method (BEM) and some additional technique that enables the fulllment of the condition that the tensions over the the crack line must be zero.The distributed

dislocation technique (DDT), the distributed dislocation dipoles method (DDDM) or the displacement discontinuity boundary element approach (DDBE) are examples of this methods. In general, the hybrid technique decomposes the problem into (n + 1) sub-problems where n is the number of crack branches. The required solution will be the sum of these (n + 1) solutions. The rst sub-problem is to nd the stress distribution induced in the body in the absence of the crack using BEM, FEM or any other method. All of the remaining sub problems, are stress disturbance ones that will be solved using DDT, DDDM or DDBE, for instance. The results will be added and compared with the boundary conditions of the original problem. Iteration will be performed between the boundaries and the crack faces until all of the boundary conditions are satised. In this case, a combination of FEM and DDT is implemented. The selected technique makes use of the separated advantages of both methods. First of all, FEM is a widely used tool in the engineering industry as well as in the research world. Secondly, the DDT is a suitable method to incorporate the NR model. In addition, the present technique requires less storage space than BEM and FEM when the crack is modeled explicitly. Furthermore, it does not present mathematical degeneracies as DBEM does and it does not need remeshing to model crack propagation, as FEM does. To conclude, several benchmark examples are solved in order to validate the proposed tool and afterwards some problems of industrial and R&D interest are presented as contribution to engineering data.

Figure 1 shows a schematic representation of the model. A polycrystalline innite body with average grain size D and a crack of length 2a is subjected to a uniform applied stress at innity. A distribution of screw dislocations subjected to an external shear stress yz = at innity would model a state of antiplane strain and the crack opened in mode III. The analysis for a distribution of edge dislocations under shear stress xy = at innity leads to a state of plane strain and the crack opened in mode II . Edge dislocations with Burgers vectors perpendicular to the plane of the crack subjected to a tensile stress yy = represents a crack opened in Mode I. The equation that determines the equilibrium of dislocations, which have the same form for the three different load cases, provides a relation between the crack length and the local tension in the barrier. It is a Cauchy-type integral equation and its expression, in terms of the nondimensional variables x and , is as follows:
1

A
1

K f () d + ( f ) = 0

(1)

where the kernel K of the equation and will adopt different expressions depending on the geometry of the position of the crack and the geometry of the solid. A= Gb Gb 2 for screw dislocations and A= 2(1) for edge dislocations, where is the Poissons ratio, G is the shear modulus and b the burgers vector of a dislocation, respectively. In equation 1, f is the friction stress. The stresses 1 ,2 , 3 represent the resistance to the movement of dislocations in the crack, plastic zone and barrier, respectively. The unknown variables are the density of dislocations f () and 3 . When modeling an innite body the kernel takes the form: 1 K = (2) x and in that case the problem has analytical solution . When there crack starts from a free edge, the semi-innite model is appropriate, and the kernel for that case is: K
2

2 Theoretical model Navarro and de los Rios [13], as commented before, developed a model for fatigue microcracks growing in plain innite bodies. The NR model incorporates the crack, the plastic zone and the barrier by a continuous distribution of dislocations, based on the work of Bilby et. al. [4].
y

1 1 2 4 2 + (3) x x + (x )2 (x + )3

With no analytical solution available. The Distributed Dislocation Technique is a numerical procedure to solve equation (1) for the innite or semiinte case. This makes the method quite suitable for application to cracked bodies of arbitrary shape, as we show below.
x,

0 0

a n1

iD 2

iD 2

+ r0

n2

Figure 1. Crack, plastic zone and barrier in a polycrystalline innite body modelled with dislocations (Mode II)

A numerical method proposed by Erdogan, Gupta and Cook [39], is used to approximate the denite integrals by an a system of algebraic equations. Within this quadrature formulae, the unknown variable f () is expressed as the product of a bounded function () and a weight

function (). This functions are evaluated at the integration points uj , that corresponds to the zeros of the appropriate Jacobi polynomials [39].
1 N N

+1 [y 3 ] = 2

() () d
1 i=1

Wi (i )

(4)
j=1 N

2(1 + u1j ) n K(v3m , u1j ) 1 (u1j )+ 2N + 1 2

(7)

The method provides a set of values (uj ) and, therefore, the solution of the unknown function is approximated at those discrete points as: f (uj ) = (uj ) (uj ) (5)

j=1

2(1 u3j ) 1n K(v3m , u3j ) 3 (u3j ) 2N + 1 2 m = 1, 2, . . . N.

where the collocation and integration points are: Once the quadratures are dened, it is possible to tackle the problem of the crack emanating form the free surface and reaching the barrier. Figure ?? shows a representation of the problem.
y

u1j = cos v1m

2j 1 2N + 1 2m = cos 2N + 1

u3j = cos v3m

2j 2N + 1 2m 1 = cos 2N + 1

(8)

f1 (1 ) 1
0 0 a n1

f2 (2 ) f3 (3 ) 2
n2

3
iD/2 iD/2 + r0 1 x , x,

If the friction stress 1 is considered to be zero, the system of equations provides 2N algebraic equations and 2N+1 unknowns, which are 1 (u1j ), 3 (u3j ) and 3 , the stress required to keep the equilibrium [32]. One further equation is thus needed to close the problem, and it is obtained from the coupling of the solutions for the two intervals: f1 (1) = f2 (1) with: f1 (1) = 1 (1)1 (1) = f2 (1) = 2 (1)2 (1) = 1 + u1 1 u1 1 u2 1 + u2 1 (1) u1 1 (9)

1 , x1

2 , x2

3 , x3
y

Figure 2. Crack and barrier in a semi-innite body subjected to Mode I. Two sub-intervals used.

(10)

2 (1) u2 1

Once the intervals of integration are normalized to [-1,1] through the corresponding changes of variable [5], it is possible to present the equilibrium equations transformed to a system of algebraic equations, using the integration points (uj ), the collocation points (vm ) and the weights corresponding to each quadrature used to model the problem. In order to avoid problems with a logarithmic singularity arising from the distinct values of the friction stress in each zone, the integration intervals are split between the crack zone (1) and the barrier zone (3). The resultant system is:
N

which leads to: 1 (1) = 2 (1) (11)

Although the quadrature formulae used does not provide the values j (1) and j (1), Krenk [41] proposed an extrapolation equation, as it is shown in Hills [5]. Finally, a 2N + 1 system of equations is solved which gives 2N values of (1 (u1j ) and 2 (u2j )) and 3 .

+1 [y 1 ] = 2

3 FEMIS: Formulation of the method. Consider the craked 2D solid of gure 3. To solve the original problem, the rst step is to calculate Subproblem 1 (Sp10 ), the stress state in the uncracked problem. The arbitrarily shaped body is subjected to the same boundary conditions as the original one (t0 =t and u0 = 0 0 u). The tractions along the crack line (tcrack = crack .n) are determined using FEM (ABAQUS).

j=1 N

2(1 + u1j ) n K(v1m , u1j ) 1 (u1j )+ 2N + 1 2

(6)

j=1

2(1 u3j ) 1n K(v1m , u3j ) 3 (u3j ) 2N + 1 2 m = 1, 2, . . . N.

model, using equations (12) to (14). Once the stresses are known, the corrective tractions are calculated: td = ij (x, y).n (17)

Figure 3. FEMIS decomposition.

The second sub problems (Sp20 ) is then solved using the distributed dislocation technique (DDT), which incorporates the micromechanical model explained earlier. The inputs for this stage are the tractions along the crack line 0 tcrack obtained in Sp10 . The output is the dislocation deni,0 sity over the crack line, f 0 (), and the tension 3 at the i barrier (e.g., grain boundary) at iteration 0. Conceptually, the dislocation density can be thought as internal disturbances affecting the stress and displacement elds of the body. If it is assume that the obtained 0 0 fx () and fy () are the components of the Burgers vector of a dislocation situated at [, 0] (over the crack line), it is possible to use the solutions of dislocations in innite or semi-innite media to calculate the inuence of each dislocation at every point of the solid. Thus ij and ui can be written as: xx (x, y) = 2 ( + 1)
c 0 (fx ()Kxxx (x, y, , 0)+ c 0 fy ()Kyxx (x, y, , 0))d c 0 (fx ()Kxxy (x, y, , 0)+ c 0 fy ()Kyxy (x, y, , 0))d c 0 (fx ()Kxyy (x, y, , 0)+ c 0 fy ()Kyyy (x, y, , 0))d c 0 (fx ()Uxx (x, y, , 0)+ c 0 fy ()Uxy (x, y, , 0))d

Now that the corrective tractions and displacements are known (td and ud ), it is necessary to modify the initial conditions, in order to satisfy the actual boundary conditions of the problem. The calculations are repeated with the newly obtained values: t1 =t0 -td ; u1 = u0 ud . The i,1 current value of 3 is compared with the value obtained i,0 in the previous iteration (3 ). This iterative scheme is repeated until convergence criterion is reached
i,k+1 i,k 3 3 i,k 3

105

where k is the number of iteration. Thus, the value of the N minimum stress needed to overcome the barrier i (Li ) is calculated and the calculations start again in order to nd the barrier strength for the next grain boundary blockage.

4 Fatigue limit calculation The proposed method outputs a relationship between the external applied load (yy ) and the minimum stress needed at the barrier to maintain equilibrium in the doi,k main (3 ). For the crack to overcome the barrier i, it is necessary to generate plastic slip in the next grain This i,k happens when the stress 3 takes a critical value in order to activate dislocation sources in the next grain, or for the dislocations of the plastic zone to be pushed to the next grain.
i,k N Once 3 is obtained, it is possible to calculate Li .as follows: i,k 1) The obtained relation between yy and 3 is:

(12)

xy (x, y) =

2 ( + 1)

(13)

2 xx (x, y) = ( + 1)

(14)

i,k 3 = (Kt , , , D, r0 ).yy

(18)

ux (x, y) =

1 2( + 1)

(15)

uy (x, y) =

1 2( + 1)

c 0 (fx ()Uxy (x, y, , 0)+ c 0 fy ()Uyy (x, y, , 0))d

(16)

Where is a numerical value obtained with FEMIS tool, K t is the stress concentrator factor of the notch, is the notch radius and is the notch depth. As mentioned above, D and r0 are the grain size and the barrier width, respectively. Equation (18) has the very important role of relating the macroscopic stresses yy , to the microscopic i,k parameter 3 . 2) The critical value is reached when:
i,k i 3 = m c i

where K rst and U rs (r,s,t = x,y) are the inuence functions for stresses and displacements, respectively, and represent the effect of a dislocation situated within the interval || c in a point (x,y). Closed-form expressions for K rst and U rs are given in [5]. The stresses ij (x, y) are calculated at the integration points (x, y) over the boundary of the nite element

(19)

Using equations (18) and (19) and assuming that the criti ical value m c is reached when the external loading is i N Li , it is obtained:
i N mi c = (Kt , , , D, r0 ).Li

(20)

3) For the innite or semiinnite component, we know [32] that:


i mi c = f (Kt , , , D, r0 )Li

(21)

where D 1 f (Kt , , , D, r0 ) = k ( ) 2 4 r0 (22)

where k=1 for an innite body and k=1.1215 for a semiinnite one. For the nite case, as mentioned, closed form expressions are not available. The advantage of the method implemented in this work relies on the numerical value (Kt,, , D, r0 ) that FEMIS provides. This value allows one to predict the fatigue behavior of components where the boundary effect is important and can not be neglected, and where the use of nite or semiinnte solutions does N not provide the required accuracy. The value of Li is rst calculated for every i barrier:
N Li =

Figure 4. Geometry and Finite element mesh of a semicircular edge notched cracked specimen

f (Kt , , , D, r0 )Li (Kt , , , a, r0 )

(23)

and, as explained above, the fatigue limit of the compoN nent will be the maximum value of Li :
N F L = M ax

f (Kt , , , D, r0 )Li (Kt , , , a, r0 )

(24)

Figure 5 shows the fatigue limit of the semicircular notched specimen, reecting the inuence of the notch radius. The specimen width was kept constant (W=70 mm) and big enough with respect to the crack length (W/a > 300) in order to compare the results with those of Chavess PhD Thesis [33], who implemented the NR model numerically using special kernels, following the approach developed by Hills [5].

5 Numerical results and application examples At this point, the accuracy of the method is assessed by considering several examples. The rst examples objective is to compare the results with the bibliography available in order to validate the tool. This example corresponds to the semicircular edge notch for a push-pull test on G40.11 steel for various notch radius (r). Comparison with the different methods of prediction are performed. It is important to remember that the formulation includes the effect of the stress raiser by modelling it in FEMThe value of the stresses at each collocation point of the crack is then passed to the DDT. In FEM (ABAQUS) the stresses are calculated at the centroids of the nite elements and interpolated to the collocation points.This way of solving the problems makes it possible to incorporate differently shaped stress raisers without the need of special kernels. Figure 4 shows the geometry of the problem and the nite element mesh used to solve Sp1.The mesh is formed by CPE4 and CPE3 elements from the ABAQUS element library. It can be seen that the mesh is much more rened near the semicircular notch, where the crack lies and this is so because very precise values of the stress gradient are needed over the collocation points of Sp2.

350

300

250

N FL

200

150

FEMIS NR

100

50 1E-5 1E-4 1E-3 0.01 0.1 1 10

r (mm)

Figure 5. Notch Fatigue Limit for the CSA G40.11 steel. Results compared with Chaves [33].

As can be seeing in Figure 5, the fatigue limit of the N material notched body (F L ) converge perfectly to F L , the material fatigue limit, when the notch radius tends to zero (r 0) In contrast, when the radius increases (r ), material the value of the fatigue limit reaches F L /3 . The notch inuence reaches the crack length, and the stresses that the crack experiments are practically constant and equal to K t yy . These results are in complete accordance with what is expected, and makes the method an interesting and valuable tool for fatigue analysis.

Next, several width dimensions were modeled in order to quantied the boundary effect. Figure 6 represents the variation of the fatigue limit with the width specimen, maintaining the radius constant (r=0.2).

140 130 120


N FL

110 100 90 0 10 20 30 40
W (mm)

r=0.2 mm

50

60

70

80

N Figure 6. Width effect on the fatigue limit (F L ) of a semi-circular notched specimen of radius r=0.2

6 Conclusions Numerical examples were solved to validate the tool, an iterative hybrid technique used to solve crack problems in nite components. The outstanding characteristic of this method is the absence of special kernels needed to solve arbitrary nite geometries. This valuable characteristic of the method is achieved by implementing an iterative scheme, that forces the boundary conditions to be satised. Additionally, the method incorporates the boundary effect. In other words, it also quanties the inuence of free edges.

Acknowledgements The authors would like to thank the Spanish Ministry of Education for its nancial support through grant DPI2008-01100 and the Junta de Andalucia through P06TEP-1752 and P07-TEP-03045.

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