Numerical modeling of interactions between a macro-crack and a cluster of micro-defects

The interactions between a macro-crack and a cluster of micro-defects are studied numerically by using a series of special finite elements each containing a defect. These special finite elements, which contain defects such as holes, cracks, and inhomogeneities, are developed based on the hybrid displacement, complex potential and conformal mapping techniques. These hybrid-type elements can be used together with the conventional finite elements without any difficulty. Thus, simple finite element models can be devised to study the interactions between a macro-crack and a cluster of micro-defects. In this paper, the mathematical and finite element modeling procedures for the study of the above-mentioned problems are presented.

Numerical study of the mode I delamination toughness of Z-pinned laminates

A finite element (FE) model is developed to investigate mode I delamination toughness of z-pin reinforced composite laminates. The z-pin pullout process is simulated by the deformation of a set of non-linear springs. A critical crack opening displacement (COD) criterion is used to simulate crack growth in a double-cantilever-beam (DCB) made of z-pinned laminates. The toughness of the structure is quantified by the energy release rate, which is calculated using the contour integral method. The FE model is verified for both unpinned and z-pinned laminates. Predicted loading forces from FE analysis are compared to available test data. Good agreement is achieved. Our numerical results indicate that z-pins can greatly increase the mode I delamination toughness of the composite laminates. The influence of design parameters on the toughness enhancement of z-pinned laminates is also investigated, which provides important information to optimise and improve the z-pinning technique.

The effect of laser power density on the fatigue life of laser-shock-peened 7050 aluminium alloy

Laser shock peening (LSP) is an innovative surface treatment method that can result in significant improvement in the fatigue life of many metallic components. The process produces very little or no surface profile modification while producing a considerably deeper compressive residual stress layer than traditional shot peening operations. The work discussed here was designed to: (a) quantify the fatigue life improvement achieved by LSP in a typical high strength aircraft aluminium alloy and (b) identify any technological risks associated with its use. It is shown that when LSP conditions are optimal for the material and specimen configuration, a —three to four times increase in fatigue life over the as-machined specimens could be achieved for a representative fighter aircraft loading spectrum when applied at a representative load level. However, if the process parameters are not optimal for the material investigated here, fatigue lives of LSP treated specimens may be reduced instead of increased due to the occurrence of internal cracking. This paper details the effect of laser power density on fatigue life of 7050-T7451 aluminium alloy by experimental and numerical analysis.

Quantitative assessment of through-thickness crack size based on Lamb wave scattering in aluminium plates

The interaction of Lamb wave modes at varying frequencies with a through-thickness crack of different lengths in aluminium plates was analysed in terms of finite element method and experimental study. For oblique-wave incidence, both numerical and experimental results showed that the wave scattering from a crack leads to complicated transmission, reflection and diffraction accompanied by possible wave-mode conversion. A dual-PZT actuation scheme was therefore applied to generate the fundamental symmetrical mode (S0) with enhanced energy to facilitate the identification of crack-scattered wave components. The relationship between crack length and the reflection/transmission coefficient obtained with the aid of the Hilbert transform was established, through which the crack length was quantitatively evaluated. The effects of wavelength of Lamb waves and wave diffraction on the properties of the reflection and transmission coefficients were analysed.

Modelling of laser beam spot-weld using 2-D hybrid crack finite elements

Laser beam spot-welding is widely applied to join sheet metals for automotive components especially for thinsheet components in automotive industries. The spot welds in such metallic structures contribute a lot to the integrated strength and fatigue life for the whole structures and they are responsible for their damage or collapse in some loading cases. In this paper, the 2-D hybrid special finite elements each containing an edge crack are employed to study the fracture behaviors of laser beam spot-welds. Hence the calculation accuracy in the vicinity of crack tips is ensured, and a better description of stress singularity with only one hybrid element surrounding one crack is provided. The numerical modeling for laser beam spot-welds subjected to three typical modes ofloadings including tension-lap, shear-lap and angle-clip can be greatly simplified with the applications of such elements. Three specimens under lap-shear, lap-tension and angle clip are devised and analyzed respectively, and main fracture parameters such as stress intensity factors and the initial direction of crack growth are obtained through tinite element analyses. The computed results ti'om numerical examples demonstrate the validity and versatility of the proposed modeling.

Hybrid special finite element method for bi-material crack

In the paper, two novel 2-D hybrid special finite elements each containing an interfacial edge crack, which lies along or vertical to the interface between two materials, are developed. These proposed elements can assure the high precision especially in the vicinity of crack tip and provide a better description of its singularity with only one hybrid element surrounding one interfacial crack, thus, the numerical modeling of fracture analysis on bi-material crack can be greatly simplified. Numerical examples are provided to demonstrate the validity and versatility of the proposed method.

Experimental and numerical analysis of the deformed process of cracks/cavities

In this paper, the three-point bending tests of beams with a small single-edge crack are conducted to demonstrate the reliability and accuracy of the laser diffraction technique in detecting its deformation and evolution. As a comparison, the quasi-static analysis of the beam subjected to 3-point bending is further proceeded using the finite element method and the related results have been in good agreement with those from the tests.

Numerical models of plastic zones and associated deformations for elliptical inclusions in remote elastic loading-unloading with different R-ratios

Plastic zones and associated deformations ahead of a fatigue crack are well established nowadays. In-depth plane strain elasto-plastic finite element analysis is conducted in this investigation to understand the nature of cyclic plastic deformation and damage around soft and hard elliptical inclusions. Similar to fatigue crack tip, cyclic/reverse plastic zone and monotonic plastic zone are visible for soft elliptical inclusion. In the cyclic plastic zone, low cycle fatigue is the dominant cyclic deformation mode during symmetric load cycling, while ratcheting is dominant during asymmetric load cycling. The size of cyclic plastic zone depends upon the amplitude of remote stress while, the size of monotonic plastic zone depends upon the maximum remote stress. The size of monotonic plastic zone is equal to cyclic plastic zone during symmetric load cycling. The shape and size of plastic zones also depend upon the orientation of the soft inclusion. Cyclic plastic damage progression in the cyclic plastic zone for soft (MnS) inclusion is significant, while no cyclic plastic zone is visible for hard inclusion (Al2O3).