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Register a new userA fretting crack initiation prediction taking into account the surface roughness and the crack nucleation process volume
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Authors
Henry Proudhon
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This paper presents an experimental study of the fretting crack nucleation threshold, expressed in terms of loading conditions, with a cylinder/plane contact. The studied material is a damage tolerant aluminium alloy widely used in the aerospace application. Since in industrial problems, the surface quality is often variable, the impact of a unidirectional roughness is investigated via varying the roughness of the counter body in the fretting experiments. As expected, experimental results show a large effect of the contact roughness on the crack nucleation conditions. Rationalisation of the crack nucleation boundary independently of the studied roughnesses was successfully obtained by introducing the concept of effective contact area. This does show that the fretting crack nucleation of the studied material can be efficiently described by the local effective loadings inside the contact. Analytical prediction of the crack nucleation is presented with the Smith-Watson-Topper (SWT) parameter and size effect is also studied and discussed.
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In this work, the crack nucleation under fretting loading is investigated experimentally with a damage tolerant 2024 aluminium alloy. A new method is introduced to determine its condition with respect to all loading parameters including the number of fretting cycles. Further work deals with the prediction of this threshold using the Smith-Watson-Topper criterion. New developments are presented, in particular a process volume of variable size is introduced in the computations of the fretting crack initiation.
In this work, the finite elements method (FEM) is used to analyse the growth of fretting cracks. FEM can be favourably used to extract the stress intensity factors in mixed mode, a typical situation for cracks growing in the vicinity of a fretting contact. The present study is limited to straight cracks which is a simple system chosen to develop and validate the FEM analysis. The FEM model is tested and validated against popular weight functions for straight cracks perpendicular to the surface. The model is then used to study fretting crack growth and understand the effect of key parameters such as the crack angle and the friction between crack faces. Predictions achieved by this analysis match the essential features of former experimental fretting results, in particular the average crack arrest length can be predicted accurately.
Crack initiation emerges due to a combination of elasticity, plasticity, and disorder, and it is heavily dependent on the materials microstructural details. In this paper, we investigate brittle metals with coarse-grained, microstructural disorder that could originate in a materials manufacturing process, such as alloying. As an investigational tool, we consider crack initiation from a surface, ellipsoidal notch: As the radius of curvature at the notch increases, there is a dynamic transition from notch-induced crack initiation to bulk-disorder crack nucleation. We perform extensive and realistic simulations using a phase-field approach coupled to crystal plasticity. Furthermore, the microstructural disorder and notch width are varied in order to study the transition. We identify this transition for various disorder strengths in terms of the damage evolution. Above the transition, we identify detectable precursors to crack initiation that we quantify in terms of the expected stress drops during mode I fracture loading. We discuss ways to observe and analyze this brittle to quasi-brittle transition in experiments.
We discuss steady state crack growth in the spirit of a free boundary problem. It turns out that mode I and mode III situations are very different from each other: In particular, mode III exhibits a pronounced transition towards unstable crack growth at higher driving forces, and the behavior close to the Griffith point is determined entirely through crack surface dissipation, whereas in mode I the fracture energy is renormalized due to a remaining finite viscous dissipation. Intermediate mixed-mode scenarios allow steady state crack growth with higher velocities, leading to the conjecture that mode I cracks can be unstable with respect to a rotation of the crack front line.
In this study, a multi-grid sampling multi-scale (MGSMS) method is proposed by coupling with finite element (FEM), extended finite element (XFEM) and molecular dynamics (MD) methods.Crack is studied comprehensively from microscopic initiations to macroscopic propagation by MGSMS method. In order to establish the coupling relationship between macroscopic and microscopic model, multi-grid FEM is used to transmit the macroscopic displacement boundary conditions to the atomic model and the multi-grid XFEM is used to feedback the microscopic crack initiations to the macroscopic model. Moreover, an image recognition based crack extracting method is proposed to extract the crack coordinate from the MD result files of efficiently and the Latin hypercube sampling method is used to reduce the computational cost of MD. Numerical results show that MGSMS method can be used to calculate micro-crack initiations and transmit it to the macro-crack model. The crack initiation and propagation simulation of plate under mode I loading is completed.
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