Appendix- 4B

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Reference
Elements of Fracture Mechanics by Prashant Kumar

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Relation between GI and Kl
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Energy release rate GI is a global parameter and deals with energy. On the other

hand, stress intensity factor KI is a local parameter which deals with displacement

and stress fields in the vicinity of the crack. Although the approaches are entirely

different, the goal is same, i.e., to characterize a crack.

Consider a crack of length a which is extended by an incremental length Δa

In order to maintain clarity the extended crack and its associated parameters are

referred by the prime system; i.e., crack length a + Δa is designated as a' and the SIP

based on a' is denoted by K'. At a distance s, which is at a distance (Δa - s) from the

extended crack tip, the displacement of a crack face (u2) is determined for plane stress

is given by

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 For θ = 180o and r = (Δa - s), the displacement u2 is

Now, each crack face in the portion Δa is moved in through the distance u2(s) with

the help of the traction σ22 so that the crack faces touch each other. The magnitude

of stress σ22 is evaluated from the stress field of the unextended crack of length a,

and therefore at a distance s, it is given by

Thus, the crack is closed by length Δa. Irwin argued that the total elastic work

required by σ22 in closing the crack is equal to the energy released. Balancing the

two energies, we have

where B is the thickness of the plate; the integral is multiplied by 2 to

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Since Δa can be chosen as small as we like, ΔKI can be made small enough to be

neglected in comparison to KI.

This integration can be solved by substitution i.e. s = Δa sin2α and

ds = 2 Δa sinα cosα dα

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The relation is simple, but is rigorous only for brittle materials in which

the components remain elastic.

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 Therefore for a plane stress,

In the case of a plane strain, the relationship becomes

In case all three modes are present, the energy of each mode is added

up to GTOT, as

GTOT = GI + GII + GIII

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CRITICAL STRESS INTENSITY FACTOR
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If the SIF of a crack approaches or exceeds an upper limit of the stress intensity factor,

the crack may grow. The upper limit is known as the critical stress intensity factor which

is a material property and is usually denoted by the symbol KIc for Mode I cases (KIIc and

KIIIc for Mode II and Mode III respectively).

In order to provide a feel of stress intensity factor and the critical stress intensity factor,

an analogy is made with stress and yield stress of a solid. Stress is a parameter which

represents internal loading within the solid and yield stress is the limit on stress, beyond

which the material is regarded to have failed by many designers.

Similarly, stress intensity factor is a parameter to measure the severity of stress at the

crack tip. But, critical stress intensity factor is the limit on the SIF, such that if the SIF

exceeds the critical stress intensity factor, the crack may grow.

Thus, in order to predict the growth of a crack in a component, the designer should find

two values: (i) the SIF determined through analysis for the geometry of the component,

crack configuration and applied loads and (ii) the critical SIF determined through

experiments for the material of the component.

If the stress intensity factor exceeds the critical stress intensity factor, the designer

should do something, such as reducing the loads on the component, modifying the

geometry of the component, or choosing a material of higher toughness.

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One difficulty, faced during the experimental determination of the critical SIF for the

material of the component, is that critical SIF is found to be dependent on the thickness

of a plate. In fact, the critical SIF is independent of the thickness only in the case of a

thick plate, because the plate is then loaded in the plane strain. One question remains-

what is the criterion of assuring that the plane strain conditions prevail? The size of the

plastic zone in the vicinity of the crack tip decides it. If the plate thickness is significantly

greater than the size of the plastic zone, then the conditions of plane strain exist.

Thus, we find that the critical SIF becomes a property of the material only for plane

strain cases. Therefore, in handbooks and literature, the values of critical SIFs of

commonly used materials (steel, aluminum, titanium, brass, etc.) are given for plane

strain conditions.

Critical stress intensity factor for thin plates depends on the plate thickness and its

value is rarely provided as a function of thickness in literature. However, the critical SIF

of a plane stress case is higher than the corresponding value in a plane strain. A

designer may find that a component is subjected to plane stress, but critical SIF is

available only for plane strain. He may safely use the critical SIF of the plane strain

because it would provide a conservative design.

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 Fracture Toughness vs Thickness

Ref. Nondestructive Evaluation Physics : Materials ([Link])

In certain design problems (e.g., components of airplanes, rockets and

spaceships), using the critical SIF of a plane strain as material property may be too

conservative, because structural plates are mostly used in plane stress. Adopting

a too conservative approach is against the philosophy of engineering profession.

Engineers should always strive to obtain numbers close to reality. In aerospace

applications, where the factor of safety is of the order of 1.1 for many

components, using material toughness properties of plane strain is likely to make

the machine heavy with poor payload.

In such a situation, stress intensity factor is determined by preparing a test-

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In such a situation, stress intensity factor is determined by preparing a test-

specimen of same thickness as of plates used in the actual application.

However, for most down-to-earth problems (such as the designing components of

automobiles, roof trusses, locomotive carriages, pipe lines, etc.) the conservative

approach of using the critical SIP of the plane strain may be quite practical and

useful.

Critical SIF of a material depends on many factors, such as

• Heat treatment which controls the yield stress of the material.

• Speed of the crack.

• Temperature of the specimen.

• Process of manufacturing (e.g., vacuum furnaced or air melted, as cast or rolled).

• Orientation of the crack with respect to the grains at the crack tip.

• Test method.

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