Adaptive FEM for 2D Crack Growth Simulation
Adaptive FEM for 2D Crack Growth Simulation
Doi:10.32604/cmes.2025.071583
ARTICLE
Department of Mechanical Engineering, College of Engineering and Computer Sciences, Jazan University, Jazan, 45142, Saudi Arabia
*Corresponding Author: Abdulnaser M. Alshoaibi. Email: alshoaibi@[Link] or alshoaibi@[Link]
Received: 07 August 2025; Accepted: 09 October 2025; Published: 30 October 2025
ABSTRACT: Fatigue crack growth is a critical phenomenon in engineering structures, accounting for a significant
percentage of structural failures across various industries. Accurate prediction of crack initiation, propagation paths,
and fatigue life is essential for ensuring structural integrity and optimizing maintenance schedules. This paper presents
a comprehensive finite element approach for simulating two-dimensional fatigue crack growth under linear elastic
conditions with adaptive mesh generation. The source code for the program was developed in Fortran 95 and compiled
with Visual Fortran. To achieve high-fidelity simulations, the methodology integrates several key features: it employs
an automatic, adaptive meshing technique that selectively refines the element density near the crack front and areas
of significant stress concentration. Specialized singular elements are used at the crack tip to ensure precise stress
field representation. The direction of crack advancement is predicted using the maximum tangential stress criterion,
while stress intensity factors are determined through either the displacement extrapolation technique or the J-integral
method. The simulation models crack growth as a series of linear increments, with solution stability maintained by
a consistent transfer algorithm and a crack relaxation method. The framework’s effectiveness is demonstrated across
various geometries and loading scenarios. Through rigorous validation against both experimental data and established
numerical benchmarks, the approach is proven to accurately forecast crack trajectories and fatigue life. Furthermore,
the detailed description of the program’s architecture offers a foundational blueprint, serving as a valuable guide for
researchers aiming to develop their specialized software for fracture mechanics analysis.
KEYWORDS: Finite element method; adaptive meshing; fatigue crack growth; mesh generation; stress intensity factor;
damage tolerant design
1 Introduction
Fatigue crack growth is a critical phenomenon in engineering structures subjected to cyclic loading,
accounting for a significant percentage of structural failures across industries. Recent studies estimate
that fatigue-related failures represent approximately 50%–90% of all mechanical failures in industrial
components [1–3]. The ability to accurately predict crack initiation, propagation paths, and fatigue life is
essential for ensuring structural integrity, optimizing maintenance schedules, and preventing catastrophic
failures. Over the past decades, computational modeling has emerged as a powerful tool for simulating
fatigue crack growth, complementing traditional experimental approaches and enabling more efficient and
cost-effective design processes in two and three dimensions. Linear Elastic Fracture Mechanics (LEFM)
provides a theoretical framework for analyzing crack growth in materials where plastic deformation is limited
to a small region around the crack tip. Within this framework, the stress intensity factor (K) characterizes
the stress field at the crack tip and serves as the primary parameter governing crack propagation. For fatigue
crack growth analysis, the range of stress intensity factor (ΔK) during a loading cycle is the key driver of
crack propagation, typically described by the Paris law:
where da/dN is the crack growth rate, ΔK is the stress intensity factor range, and C and m are material
constants determined experimentally. While this classical relationship remains foundational, recent research
has extended its application to more complex scenarios, including variable amplitude loading, environmental
effects, and functionally graded materials [4].
The finite element method (FEM) has been widely adopted for numerical simulation of fatigue crack
growth due to its versatility in handling complex geometries and loading conditions. However, conventional
FEM approaches face challenges in accurately capturing the stress singularity at the crack tip and efficiently
updating the mesh as the crack propagates. These challenges have motivated the development of specialized
techniques, including singular elements at the crack tip and adaptive mesh refinement strategies. Jaccon
et al. [5] demonstrated that coupling adaptive mesh refinement with cycle jump techniques can significantly
accelerate computation time while maintaining solution accuracy, making it feasible to simulate high-cycle
fatigue scenarios that were previously computationally prohibitive. Adaptive mesh generation is particularly
valuable in fracture mechanics simulations, as it allows for optimal allocation of computational resources by
refining the mesh in regions of high stress gradients (especially near the crack tip) while maintaining a coarser
mesh elsewhere. This approach not only improves accuracy but also enhances computational efficiency,
making it possible to simulate complex crack growth scenarios with reasonable computational resources.
The advancing front method represents one particularly effective approach for generating high-quality
meshes that adapt to evolving crack geometries during propagation simulations. Recent advancements
in the fracture mechanics field include sophisticated modeling techniques, such as the stress-intensity-
factor-driven phase field approach for mixed-mode fracture analysis, which offers a more comprehensive
understanding of complex crack behaviors by bridging phase-field formulations with linear elastic fracture
mechanics [6]. Concurrently, research continues to address practical challenges like the fatigue crack prop-
agation in corroded steel box girders found in long-span bridges, highlighting the ongoing need for robust
predictive models and material characterization under adverse conditions [7]. Furthermore, recent studies
by Thiruvannamalai et al. [8] have shown that adaptive meshing techniques can reduce simulation time
compared to uniform refinement while maintaining solution accuracy within 2% of analytical benchmarks.
Furthermore, Zhang et al. [9] introduced an adaptive phase-field framework with variable-node elements
that significantly improves the efficiency of crack nucleation and propagation simulations in brittle materials.
The field of structural optimization has seen significant advancements, particularly in addressing complex
real-world challenges such as fatigue. In this context, recent research has focused on integrating advanced
crack propagation analysis into topology optimization methodologies. For instance, one notable study
introduces an advanced structural topology optimization approach that integrates fatigue crack propagation
analysis. Utilizing the Extended Finite Element Method (X-FEM) for initial crack propagation and the
Paris model for fatigue crack growth, the methodology aims to minimize structural compliance under
volume and fatigue constraints. The proposed bi-directional evolutionary structural optimization (BESO)
algorithm effectively adapts material distribution based on various crack conditions, including presence,
direction, and length. The results demonstrate the algorithm’s ability to achieve optimal topologies that
balance structural integrity and performance, highlighting the significant influence of crack characteristics
on the final design and structural stiffness [10]. To further strengthen the scientific scope and neutrality
of this study, it is pertinent to acknowledge and briefly discuss recent advancements in alternative and
Comput Model Eng Sci. 2025;145(1) 191
complementary methodologies for fatigue crack growth simulation. These include the Extended Finite
Element Method (XFEM), phase-field approaches, and modern adaptive remeshing techniques, which offer
distinct advantages and address various challenges in fracture mechanics. XFEM has emerged as a powerful
tool for simulating crack propagation without the need for continuous remeshing along the crack path,
significantly simplifying the modeling of complex crack geometries and arbitrary crack growth [11,12]. Recent
studies have demonstrated XFEM’s effectiveness in various fatigue crack growth scenarios, including those
in welded joints and cladded structures [13,14]. While, phase-field models represent cracks as diffuse zones
rather than sharp discontinuities, offering a robust framework for simulating complex fracture phenomena
such as crack initiation, propagation, and branching, especially in brittle and quasi-brittle materials [5,15].
These methods are particularly adept at handling multiple interacting cracks and complex crack patterns
without explicit crack tracking algorithms. Recent research has focused on adaptive finite element methods
for phase-field fracture to improve computational efficiency while maintaining accuracy [16].
Such developments are crucial for designing robust and durable structures under cyclic loading
conditions. The accurate calculation of stress intensity factors (SIFs) remains a critical aspect of fatigue
crack growth simulation. Among various methods, the displacement extrapolation technique has gained
prominence due to its relative simplicity and accuracy. This method involves extrapolating the displacement
field near the crack tip to determine the SIFs. The splitting node approach represents a significant advance-
ment in computational fracture mechanics. This methodology enables precise tracking of crack propagation
by duplicating nodes along the predicted fracture path, effectively creating new surfaces that represent
the physical separation of material. In computational fracture mechanics, the evaluation of strain energy
fields or displacement openings near crack tips is conducted based on fundamental mechanical principles.
When these parameters surpass their critical thresholds, crack propagation occurs as a natural consequence
of the material’s response to loading conditions. The integration of these methodologies—splitting node
approach, displacement extrapolation technique, adaptive meshing, and linear elastic fracture mechanics
principles—creates a powerful computational framework for investigating complex fracture phenomena.
This integrated approach enables researchers to predict crack initiation, propagation paths, and ultimate
failure conditions across a diverse range of materials and loading scenarios with unprecedented accuracy. The
implementation of three-dimensional re-meshing algorithms presents substantial computational challenges
compared to two-dimensional analyses. These challenges include more complex geometry representation,
increased computational resources, and sophisticated mesh adaptation strategies. Despite these differences,
research has demonstrated that stress intensity factor predictions in both 2D and 3D simulations achieve
remarkable consistency when equivalent mesh refinement techniques are applied [17,18]. This convergence
validates the robustness of the underlying mathematical models across dimensional frameworks. The
developed computational platform employs finite element methodologies that produce results comparable
to those obtained from established commercial fracture analysis software. However, commercially available
software packages often present limitations in two critical aspects: they frequently operate as “black boxes”
with limited transparency regarding their core algorithms, and they may not incorporate state-of-the-art
programming techniques that enhance computational efficiency and accuracy. These limitations under-
score the importance of developing specialized research-oriented software that provides full algorithmic
transparency and leverages cutting-edge programming methodologies. For more than two decades, this
software has been refined to accurately model 2D fatigue crack growth, incorporating LEFM assumptions.
The effectiveness of the computational approach has been validated through extensive testing across diverse
specimen configurations [19,20].
192 Comput Model Eng Sci. 2025;145(1)
This paper presents a comprehensive finite element approach for simulating two-dimensional fatigue
crack growth under linear elastic conditions with adaptive mesh generation. The methodology incorporates
several key features:
1. Automatic adaptive mesh refinement in the vicinity of the crack front and regions of high stress gradients,
building on recent advancements in error estimation and mesh quality control.
2. Singular crack tip elements to accurately capture the stress singularity, incorporating the latest develop-
ments in element formulation for fracture mechanics.
3. Displacement extrapolation technique for stress intensity factor calculation, enhanced with recent
improvements in accuracy and robustness.
4. Maximum tangential stress criterion for crack growth direction determination, validated against con-
temporary experimental studies.
5. Paris law for fatigue life prediction.
This paper introduces an automated adaptive finite element methodology for 2D linear elastic fatigue
crack growth simulation. While building upon established principles of fracture mechanics and numerical
methods, the framework’s primary novelty stems from the synergistic integration, specific enhancements,
and robust implementation of several key components within a custom-developed, transparent computa-
tional tool. This integrated approach enables robust and efficient simulation of complex crack propagation
scenarios that are often challenging for conventional or ‘black-box’ commercial software, offering significant
advancements in algorithmic aspects, accuracy, and efficiency compared to existing methods.
This framework presents notable algorithmic advancements, including a highly integrated and auto-
mated adaptive mesh refinement strategy that precisely refines the mesh around crack fronts. This is coupled
with a robust crack propagation algorithm featuring a consistent transfer and crack relaxation method,
ensuring solution stability and accuracy during complex crack growth while minimizing re-meshing to only
the affected regions. Furthermore, the entire framework is implemented in a transparent, modular Fortran 95
code, providing researchers with full algorithmic access for further development and customization. These
algorithmic innovations lead to enhanced accuracy through the integration of specialized singular crack tip
elements directly into the adaptive meshing scheme, ensuring high-precision capture of stress singularities
at every crack increment. This, combined with an enhanced displacement extrapolation technique, yields
more reliable SIF calculations and accurate fatigue life predictions. This approach distinguishes itself from
the Extended Finite Element Method (XFEM), which uses enrichment functions to decouple cracks from the
mesh [21,22]. In contrast, the present adaptive FEM maintains explicit control over mesh quality and element
alignment with the crack path. This meticulous control is critical for accurately capturing stress fields and
SIFs in highly localized regions. While XFEM avoids re-meshing, our method focuses on optimizing the
mesh locally to the crack path, ensuring high-fidelity stress and displacement fields directly from the mesh
geometry, which can offer competitive efficiency for 2D linear elastic problems. Moreover, our framework
differs from Phase-Field models, which represent cracks as diffuse zones governed by a continuous phase-
field variable. While powerful for complex crack phenomena, phase-field models often require extensive
parameter calibration and very fine meshes, leading to high computational costs [23,24]. The present LEFM-
based framework, with its explicit crack tracking, is specifically accurate alternative for specific LEFM
applications, especially when leveraging our advanced adaptive meshing and solution transfer techniques.
The proposed approach is implemented in a custom finite element software that handles arbitrary 2D
geometries under constant amplitude loading. The software focuses on determining crack paths and stresses
as well as evaluating component lifetimes as part of damage-tolerant assessment.
Comput Model Eng Sci. 2025;145(1) 193
INTEGER:: mesh_iter,maxmesh_iter=1,maxgrow=10,kgrow
REAL*8:: elapse_time
LOGICAL:: igrow
! Input files (STATUS=‘OLD’)
OPEN(10,FILE=‘[Link]’,STATUS=‘OLD’)
OPEN(11,FILE=‘[Link]’,STATUS=‘OLD’)
OPEN(16,FILE=‘[Link]’,STATUS=‘OLD’)
OPEN(18,FILE=‘[Link]’,STATUS=‘OLD’)
OPEN(25,FILE=‘[Link]’,STATUS=‘OLD’)
! Output/Scratch files (STATUS=‘REPLACE’)
OPEN(12,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(13,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(14,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(15,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(17,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(19,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(20,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(21,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(22,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(23,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(24,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(26,FILE=‘[Link]’,STATUS=‘REPLACE’)
OPEN(27,FILE=‘[Link]’,STATUS=‘REPLACE’)
• The Crack Propagation Loop
The core of the fatigue crack growth simulation lies within the propagate DO loop. This loop iteratively
advances the crack, performing a complete finite element analysis at each step. The simulation continues until
either the maximum number of crack growth increments (maxgrow) is reached or the crack propagation
criteria are no longer met.
propagate: DO
! Preprocessing steps: Geometry and Mesh Generation
CALL rostemp ! Cuts out a rosette template from the geometry
CALL bmstruc
mesh_iter=0
remesh: DO ! Inner loop for adaptive remeshing
! Mesh Creation and Refinement
CALL advfrom
CALL addrose ! Patches singular elements around the crack tip
CALL writer6 ! Writes the six-noded triangular mesh and loading data
Comput Model Eng Sci. 2025;145(1) 195
CLOSE(26)
CLOSE(27)
END PROGRAM
• Implementation and Workflow
The overall workflow of the simulation is controlled by two nested loops:
1. The outer loop (propagate loop) manages the crack growth process, with each iteration representing a
crack extension step.
2. The inner loop (remesh loop) handles the adaptive mesh refinement, ensuring mesh quality and solution
accuracy at each crack configuration.
The implementation follows this sequence:
kgrow = 0
propagate: DO
! Cut out rosette template from geometry
CALL rostemp
! Create structured background mesh
CALL bmstruc
mesh_iter = 0
remesh: DO
! Create mesh by the advancing front method
CALL ADVROM
! Patch the singular elements to template
CALL ADDROSE
! Six noded the mesh triangles and loading etc
CALL writer6
! Solve system by iterative Preconjugate Gradient
CALL PROCESS
! Evaluate unsmoothed and smoothed stress field
CALL STRESES
IF (mesh_iter == maxmesh_iter) EXIT remesh
! Evaluate error estimator for h-type adaptive mesh
CALL ESTIMAT
mesh_iter = mesh_iter + 1
END DO remesh
! Calculate stress intensity factor
CALL sifcalc
! Write result for Post2D
CALL results
IF (kgrow == maxgrow) EXIT propagate
Comput Model Eng Sci. 2025;145(1) 197
2.2 Preprocessing
2.2.1 Geometry and Initial Crack Definition
The simulation begins with the definition of the problem geometry, initial crack configuration,
boundary conditions, and material properties. These are specified through input files:
• [Link]: Contains the geometric definition of the domain.
• [Link]: Specifies the initial crack tip location and orientation.
• [Link]: Defines boundary conditions and loading information.
• [Link]: Contains material properties, including elastic modulus, Poisson’s ratio, fracture tough-
ness, threshold stress intensity factor, thickness and Paris law constants.
The program supports arbitrary 2D geometries, allowing for the simulation of various test specimens
and structural components with different crack configurations and geometric discontinuities such as holes.
This specialized node positioning creates the mathematical foundation for accurately representing the
stress singularity that characterizes crack tip behavior in fracture mechanics. The quarter-point elements
√
effectively capture the 1/ r singularity in the stress field, which is essential for precise stress intensity factor
calculations [2]. Without this modification, conventional elements would fail to represent the steep stress
gradients near the crack tip, leading to significant computational errors.
Background Mesh Generation
Creating a high-quality computational mesh is crucial for accurate simulations, especially when dealing
with complex geometries or phenomena requiring varying levels of detail. Highly refined and specialized
meshes are achieved by employing a background mesh. This background mesh acts as a guide, dictating the
geometric characteristics of the final mesh.
One of its key benefits is enabling a non-uniform distribution of element sizes throughout the domain.
This is particularly important for highly graded meshes, where specific areas demand finer resolution
(smaller elements) while others can tolerate coarser elements, optimizing computational efficiency without
sacrificing accuracy.
The process of generating a mesh generally follows these three fundamental steps, as outlined by
Zienkiewicz et al. [30]:
1. Boundary Node Generation: Nodes are placed along the boundary edges of the domain. This effectively
creates a discretized representation of the domain’s outer shape.
2. Internal Element and Node Generation: Once the boundary is defined, elements and their corresponding
nodes are generated within the discretized boundary. This populates the interior of the domain with the
computational grid.
3. Element Shape Enhancement: The final step is crucial for mesh quality. Element shape enhancement
techniques are applied to improve the overall quality of the generated elements. This often involves
optimizing factors like aspect ratio, skewness, and Jacobian determinants to ensure stable and accurate
numerical solutions. Poorly shaped elements can lead to inaccuracies or even divergence in simulations.
A structured background mesh is generated for the entire domain using the bmstruc subroutine. This
background mesh provides a framework for the advancing front mesh generation algorithm and ensures
proper element size transitions throughout the domain.
Advancing Front Method
An unstructured mesh is generated using the advancing front technique implemented in the advfrom
subroutine. This method starts from the domain boundaries and progressively creates elements inward,
Comput Model Eng Sci. 2025;145(1) 199
ensuring mesh quality and gradual size transitions. The advancing front mesh generation algorithm oper-
ates sequentially, beginning with discretization of domain boundaries into segments that serve as the
initial “front.” As triangulation progresses, this front evolves dynamically, with new elements continuously
modifying its configuration. The algorithm prioritizes element quality through careful consideration of
size transitions and angular distributions, particularly critical in regions with high stress gradients such
as crack tips [31]. Modern implementations of this technique incorporate adaptive refinement strategies
that automatically adjust element density based on error estimators. These estimators evaluate solution
gradients and identify regions requiring finer discretization, ensuring computational resources are allocated
efficiently [32]. The topological bisection algorithm represents a powerful approach for background mesh
generation, utilizing boundary node information to construct a robust triangular discretization framework.
Unlike conventional techniques, this method leverages both external and internal boundary definitions
to create a cohesive computational representation. The fundamental principle of topological bisection
involves conceptualizing the computational domain as a complex polygonal entity. Through systematic
recursive partitioning, the algorithm progressively divides the domain into increasingly simplified polygonal
subregions until reaching optimal granularity for finite element analysis. This divide-and-conquer strategy
enables efficient handling of complex geometries while maintaining high-quality element formation. A
distinguishing characteristic of advanced topological bisection implementations is their treatment of multi-
connected domains containing internal voids or holes. Rather than processing these features independently,
the algorithm establishes strategic connector pathways between internal and external boundaries. These
connectors transform the multi-connected domain into a simply-connected polygonal region, significantly
simplifying the subsequent triangulation process. This topological modification preserves the geometric
integrity of the original domain while enabling more efficient computational processing. The connector
pathway generation between internal and external boundaries represents a critical aspect of the algorithm.
Modern implementations utilize computational geometry principles to identify optimal connector routes,
typically employing shortest-path algorithms between strategically selected boundary points. These connec-
tors effectively “stitch” the domain into a topologically simpler structure while minimizing distortion of the
resulting mesh elements [33]. The selection of division points for domain partitioning follows a sophisticated
hierarchical approach. The process begins by identifying boundary vertices with significant angular features,
as these locations typically represent critical geometric characteristics that should be preserved in the final
mesh. The algorithm establishes angular thresholds for identifying these features, creating a prioritized
sequence of potential division points [34].
For each candidate division point, the algorithm constructs an angular search sector to identify optimal
connection targets on non-adjacent boundary segments. This sector-based search strategy ensures that
resulting subdivisions maintain favorable geometric properties, avoiding highly acute or obtuse angles that
would compromise element quality. The angular sector parameters are dynamically adjusted based on local
geometric characteristics to optimize subdivision quality [35]. When primary division strategies fail to
identify suitable connection points, the algorithm implements a cascading fallback mechanism. This involves
progressively relaxing the angular constraints and considering boundary vertices with less pronounced
features. This adaptive approach ensures robust performance across diverse geometric configurations,
including those with challenging features such as narrow channels or sharp protrusions [36].
Singular Element Integration
The rosette template with singular elements is integrated with the global mesh using the addrose
subroutine. This integration ensures that the singular elements at the crack tip are properly connected to the
surrounding mesh, maintaining both geometric and solution continuity.
200 Comput Model Eng Sci. 2025;145(1)
Mesh Refinement
Adaptive mesh refinement represents a sophisticated optimization methodology within the domain
of finite element analysis. This approach dynamically adjusts mesh density to maximize computational
efficiency while maintaining solution accuracy. The refinement process strategically concentrates elements
along crack propagation paths and intensifies mesh density toward crack tips through a specialized adaptive
refinement algorithm. This methodology leverages a posteriori error estimation derived from preceding
mesh generations, creating an iterative refinement process that continuously improves solution quality.
An error estimation procedure is implemented in the estimat subroutine to identify regions requiring
mesh refinement. The refinement is applied in two key areas:
1. In the vicinity of the crack front nodes to accurately capture the stress singularity
2. In elements representing higher stress distributions to ensure accurate stress field calculation
The mesh refinement process is iterative, with the number of iterations controlled by the maxmesh_iter
parameter. This adaptive approach ensures that computational resources are allocated efficiently, with finer
mesh in critical regions and coarser mesh elsewhere. The relative stress norm error serves as the fundamental
metric for quantifying discretization error in adaptive mesh refinement. This dimensionless parameter
provides a reliable approximation of local and global solution errors, guiding the refinement process with
mathematical precision. The h-type adaptive mesh optimization utilizes this error metric to determine
optimal element sizing throughout the computational domain. Additional information on the refinement of
the adaptive mesh can be found in [37].
2.3 Processing
2.3.1 Element Formulation
Six-noded triangular elements are used for the main domain, providing quadratic interpolation of
displacements. This element type offers a good balance between accuracy and computational efficiency for
2D problems. The element formulation is implemented in the writer6 subroutine.
√
At the crack tip, quarter-point singular elements are employed to accurately represent the 1/ r stress
singularity predicted by linear elastic fracture mechanics. These elements are created by moving the mid-side
√
nodes to the quarter-point position, resulting in a 1/ r strain variation near the crack tip. To characterize
the stress field around a crack tip, Irwin [38] applied Westergaard’s [39] semi-inverse method. This approach
allowed him to show that the primary stress components associated with the three displacement modes could
be expressed in the following form:
σ y = √K2πr
I
f (θ)
τ x y = 2πr f (θ)
√K II
(2)
σ yz = √K2πr
III
f (θ) .
In these expressions, r denotes the radial distance emanating from the crack tip, and the other terms are
functions of the polar angle θ, as shown in Fig. 2. Critically, every mode of loading results in a characteristic
√
1/ r singularity at the crack tip, providing the mathematical basis for understanding the stress concentration
phenomenon in cracked materials. Furthermore, KI , KII and KIII are designated as the stress intensity factors,
each corresponding to one of the three fundamental cracking modes.
Comput Model Eng Sci. 2025;145(1) 201
2.4 Postprocessing
2.4.1 Stress Intensity Factor Calculation
Stress intensity factors are calculated using the displacement extrapolation technique implemented in
the sifcalc subroutine. This method involves:
1. Extracting nodal displacements near the crack tip
2. Calculating the relative displacements of crack faces
3. Extrapolating these displacements to determine KI and KII
4. For mixed-mode loading, stress intensity factors are calculated, and the equivalent stress intensity factor
is derived from these components using the following formula [40]:
1 θ
ΔK e q = cos ( ) [ΔK I (1 + cos θ) − 3ΔK II sinθ] (3)
2 2
202 Comput Model Eng Sci. 2025;145(1)
This criterion is implemented as part of the crack propagation algorithm in the cracpro subroutine.
Future research will aim to extend this framework by integrating more advanced material constitutive
models, such as elastoplastic formulations, to capture a broader range of material responses. Additionally,
incorporating more sophisticated fatigue crack growth models that can account for load sequence effects,
retardation, 3D crack growth, and variable amplitude loading will enhance the predictive capabilities and
applicability of the topology optimization framework to a wider array of engineering scenarios.
The current framework, utilizing the maximum tangential stress criterion, is limited to simulating single
crack propagation and does not inherently predict or model crack branching. Future work could extend the
framework by incorporating advanced branching criteria or employing methods like XFEM or phase-field
models to handle multiple and complex crack geometries. This continuous refinement will contribute to the
development of more comprehensive and accurate design tools for fatigue-critical structures.
(a) (b)
Figure 4: (a) Geometrical representation of a plate with an edge crack and a circular hole, (b) Initial mesh
For the purpose of rigorous comparative analysis and validation, the crack growth trajectory predicted
by the present study’s simulations (Fig. 5a) was benchmarked against results obtained from two well-
established numerical techniques: the Multi-scale Cell-based Meshless Method (MCMM), as documented
by [43] (Fig. 5b), and the Virtual Node Extended Finite Element Method (VNXFEM), as presented in [44],
(Fig. 5c). This comparative approach is paramount for substantiating the accuracy, reliability, and general
applicability of the developed program in simulating complex fracture mechanics problems. The simulations
conducted within this study consistently demonstrated a remarkable concordance between the predicted
crack growth trajectories and the findings reported in the independent studies utilizing MCMM [43] and
VNXFEM [44]. This strong agreement serves as compelling evidence of the robustness and predictive
capability of the developed program. The congruence across different methodologies, each with its unique
theoretical underpinnings and computational advantages, significantly enhances the confidence in the
obtained results. The visual comparison of these crack growth paths, highlighting the close alignment
between the present study’s results and those from [43] and [44], is comprehensively illustrated in Fig. 4.
with its initial mesh. The specimen is subjected to uniaxial cyclic loading, a common scenario in engi-
neering components, to understand the interplay between applied stress, geometric discontinuities, and
material response. The primary objective is to analyze the propagation behavior of these interacting
cracks, particularly focusing on the influence of stress intensity factors (SIFs) and their impact on crack
path deviation.
Figure 5: Crack growth path, (a) Present study, (b) Numerical results [43], and (c) Numerical results [44]
(a) (b)
Figure 6: Geometrical representation of the plate with central hole and three edge cracks (left), and initial mesh (right)
206 Comput Model Eng Sci. 2025;145(1)
The boundary conditions and loading details are critical for understanding the stress distribution within
the specimen. The plate is subjected to cyclic loading with a controlled displacement of −0.005 mm, applied
at the base to induce tensile stress in the upper region. This controlled displacement simulates real-world
fatigue scenarios where components experience repeated stress cycles.
The material chosen for this investigation is Aluminum 7075, a high-strength aluminum alloy widely
used in aerospace and structural applications due to its excellent mechanical properties. Specifically, Al-
7075 exhibits a high strength-to-weight ratio, good fatigue resistance, and toughness. For the purpose of this
study, the elastic modulus of Al-7075 is taken as 72 GPa, and its Poisson’s ratio is 0.33. The plate thickness is
maintained at 3 mm to ensure plane stress conditions, simplifying the analytical and numerical modeling of
crack behavior.
Fig. 7a,b compares the predicted crack growth paths from the current study (with and without mesh) to
numerical results obtained by Dündar and Ayhan [45] using FEM. This is further validated against Judt and
Ricoeur’s [46] findings, which utilized the remote contour interaction integrals method, as shown in Fig. 7c.
The close agreement across these results underscores the validity of the present study’s methodology
and observations.
Figure 7: Comparison of predicted crack growth paths (a) Present study with mesh, (b) Present study without mesh,
(c) Numerical results of [45,46]
In scenarios involving multiple cracks, the propagation sequence is dictated by the SIF values. Based
on Fig. 7, crack 3 is predicted to propagate first, followed by crack 2, and finally crack 1. This sequential
propagation highlights the dynamic nature of multi-crack systems, where the evolution of SIFs at each crack
tip determines the overall fracture process.
As depicted in Fig. 7, the eccentricity of the cracks induces significant shear stress, leading to the
dominance of Mode II SIFs. This prevalence of KII is directly responsible for the observed deviation of crack
propagation paths from the initial horizontal plane. A key finding is that the close vertical proximity between
the second and third cracks results in elevated SIFs within this localized region, surpassing those observed
around the first crack. Consequently, the second and third cracks exhibit a more rapid propagation rate
compared to the first crack, which advances at a comparatively slower pace. A critical observation from the
study is the faster growth rate of the second and third cracks compared to the first. This is attributed to the
smaller vertical distance between them, leading to higher localized SIFs in their vicinity. Conversely, the
effect of the load on crack 1 is less pronounced compared to the other two cracks, and the hole’s influence
on its direction is minimal. Consequently, crack 1 propagates in a direction away from the hole’s vicinity,
extending up to 15 mm. This emphasizes the importance of crack interaction in multi-crack systems, where
Comput Model Eng Sci. 2025;145(1) 207
the stress fields of adjacent cracks can significantly influence each other’s propagation behavior. To ensure
a valid comparison for all three cracks, regardless of their length, the crack increments in the current
analyses were adjusted to match those in Ref. [45]. Accordingly, the Equivalent Stress Intensity Factors (SIFs)
are calculated using Eq. (3) and compared to the results obtained by Ref. [45], as shown in Fig. 8. This
comparison demonstrates good agreement.
As illustrated in Fig. 9a, c and b are length parameters equal to 54 mm, and α is defined as the
loading angle.
2. Lower Holes: The second set of boundary conditions utilizes kinematic constraints to secure the lower
holes, thereby replicating the effect of structural pins at their respective centers.
The finite element analysis was conducted with a constant applied load of 14 kN and a stress ratio of 0.1,
while the loading angle was varied across 30○ , 45○ , and 60○ . The initial generated mesh is shown in Fig. 9c.
208 Comput Model Eng Sci. 2025;145(1)
Figure 9: (a) CTS Specimen Geometry and Boundary Conditions, (b) The loading device for applying various loading
angles, (c) The initial generated mesh
The predictive capability of the developed program was rigorously tested by comparing its results with
established experimental data. As illustrated in Figs. 10 and 11, the crack growth directions simulated by
the analysis show a strong correlation with the physical experiments conducted by Sajith et al. [49]. This
comparison, performed across a range of loading angles (30○ , 45○ , and 60○ ), serves as a critical validation
of the methodology, demonstrating its effectiveness in accurately modeling fracture behavior under varied
stress conditions.
Figure 10: Predicted crack growth path: (a) 30○ loading angle, (b) 45○ loading angle, and (c) 60○ loading angle
Comput Model Eng Sci. 2025;145(1) 209
Figure 11: Experimental crack growth path: (a) 30○ loading angle [49], (b) 45○ loading angle [49], and (c) 60○ loading
angle [49]
This investigation estimated the number of cycles for various loading angles (30○ , 45○ , and 60○ ), and
these estimations align significantly with experimental results for mixed-mode (I/II) loading reported by [49]
as illustrated in Figs. 12–14. The present study’s predicted fatigue life cycles demonstrated high fidelity, with a
maximum relative error of no more than 1% compared to the experimental data reported by Sajith et al. [49].
The proposed adaptive finite element methodology demonstrates robust performance in 2D linear
elastic fatigue crack growth simulation, primarily due to its algorithmic transparency, accurate adaptive
meshing with specialized crack tip elements, and computational efficiency achieved by optimizing mesh
refinement. The integration of a consistent transfer algorithm and crack relaxation method further ensures
solution stability during incremental crack propagation. However, certain limitations were taken into
account when developing the program:
• Mesh Distortion: While adaptive remeshing is employed, complex crack paths or large deforma-
tions can lead to mesh distortion, potentially affecting accuracy and simulation stability. The current
implementation includes element shape checks and criteria for remeshing to mitigate this limitation.
• Convergence Problems: Convergence issues can arise from the non-linear nature of crack growth and
data transfer during remeshing. This framework addresses this through a consistent transfer algorithm
using advanced interpolation and a crack relaxation method to stabilize solutions.
5 Conclusions
This paper presents a comprehensive finite element methodology for simulating two-dimensional
fatigue crack growth under linear elastic conditions, leveraging a custom program developed in Fortran 95.
The approach is built upon a robust computational framework that integrates several advanced techniques
to ensure both accuracy and efficiency. Key features of the methodology include:
• Adaptive Mesh Generation: The system employs automatic adaptive mesh refinement, which strategi-
cally increases mesh density in critical areas, such as the vicinity of the crack front and regions with
high stress gradients. This selective refinement optimizes computational resources while maintaining
high precision.
• Accurate Stress Calculation: To accurately capture the stress singularity at the crack tip, specialized sin-
gular crack tip elements are utilized. The stress intensity factors (SIFs), which govern crack propagation,
are calculated using the reliable displacement extrapolation technique.
• Crack Growth Prediction: The direction of crack propagation is determined using the maximum
tangential stress criterion. The rate of growth and the fatigue life of the component are then predicted
based on the Paris law, which relates the crack growth rate to the stress intensity factor range.
• Stable Simulation: A consistent transfer algorithm and a crack relaxation method are implemented to
ensure the stability and reliability of the solution as the crack propagates through the material.
Comput Model Eng Sci. 2025;145(1) 211
The effectiveness and accuracy of this integrated approach were validated through three distinct case
studies: edge-cracked plates containing a circular hole, plate with central hole and three edge cracks, and a
compact tension shear specimen with different loading angle. In addition, the program’s validity and accuracy
are corroborated by numerous published articles in the existing literature. The results from these studies,
which utilize the developed program, show a strong correlation with both experimental data and other
numerical results. This confirms the methodology’s capability to accurately predict physical crack paths and
component fatigue lives. Ultimately, this work provides a powerful and validated computational tool for
engineering applications, particularly in the fields of damage-tolerant design, fitness-for-service assessments,
and failure analysis. By providing a clear and detailed procedure, the developed program serves as a valuable
guide for researchers, offering a foundational blueprint that can help them build their own customized
simulation tools for fracture mechanics analysis. This makes the work a powerful resource for engineering
applications in damage-tolerant design, fitness-for-service assessment, and failure analysis.
Acknowledgement: Not applicable.
Funding Statement: The authors gratefully acknowledge the funding of the Deanship of Graduate Studies and Scientific
Research, Jazan University, Saudi Arabia, through Project number: JU-20250230-DGSSR-RP-2025.
Author Contributions: Conceptualization, Abdulnaser M. Alshoaibi; Methodology, Yahya Ali Fageehi; Software,
Abdulnaser M. Alshoaibi; Validation, Abdulnaser M. Alshoaibi; Formal analysis, Yahya Ali Fageehi and Abdulnaser M.
Alshoaibi; Investigation, Yahya Ali Fageehi and Abdulnaser M. Alshoaibi; Resources, Yahya Ali Fageehi and Abdulnaser
M. Alshoaibi; Data curation, Abdulnaser M. Alshoaibi; Writing—original draft, Abdulnaser M. Alshoaibi; Writing—
review & editing, Abdulnaser M. Alshoaibi; Visualization, Abdulnaser M. Alshoaibi; Supervision, Yahya Ali Fageehi and
Abdulnaser M. Alshoaibi; Project administration, Yahya Ali Fageehi and Abdulnaser M. Alshoaibi; Funding acquisition,
Yahya Ali Fageehi and Abdulnaser M. Alshoaibi. All authors reviewed the results and approved the final version of
the manuscript.
Availability of Data and Materials: The original contributions presented in this study are included in the article.
Further inquiries can be directed to the corresponding author.
Ethics Approval: This study did not involve any human participants, animals, or sensitive personal data. Therefore,
ethics approval was not required in accordance with institutional and national guidelines.
Conflicts of Interest: The authors declare no conflicts of interest to report regarding the present study.
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