Crack Paths and The Linear Elastic Analy
Crack Paths and The Linear Elastic Analy
16
L. P. Pook
21 Woodside Road, Sevenoaks TN13 3HF, United Kingdom
ABSTRACT. The linear elastic analysis of cracked bodies is a Twentieth Century development, with the first
papers appearing in 1907, but it was not until the introduction of the stress intensity factor concept in 1957 that
widespread application to practical engineering problems became possible. Linear elastic fracture mechanics
(LEFM) developed rapidly in the 1960s, with application to brittle fracture and fatigue crack growth. The first
application of finite elements to the calculation of stress intensity factors for two dimensional cases was in 1969.
Finite element analysis had a significant influence on the development of LEFM. Corner point singularities were
investigated in the late 1970s. It was soon found that the existence of corner point effects made interpretation
of calculated stress intensity factors difficult and their validity questionable. In 1998 it was shown that the
assumption that crack growth is in mode I leads to geometric constraints on permissible fatigue crack paths.
Current open questions are. The need for a new field parameter, probably a singularity, to describe the stresses
at surfaces. How best to allow for the influence of corner point singularities in three dimensional numerical
predictions of fatigue crack paths. Adequate description of fatigue crack path stability.
KEYWORDS. Linear elastic analysis; Stress intensity factors; Corner point singularities; Crack paths; Finite
element analysis.
INTRODUCTION
T he complete solution of a crack growth problem includes determination of the crack path. This review is a brief
survey of the development of ideas on the linear elastic analyis of cracked bodies that are relevant to crack path
determination. It is based on the author’s personal involvement over more than 50 years. The review is restricted
to linear elastic, homogeneous, isotropic materials, with any yielding confined to a small region at a crack tip. The first
relevant papers had been published 50 years earlier, but in the late 1950s theoretical understanding of crack growth due to
fatigue and static loadings was limited. The situation changed dramatically in the 1960s with the development of fracture
mechanics, which is the applied mechanics of crack growth [1]. It was realised that linear elastic fracture mechanics, based
on linear elastic analyses, sufficed for the solution of many practical engineering problems. By the mid 1970s practical
applications of fracture mechanics were well established. In considering practical aspects of linear elastic fracture
mechanics, scales of observation need to be taken into account since the scale chosen can make a considerable difference
to the appearance of an object in general, and a crack in particular [2]. Scales of observation of 0.1 mm and above are
usually described as macroscopic. The linear elastic concept of stress intensity factor describes the linear elastic stress field
in the vicinity of a crack tip, and is a singularity. Stress intensity factors may be used to characterise the mechanical
properties of cracked test pieces in just the same way that stresses are used to characterise the mechanical properties of
uncracked test pieces. The conventional notation for the position of a point relative to the crack tip, and for the stresses at
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this point, is shown in Fig. 1. A point on the crack tip is the origin of the Cartesian coordinate system and the z axis lies
along the crack tip. Displacements of points within the cracked body when the body is loaded are u, v, w in the x, y, z
directions. A fundamental fracture mechanics concept is that of crack tip surface displacement [3]. There are three
possible modes of crack tip surface displacement, as shown in Fig. 2. These are: mode I where opposing crack surfaces
move directly apart in directions parallel to the y axis; mode II where crack surfaces move over each other in the xz plane
in directions parallel to the x axis, that is perpendicular to the crack tip; and mode III where crack surfaces move over
each other in the xz plane in directions parallel to the z axis, that is parallel to the crack tip. By superimposing the three
modes, it is possible to describe the most general case of crack tip surface displacement. Where more precise description
is needed Volterra distorsioni can be used [1]. The term mixed mode means that at least one mode, other than mode I, is
present. It is matter of observation that, when viewed on a macroscopic scale, and under essentially elastic conditions,
cracks in metals tend to grow in mode I, so attention is largely confined to this mode. Crack surfaces are assumed to be
smooth, although on a microscopic scale they are generally very irregular.
Figure 1: Notation for crack tip stress field. Figure 2: Notation for modes of crack tip surface displacement.
T he philosophical basis for a fracture mechanics analysis is that for crack growth to take place two conditions need
to be satisfied [4]. Firstly, sufficient energy needs to be available to operate a crack growth mechanism
(thermodynamic criterion). secondly crack tip stresses must be high enough to operate the mechanism (stress
criterion).
crack tip, radius r a/10 where a is crack length, as shown in Fig. 3. An apparent objection to the use of the stress
A stress intensity factor provides a reasonable description of the crack tip stress field in a K – dominated region at the
intensity factor approach is the violation, in the immediate vicinity of the crack tip, of the initial linear elastic assumptions,
in that strains and displacements are not small. However, as noted by Williams in 1962 [10], if the assumptions are
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violated only in a small core region, radius << r, than the general character of the K-dominated region is, to a reasonable
approximation, unaffected. Similarly, by this small scale argument, small scale non-linear effects due to crack tip yielding,
microstructural irregularities, internal stresses, irregularities in the crack surface, the actual fracture process, etc, may be
regarded as within the core region. In the early 1960s there was scepticism about the validity and utility of stress intensity
factors [8]. However, collaborative theoretical and experimental work in the late 1960s helped to establish confidence [11,
12]) and by 1974 their use for the solution of practical engineering problems was well established [13], nearly two decades
after Williams’ discovery of stress intensity factors.
Figure 3: K-dominated and core regions at a crack tip. Figure 4: Fracture surface of 19 mm thick aluminium alloy fracture
toughness test piece.
spherical coordinates (r, , ) with origin at the corner point. The angle is measured from the crack front.
mode, a combination of modes II and III. For corner point singularities, the polar coordinates in Fig. 1 are replaced by
There do not appear to be any exact analytic solutions for corner point singularities. An approximate solution was
obtained in 1977 by Benthem [15] for the restricted case of a quarter infinite crack in a half space. A more general
analysis they assumed that all three modes of crack tip surface displacement are proportional to rλF(θ, ). They then
approximate solution, using essentially the same approach, was obtained in 1979 by Bažant and Estenssoro [16]. In their
calculated λ numerically for a range of situations. The stress intensity measure, K, may be used to characterise corner
point singularities, where can be regarded as a parameter defining the corner point singularity. It follows from the initial
assumption that stresses are proportional to K/r and displacements to Kλr1-λ, where r is measured from the crack front.
from finite element analyses can be used to determine values of λ. For a crack surface intersection angle, , of 90 and a
Hence, stress and displacement plots are straight lines when plotted using logarithmic scales, and such plots obtained
crack front intersection angle, , of 90 there are two modes of stress intensity measure corresponding to the modes of
crack tip surface displacement. For the symmetric mode the stress intensity measure is KS, and for the antisymmetric
mode it is KA. For Poisson’s ratio, ν = 0.3 λ = 0.452 for the symmetric mode and 0.598 for the antisymmetric mode.
latter value. Bažant and Estenssoro’s analysis shows that, for a crack surface intersection angle, , of 90, is a function of
Recent highly accurate finite element results for discs and plates under anti plane loading [17, 18, 19] do not confirm the
Poisson’s ratio, , and the crack front intersection angle. At a critical crack front intersection angle, c, = 0.5 and stress
intensity factors are recovered. KS becomes KI, and KA a combination of KII and KIII. For a growing crack the crack front
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shape adjusts itself such that the crack front intersection angle tends to c. For the symmetric mode and = 0.3, c =
0.3, c 67.0. Crack front intersection angles of about this value have been observed [20].
100.4 which, as predicted, is approximately the crack front intersection angle in Fig. 4. For the antisymmetric mode and
Figure 5: Angle crack test piece, definition of crack Figure 6: Definition of crack front intersection angle, .
surface intersection angle, γ.
CRACK PATHS
A crack has some analogies with a crystal dislocation. In particular, the elastic stress fields associated with a crack
front and with a dislocation are both singularities. The associated energy means that a dislocation has a line
tension, which controls its shape under an applied stress field. Similarly [21], a crack front has a line tension
which controls its shape, but with the important difference that a crack can grow, but in general cannot contract. At a
corner point the corner point singularity provides a point force which balances the line tension in a direction
corresponding to the crack front intersection angle. In consequence on a macroscopic scale, a crack front is smooth, and
is usually curved as in Fig. 4. Any initial sharp corners rapidly disappear [22]. Further in some circumstances, a growing
fatigue crack tends to a particular stable shape [23, 24].
leads to KIsin = KII(3cos - 1) (70.5… -70.5…) where KI and KII are the modes I and II initial crack stress
growth to be in the direction of the maximum tangential stress. This is a principal stress so the shear stress is zero, and
intensity factors. An alternative approach is to find the value of θ for which the mode I branch crack stress intensity
factor, kI, has its maximum value and the mode II stress intensity, kII, is zero. Calculation of kI and kII by comparison of
stress field components leads to the same result [26, 27], so the two approaches are equivalent.
Several criteria have been proposed for the initial direction of crack growth in the general three dimensional case of mixed
modes I, II and III loading [28]. In 2001 Schöllmann et al [32] proposed a new criterion, which assumes that crack growth
from a point on the crack front is perpendicular to the maximum principal stress. In two dimensions this is equivalent to
the MTS criterion. A complication is that, in the presence of mode III on the initial crack, a mode I branch crack only
intersects the initial crack front at one point [26, 27, 28]. What happens when a fatigue loading is applied in the presence
of mode III on the initial crack is illustrated by the fracture surface of the mild steel angle notch test piece shown in Fig. 8
[33] (cf Fig. 5). The rough area is static fracture where the test piece was broken open for examination. The expected
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tendency to mode I fatigue crack growth was observed on two distinct scales. On a scale of 1 mm crack the crack growth
surface was smooth, crack fronts were approximately straight, and initially crack growth was mixed mode. As the fatigue
crack grew the crack front rotated and crack growth eventually became mode I. Rotation continued until the crack surface
intersection angle was 90, and the crack front was curved. On a smaller scale of 0.1 mm the tendency to mode I fatigue
crack growth results in the production of what is known as a twist crack [34]. A twist crack consists of narrow mode I
facets usually connected by irregular, predominantly mode III cliffs. The mode I facets gradually merged and the crack
growth surface became smooth on this scale.
Figure 7: Quasi two dimensional mixed modes I and II initial Figure 8: Twist crack fracture surface of mild steel angle notch
crack with a small mode I branch crack, crack growth angle, θ. test piece, fatigue loading.
Figure 9: Directionally stable mode 1 fatigue crack growth. Figure 10: Mode I fatigue crack paths in a double cantilever beam
specimen.
T a
B (1)
KI
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where a is the crack length (half crack length for an internal crack), and KI is the mode I stress intensity factor. It is
sometimes found that cracks are directionally stable even when the T-stress is tensile (or B is positive). In particular, the T-
stress is tensile for the widely used compact tension test piece (Fig. 11). This is specified in some fracture mechanics based
mode I testing standards [12], and in practice cracks are usually directionally stable. An alternative approach, proposed by
simply T. The stress, x, due to the Mode I stress intensity factor, on the crack line and ahead of the crack, is given by:
Pook [36] in 1998, is to consider the direct stresses, on the crack line, and near the crack tip. That due to the T-stress is
x
2 r
KI
(2)
where r is the distance from the crack tip. The T-stress ratio, TR, may now be defined as the ratio of the T-stress to x,
given by Eq. (2), at some characteristic value of r, rch. Provided that rch is small TR is a point criterion which is within the
K-dominated region. Since the T-stress criterion is based on the idea of random crack path perturbations due to
microstructural irregularities, rch should be of the same order of size as microstructural features. Taking rch = 0.0159... mm
leads, using MN-m units, to the convenient expression
TR
a
0.01B
(3)
which implies that there is a size effect. For a particular material, there is a critical value of TR, TRc, below which a fatigue
crack path is directionally stable [28]. For fatigue tests on biaxially loaded Waspaloy sheets TRc = 0.022 and for static tests
on biaxially loaded PMMA sheets TRc = 0.013. For a compact tension test piece with W = 50 mm TRc < 0.22. It is
unusual to carry out tests using compact tension test pieces with W < 50 mm so this value is consistent with the Waspaloy
result.
Figure 11: Compact tension test piece. Figure 12: Crack fronts (solid lines) and trajectories (dashed lines)
on a smoothly curved crack growth surface.
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is an important exception to the geometric constraint on permissible mode I crack front families. On a plane the curvature
is zero in all directions, so principal directions cannot be defined, and there is no orthogonal net of principal curvature
directions. Therefore, for a flat mode I crack there is no geometric constraint on permissible crack front families, and a
wide range of crack front families is possible and, indeed, observed [39, 40].
I nterest in assessing the fracture toughness, or resistance to brittle fracture, of metals goes back to 1822 when
Tredgold commented on the assessment of cast iron [1]. By 1962 numerous empirical tests had been developed in
order to determine whether a steel was brittle or ductile [1]. The best known test is the Charpy impact test using
notched test pieces. It is still in use, but it does not provide quantitative fracture toughness data that can be used in design
[13]. The situation changed dramatically in the 1960s with the development of standards for plane strain fracture
toughness (KIc) testing. This was based on two empirical observations [1, 46]. First, that the sharpest possible machined
notch may not adequately represent a crack. Second, that in a test piece of constant thickness, the fracture toughness is a
function of test piece thickness. However, if the test piece thickness is above a minimum value, which depends on the
material, then the fracture toughness is a minimum, and it is a material constant [46]. This minimum value became known
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as KIc. The minimum thickness depends on the yield stress, Y, of the material, and is given by 2.5(KI/Y)2. The factor 2.5
is empirical and is a compromise. It was also found that consistent values are obtained for KIc if it is calculated from the
load necessary to cause a significant amount of crack growth, defined as 2 per cent of the initial crack length. Only two
dimensional stress intensity factor solutions were available for test pieces of constant thickness, such as the compact
tension test piece, shown in Fig. 11 so a limit had to be based on permissible crack front curvature, and an appropriate
through thickness average crack length defined. The empirical basis of some aspects of KIc testing meant that extensive
development work was needed to develop workable standards [8, 12]. It also means that standards contain very detailed
requirements to ensure reproducibility between laboratories.
T he linear elastic analysis of cracked bodies, usually known as linear elastic fracture mechanics (LEFM), is a
Twentieth Century development. The first theoretical analysis appeared in 1907, but it was not until the
introduction of the stress intensity factor concept in 1957 that widespread application to practical engineering
problems became possible. LEFM developed rapidly in the 1960s, with application to brittle fracture and fatigue crack
growth, and the development of a standard for the plane strain fracture toughness testing of metals. The first application
of finite elements to the calculation of stress intensity factors for two dimensional cases was in 1969. The 1970s were a
period of consolidation. LEFM was increasingly used in failure analysis. Analyses were assisted by the publication of stress
intensity factor handbooks.
Corner point singularities were investigated in the late 1970s. A key finding was that a corner point modes II and III
cannot exist in isolation. Hence, the presence of one of these modes always induces the other, and is sometimes called a
coupled mode. By 1986 the increasing power of mainframe computers meant that three dimensional finite element
analysis of cracked bodies became feasible. Finite element analysis of cracked three dimensional configurations, which
started in the late 1980s, confirmed the existence of coupled modes. It was soon found that the existence of corner point
effects made interpretation of calculated stress intensity factors difficult, and their validity questionable. In a recent
investigation a coupled mode generated by anti-plane loading of a straight through-the-thickness crack in linear elastic
discs and plates was studied using accurate three dimensional finite element models. The results make it clear that Bažant
and Estenssoro’s analysis of corner point singularities is incomplete. An open question is the need for a new field
parameter, probably a singularity, to describe the stresses at surfaces. Finite element analysis had a significant influence on
this aspect of the development of LEFM.
Numerical two dimensional mode I crack path predictions were carried out in the early 1990s. Agreement between
theoretical predictions and experimental data obtained using thin sheets is variable. The availability of increasingly
powerful computers means that two dimensional predictions have now largely been superseded by three dimensional
predictions. Numerical three dimensional predictions of fatigue crack paths between 2003 and 2014 showed good
agreement with observed fatigue crack paths. However, how best to allow for the influence of corner point singularities in
three dimensional numerical predictions of fatigue crack paths is an open question. Crack path prediction would not have
been possible without the use of finite element analysis or boundary element analysis.
In 1998 it was shown that the assumption that crack growth is in mode I leads to geometric constraints on permissible
fatigue crack paths. Line tension ensures that crack fronts are smooth curves. A necessary condition for crack growth to
be in mode I is that the crack growth surface must be smooth. On a smoothly curved crack growth surface there is an
ordered family of smooth curves representing successive positions of the crack front and a family of crack growth
trajectories. These are an orthogonal net passing along directions of maximum and minimum curvature. On a plane the
curvature is equal in all directions, there is no orthogonal net, and therefore no geometric constraint on permissible crack
front families.
The biaxiality ratio, a nondimensional function of the T-stress, is sometimes used as a crack path stability criterion, but it
is not satisfactory. An alternative approach suggested in 1998, is to use the T-stress ratio, TR, which is a point criterion
based on the T-stress. For a particular material, there appears to be a critical value of TR, TRc, below which a fatigue crack
path is directionally stable. However, adequate description of fatigue crack path stability is an open question.
Requirements for a valid KIc fracture toughness test in the latest standard [47] and are essentially unchanged from those in
the first standard published in 1970 [48]. In other words, 1960s technology is still being used. This would not matter if the
latest standards were satisfactory in practice. However, in 2012 Schijve pointed out that the transferability of fracture
toughness test data to practical situations was restricted so structural testing was sometimes needed [49]. Also in 2012
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Kotousov et al [50] remarked that current standards ignore three dimensional effects. Development of an adequate plane
strain fracture toughness testing standard is an open question.
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