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Analytical Bounds for Efficient Crack Growth Computation
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Abstract
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In linear elastic fracture mechanics, the rate of crack propagation is proportional to the range of
stress intensity factors. The most popular model relating these quantities is the Paris-Erdogan law.
Crack growth computation is an initial value problem whose solution cannot be obtained in closed
form, as stress intensity factors, hence crack growth rates, depend on the accumulated growth. For
complex geometries, stress intensity factors are evaluated numerically, and crack growth
computations can become computationally intensive. This paper presents a theoretical result
establishing upper and lower bounds for the crack size function for any number of cycles. The
bounds are very narrow, hence accurate crack size approximations can be obtained from only two
stress intensity factor evaluations. This leads to a huge gain in computational effort for numerical
crack growth computations. Two examples are used herein to explore the accuracy and efficiency of
the proposed solution for the crack growth initial value problem.
NuMAT/PPGEM, Federal University of Technology of Parana
Av. Sete de Setembro, 3165, Curitiba, PR, Brazil.
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PPGMNE/CESEC, Federal University of Parana
Centro Politcnico, Jardim das Amricas, C. P. 19011
81531-980, Curitiba, PR, Brazil.
Rodrigo Villaca Santos,
[email protected]NuMAT/PPGEM, Federal University of Technology of Parana
Av. Sete de Setembro, 3165, Curitiba, PR, Brazil.
DAMEC, Federal University of Parana
Via do Conhecimento, Km 1, Pato Branco, PR, Brazil.
Andr Tefilo Beck,
[email protected]Structural Engineering Department, EESC, University of So Paulo
Av. Trabalhador Sancarlense, 400, So Carlos, SP, Brazil.
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Keywords
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Fracture mechanics, Crack size; Paris-Erdogan law;Initial value problem;
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Nomenclature
FE
H
Finite Element
Hypotheses
Avila et al., Analytical Bounds for Efficient Crack Growth Computation. Submitted to AMM, March 2014. Page2of27.
IVP
RK4
a
a0
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Initial Value Problem
Fourth-Order Runge-Kutta Method
Crack Size
Initial Crack Size
Rate of Crack Propagation
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da
dN
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f(a)
C
m
N
Geometry Function
Material Constant (Paris Law)
Material Constant (Paris Law)
Number of Load Cycles
Stress Intensity Factor
Critical Stress Intensity Factor
Stress Range
Relative Deviation Function Upper Bound
Relative Deviation Function Lower Bound
Polynomial coefficient
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Polynomial coefficient
Polynomial coefficient
Kc
UB
LB
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Introduction
In linear elastic fracture mechanics, the rate of crack propagation
da is assumed proportional
( dN
)
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to the range of stress intensity factors, ( K ) . In Figure 1, Region I represents near-threshold crack
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growth. Region II represents intermediate crack propagation, where crack propagation rate is linearly
proportional to K (on a log-log scale) and where a small plastic zone appears ahead of the crack
tip. Region II is the range of application of linear elastic fracture mechanics. Finally, Region III
accounts for the accelerated crack growth just prior to failure. Non-linear fracture mechanics
concepts are required to model crack growth in this region.The Paris-Erdogan [1]crack propagation
equation describes crack growth in the linear region (Region II in Figure 1).
Due to its simplicity (only two parameters need to be identified experimentally), the Paris
equation is widely employed in many applications. However, this equation presents some major
limitations: a. it only represents crack growth in the so-called region II (linear); b. mean stress effects
are not taken into account and c. it does not take into account the loading history and resulting load
interaction effects.Several variants of the Paris equation have been developed to address these
particular aspects. This includes the model of Elber [2], which uses an equivalent stress intensity
factor to take into account crack closure under compressive stresses; and Forman [3], which includes
mean stress and stress ratio effects. Many other models are available in the literature; however, the
very existence of a myriad of crack propagating equations is evidence that no single equation is
overwhelmingly better than the others.
In order to simulate crack growth in components or structureswith complex geometry,
numerical analysis has been used extensively in recent years. This includes computation of stress
intensity factors by the Boundary Element Method [4-6], Generalized FE methods [7-9], and
Extended Finite Element Method [10-13], including cohesive crack modeling. Numerical
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computation of stress intensity factors and complex re-meshing schemes add significantly to the
computational burden of crack growth estimation. This is especially the case when random crack
propagation and/or reliability analysis is considered [14-19]; as uncertainty propagation studies
increase the computational effort significantly.
Considering the aforementioned computational burden, this paper presents a theoretical result,
in the form of a theorem, which allows to evaluateupper and lower bounds for crack growth based on
only two evaluations of the stress intensity factor. In this first study, only the Paris-Erdogan crack
propagation equation is considered. The bounds derived herein are based on polynomial functions of
the number of load cycles. The examples presented herein consider problems with analytical
geometry functions, but results can be readily extended to more general problems where stress
intensity factors are computed numerically.
The remainder of this article is organized as follows. The Paris-Erdogan crack propagation
equation is presented in Section 2. The theorem providing the crack growth bounds and its proof are
presented in Section 3. In Section 4, two example problems are addressed. Concluding remarks are
presented in Section 5.
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Paris-Erdogan Crack Propagation Equation
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Using the Paris-Erdogan crack propagation model, the crack growth problem can be written as,
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Find a C1 ( N 0 , N1 ) , such that :
m
da
dN ( N ) = C K ( a ( N ) ) , N ( N 0 , N1 ) ;
a ( N0 ) = a0 ;
( )
(1)
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whereCandmare material constants and Nrepresents number of load cycles. The term K ( ) is the
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range of stress intensity factors, defined as,
K ( a ( N ) ) = ( K max K min ) ( a ( N ) )
= a ( N ) f ( a ( N ) ) ( max min )
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(2)
= a ( N ) f ( a ( N ) ) .
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In Eq. (2), f ( ) is the geometry function and is the far-field stress range. The problem
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stated in Eq. (1) is classified as an initial value problem (IVP). Replacing Eq. (2) in Eq. (1), one
obtains,
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Find a C1 ( N0 , N1 ) such that :
da
dN ( N ) = C a ( N ) f a ( N )
a ( N0 ) = a0 .
( )
))
, N ( N0 , N1 ) ;
(3)
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Eq. (3) is an IVP, defined by an ordinary, first order, non-linear autonomous differential
equation. More generally, Eq. (3) can be classified as a Cauchy problem, which consists in finding
the trajectories which satisfy the IVP differential equation and the initial value, ( a ( N0 ) = a0 ) . The
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existence and uniqueness of the solution to this Cauchy problem depend on certain regularity
conditions [20]on the functions at the right of Eq. (3). Interval ( N 0 , N1 ) corresponds to load cycle
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( )
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Lower and upper bounds for the crack size function are determined in this section based on the
following hypotheses about the loading and the geometric correction function:
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numbers, which are within RegionII in Fig. (1).
Lower and Upper Bounds for Crack Size Function
H1: ( N ) = 0 , N [ N 0 , N1 ] ;
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f C1 ([ a0 , a1 ] ; + \ {0}) ;
H2 : 0 < f ( a0 ) f ( x ) f ( y ) , x y, x, y [ a0 , a1 ] ;
f ( a0 ) f ( x ) f ( y ) , x y, x, y [ a0 , a1 ] ;
H3: m 2;
(4)
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where a0 = a ( N 0 ) and a1 = a ( N1 ) . Hypotheses (H1) assumes constant loading. Hypothesis (H2) states
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that the geometry function must be a monotonously non-decreasing function, and that its derivative
must also be a monotonously non-decreasing functions. These conditions are met for most common
geometry functions, since they represent an intrinsic characteristic of the crack propagation problem.
Hypotheses (H1) and (H2) form the basis for the following theorem, which defines upper and lower
bounds for the crack size function.
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Theorem: Let f ( ) and ( ) be functions which satisfy hypotheses (H1) and (H2), respectively, and
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a [ a0 , a1 ] , the following lower and upper bounds are valid:
K ( a ) m + ( mC ) K a 2.m
( )
0 )
2
(
a
N
C
(
)
( N N0 ) ;
0
2a + f ( a ) ( N N0 )
1 + ( mC ) ( K ( a ) )m
0
2
m
a ( N ) a0 C ( K ( a0 ) )
( N N0 ) , N [ N0 , N1 ] .
f
21a0 + f ( a0 ) ( N N0 )
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( )
( )
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(5)
Avila et al., Analytical Bounds for Efficient Crack Growth Computation. Submitted to AMM, March 2014. Page5of27.
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Proof:From hypothesis (H2) and a second-order Taylor expansion of crack size, around a0 , one
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obtains,
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da
a ( N ) = a0 + ( dN
( N0 ) ) ( N N0 ) + 12
d 2a
dN 2
( ) ) ( N N0 )
, with [ N0 , N ] .
The second-order term is called the Lagrange rest. Naturally, and from hypothesis(H2), the
following inequalities can be written:
m
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a ( s ) a ( t ) , s t with s,t [ N0 , N ] ( a ( s ) ) ( a ( t ) ) .
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From hypothesis (H2) one obtains,
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( f ( s )) ( f (t ))
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Hence, oneconcludesthat,
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( K ) ( a ( s ) ) ( K ) ( a ( t ) ) ,
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Now, since C > 0 oneobtains,
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( )
a2 . f
da
dN
( s) (a
1
2
.f
(t ) , s t
with s,t [ N0 , N ] .
with s,t [ N 0 , N ] .
( s ) dNda ( t ) , s t
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The second derivative of the crack size function is evaluated as,
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d 2a
d da
d da
da ( a ( N ) )
a N )) =
a ( N )) =
( a ) dN
(
2 ( (
dN
dN
dN
dN
da
2m d
m
m
m
m
= C 2
a 2 ( f ( a )) a 2 ( f ( a ))
da
)(
2m
= mC 2
)
(
1 a m2 1 ( f ( a ) )m + a m2 ( f ( a ) )m1 f ( a ) a m2 ( f ( a ) )m
2
m m1
) ( a ( f ( a )) )
2m
12 f ( a ) + af ( a ) .
)
(7)
Inserting Eq. (7) in Eq. (6), the Taylor-expanded crack size function becomes,
a ( N ) a0 = C ( K ( a0 ) )
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= mC 2
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(6)
2a1( ) +
( N N0 ) + mC2
( K ( a ( ) ))
( ) ( a ( ) ) ( N N )
f
f
2m
(8)
, with [ N0 , N ] .
The lower and upper bounds are obtained from a reformulation of the Lagrange restin Eq.(8).
From the behavior of the geometric correction function in hypothesis (H2), the following inequality
is proposed,
m m1
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( a ( f ( a )) )
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Similarly,
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( a ( f ( a )) )
m m1
12 f ( a ) + af ( a ) a f ( a )
2m
12 f ( a ) + af ( a ) a0 f ( a0 )
2m
1 +
2a
( ) ( a ) , a [a , a ] .
(9)
1 +
2 a0
( ) ( a ) , a [ a , a ] .
(10)
f
f
f
f
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Replacing Eq. (9) in Eq. (7), one obtains the following estimate,
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d 2a
( ) mC 2 K ( a )
dN 2
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The function leading to the lower bound is obtained by inserting Eq. (10) in Eq. (7),
2m
1 +
2a
2m
d 2a
mC 2 ( K ( a0 ) ) 21a0 +
2 ( )
dN
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( ) ( a ) , [ a , a ] .
f
f
(11)
( ) ( a ) , [ a , a ] .
f
f
(12)
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ReplacingEqs. (11) and (12) in Eq. (8), one obtains the upper and lower bounds stated in the
theorem.
It is noted that the lower and upper bounds for crack size, stated in the theorem, depend only
on the evaluation of the geometryfunction and its derivative at two points, a0 anda*. Obtaining the
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coefficients of Eq. (5) only requires the evaluation of f ( a0 ) , f ( a0 ) , f a , f a
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computational cost for evaluating the bounds proposed in this paper is a small fraction of the
computational cost for the traditional, cycle-by-cycle integration of Eq. 1. Clearly, the computed
bounds depend on a proper choice for the value a*. It is proposed that traditional engineering insight
be used to select this value. For instance, the critical stress intensity factor, ( K C ) , could be used to
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obtain a*. In the numerical examples presented herein, narrow bounds are obtained for a*=2 a0.
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In order to evaluate the accuracy of the upper and lower bounds proposed in this paper (Eq. 5),
the IVP in Eq. (3) is solved for two example problems. Since the differential equation is autonomous,
Eq. 3 is separable; hence the crack size for any number of cycles can be obtained by direct
integration, starting at the initial value. Unfortunately, analytical integration is possible only for a
limited number of problems, for which the geometry function is analytical. For practical problems,
numerical computation of stress intensity factors and numerical integration is often required. In the
examples below, the classical fourth-order Runge-Kutta method (RK4) is employed:
NumericalExamples
Find ak +1 + , such that :
N
ak +1 = ak + ( 6 ) .( K1 + 2 K 2 + 2 K3 + K 4 ) , k {0,1,..., n} ;
m
K1 = C ak f k ;
N
K 2 = ak + ( 2 ) .K1 ;
N
K3 = ak + ( 2 ) .K 2 ;
K = a + ( N ) .K ;
k
3
4
a0 = a ( N 0 ) ;
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( ) ( )} . Hence, the
(13)
Avila et al., Analytical Bounds for Efficient Crack Growth Computation. Submitted to AMM, March 2014. Page7of27.
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where ak = a ( N k ) , f k = f ( ak ) and N = N k +1 N k , k {0,1,..., n} . The RK4 method has precision
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of fourth order, O N 4
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to evaluate the accuracy of the numerical RK4 solution. Figure 2 shows the relativeerror,
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( ( N ) = 100.(
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numerical solutions ( a RK 4 ( ) ) to the problem of propagation of a crack in an infinite plate, with the
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parameters given in Eq. (14).
( (
) [ % ] , N
{0, 50,100, ..., 90000} ,between the exact a ( ) and approximate
(14)
The lowerand upper bound crack size functions are second-degree polynomials in the number
of cycles (N),and are defined as follows:
aLB ( N ) = N 2 + N + a0 ;
2
5
aUB ( N ) = N + N + a0 , N 0,9 10 .
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a( N k )
C = 109 ; m = 2; N 0 = 0; N1 = 9 10 5cycles;
a = 0.005 in; = 20 ksi, N 0,9 10 5 .
0
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a RK 4 ( N k ) a ( N k )
) ) . For example one below, which has exact analyticalsolution, it is possible
(15)
For the two examples, the coefficients of these polynomials are presented in Table 1, whose
definitions are given in Eq. (5). The accuracy of upper and lower bounds, proposed in Eq. (5), is
measured by the following relative deviationfunction,
UB ,LB ( N k ) = 100.
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aUB ,LB ( N k ) a RK 4 ( N k )
a RK 4 ( N k )
) [% ] , N {0, 50,100, ..., 9 10 } .
5
(16)
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a.
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Figure3 shows the geometrical configuration of the finite width center cracked plate considered
in Example 1. The geometryfunction is given by
f ( a ( N ) ) = sec
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Example1: Finite width plate with center crack
a ( N )
2b
),
N 0, 9 105 .
(17)
Results of crack size function, obtained by the RK4method, and the computed upper and lower
bounds, are shown in Figure 4. Figure 5 shows the relative deviation of upper and lower bounds
w.r.t. the exact solution.In Figures 4 and 5 one observes that the bounds proposed herein are quite
narrow, providing accurate estimates of the actual crack size function.
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b.
Example2: Finite plate with corner cracks
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Figure 6illustrates a finite width plate with two corner cracks, with initial crack size a0 and
widthb=1/2 in.The geometry function for this example is,
Avila et al., Analytical Bounds for Efficient Crack Growth Computation. Submitted to AMM, March 2014. Page8of27.
( )
( )
21.72 ( ( ) ) + 30.39 ( ( ) ) , N 0,9 10 .
f ( a ( N ) ) = 1.122 0.231
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a( N )
b
+ 10.55
a N
b
a( N )
b
a N
b
(18)
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Figure 7 shows the numerical solution through the RK4 method for the crack sizefunction, as
well as the computed upper and lower bounds. Again, the bounds obtained with the proposed
methodology are quite narrow, providing accurate estimates of the actual crack size.
Figure 8 shows the relative deviation of upper and lower bounds w.r.t. the exact result. A
comparison of Figures 5 and 8 reveals that, for this example, the relative deviation function for the
lower bound, ( LB ( ) ) assumed larger values. On the other hand, the relative deviation for the upper
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bound function was smaller, for N = 9.105 cycles: UB ( 9 10 5 ) = 10.1597 %
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UB ( 9 105 ) = 6.9573 % (example 2).
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c.
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(example 1),
Evaluation of the results
In both examples it is observed that the lower boundleads to smaller relative deviation,hence
to more accurate yet unconservative approximations. Table 2 shows the maximum and minimum
values of relative deviation for the upper and lower bounds, ( max ( UB ) , min ( LB ) ) , for both
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examples. In particular, it can be seen in Table 2 that the relative deviation with respect to lower
bound, for example 2,resulted in larger value (in modulus).
Since computation of the bounds only requires evaluation of the geometry function (and its
derivative) for two crack sizes, it is much faster than direct numerical integration. For example 2,
computing the bounds took only 0.80 s, while numerical integrationtook 1642.67 s, leading to a
reduction factor of 1640 times. This result boosts the potential application of the bounds proposed
herein to problems involving complex geometries and solution by numerical analysis.
The computed upper bound also depends, to some extent, on the choice of a* points where
geometry function and its derivative are evaluated. Figure 9 shows the upper bound and relative
deviation of the upper bound, for example 2,with a = 2 a0 , 3a0 , 4 a0 . It is observed that the upper
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bound functions are sensitive to different choicesof a , since the coefficient inEqs. (5) and (15)
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depends on a . It is proposed that engineering insight should be used to select a . The largest value
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of a , for instance, would be that leading to f ( a ) = K c , where Kc is the critical stress intensity
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factor.
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In this paperthe Lagrange rest, a classical result of calculus, was employed to propose a
theorem providing lower and upper bounds for function crack size, based on the solution of an initial
value problem involving the Paris-Erdogan law.The required assumption or hypothesis about the
geometry function, i.e., that it be a monotonously non-decreasing function of crack size, is generally
met in practice. Two polynomial functions are used to construct the lower and upper bounds. To
evaluate the bounds one only needs to evaluate the geometry function and its derivative for two crack
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CONCLUDINGREMARKS
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sizes. Hence, the reduction in computational effort is huge, when compared with direct numerical
integration. This is especially true when the geometry function is not analytical, and stress intensity
factors are evaluated numerically. The accuracy of the proposed bounds was evaluated for two
example problems solved herein. In general, deviations were found to be around 10 to 20% for
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a = 2a0 , which can be acceptable for engineering purposes. This accuracy can be improved by
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proper choice of the support pointa*.
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The first and third authors acknowledge theBrazilian National Research Council (CNPq) for
sponsoring this research.
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ACKNOWLEDGEMENTS
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( )
da
log dN
II
III
da
= C K
dN
( )
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log ( K)
da
Figure 1: Diagram log ( dN
) log ( K ) .
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Figure 2: Relative error ( ( N k ) N k ) for RK4 solution of
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example 1.
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Table 1: Polynomial coefficients of Eq. (15) for the example problems.
Example
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351
7.958310
1.317310
15
3.955610
14
6.236110
15
15
6.286310
7.873610
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355
356
357
358
359
360
361
362
363
364
365
366
367
a0
Figure 3: Finite width center-cracked
plate, subject to tensile loading.
368
369
370
371
Figure 4: Crack size function and lower and upper
bounds for example 1.
Figure 5: Relative deviationof lower and upper bounds,
Avila et al., Analytical Bounds for Efficient Crack Growth Computation. Submitted to AMM, March 2014. Page13of27.
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
UB ,LB
( N ) N ) , for example 1.
a0
a0
2b
Figure 6: Finite width plate with two corner
cracks subject to tensile loading.
Figure 7: Crack size function and lower and upper
bounds for example 2.
Avila et al., Analytical Bounds for Efficient Crack Growth Computation. Submitted to AMM, March 2014. Page14of27.
Figure 8: Relative deviation of lower and upper bounds,
395
396
UB , LB
( N ) N ) , for example2.
397
398
Table 2: Maximum and minimum values of relative deviation ( max ( UB ) , min ( LB ) ) ,
399
for upper and lower bounds, for examples 1 and 2.
Example
N1
N1
min { LB ( N k )}k =1 , [% ]
10.4989
11.6396
-10.7216
-19.4529
1
2
max {UB ( N k )}k =1 , [% ]
400
401
402
403
404
405
406
Figure 9: a)Crack size function and upper bounds, ( a ( N ) , aUB ( N ) N ) ;
b) Relative deviation of upperbound, ( UB ( N ) N ) .