Filtern
Erscheinungsjahr
Dokumenttyp
- Beitrag zu einem Tagungsband (22) (entfernen)
Sprache
- Englisch (22)
Schlagworte
- Fracture mechanics (22) (entfernen)
Organisationseinheit der BAM
Aero-engine turbine disks are safety-relevant components which are operated under high thermal and mechanical stress conditions. The actual part qualification and certification procedures make use of spin-tests conducted on production-similar disks. The aim of this work is to present part of a fracture mechanics-based procedure under development which aims at replacing the tests on production-similar disks with lab tests on fracture mechanics specimens. The finite element simulation of the cracked disk considers the real thermal and mechanical loading conditions. In order to design a lab representative specimen, beside the crack driving force, expressed in terms of 𝐽-integral, also the constraint to plastic deformation e.g., stress triaxiality, at the crack-tip must be similar for the same crack in the specimen and in the disk. This has been achieved and as expected, both the highest 𝐽 -integral and constraint factor are calculated at the same location along the crack front for both disk and specimen. The results of the structural integrity assessment in the form of a Failure Assessment Diagram (FAD) show good agreement between designed specimen and disk both in terms of expected failure mode and value of the critical speed. In addition, probabilistic aspects are also considered in the calculations.
Aero-engine turbine disks are safety-relevant components which are operated under high thermal and mechanical stress conditions. The actual part qualification and certification procedures make use of spin-tests conducted on productionsimilar disks. While these tests provide, on the one hand, a reliable definition of the critical conditions for real components, on the other hand they represent a relevant cost item for engine manufacturers. The aim of this work is to present part of a fracture mechanics-based procedure under development which aims at replacing the tests on production-similar disks with lab tests on fracture mechanics specimens. In particular, the rimpeeling failure mode is considered as case study. A semi-circular surface crack is modelled at the most stressed region at the diaphragm of a turbine disk, with the crack plane perpendicular to the radial direction. The crack is therefore subjected to a biaxial stress state and grows under increasing rotational speed until it triggers the rim-peeling failure. The finite element simulation of the cracked disk considers the real thermal and mechanical loading conditions. In order to design a lab representative specimen, beside the crack driving force, expressed in terms of -integral, also the constraint to plastic deformation e.g., stress triaxiality, at the crack-tip must be similar for the same crack in the specimen and in the disk. This has been achieved and as expected, both the highest -integral and constraint factor are calculated at the same location along the crack front for both disk and specimen. The results of the structural integrity assessment in the form of a Failure Assessment Diagram (FAD) show good agreement between designed specimen and disk both in terms of expected failure mode and value of the critical speed. Probabilistic aspects are also considered in the calculations.
Experimental determination and analysis of dynamic fracture toughness data of ductile cast iron
(2017)
Ductile Cast Iron materials (DCI) have become important structural materials. Neverthe-less, to draw maximum benefit from DCIs property potential, tailored testing methods must be provided. The established dynamic Jd-R and CTOD 5d-R curve procedures are based on material specifically developed, independent experimental techniques but pro-vide almost matching results. This can be seen as additional validation of the Jd procedure which was mandatory.
The damage process of short glass fibre (30% weight) reinforced polyamide caused by mechanical loading was investigated from the beginning on micro cracking level to the incipient crack of mm-dimension. Based on high resolution computer tomography and the X-ray-refraction technique the inner surface due to micro-cracking at the short fibre ends and the fibre matrix debonding of the skin surface of the filament was determined quantitatively. With the knowledge of the fatigue crack propagation rate and fracture toughness of the material from former research projects, it was derived that the total inner surface due to micro cracks measured by X-ray refraction is much higher than the specimen could have withstand the load, supposed the surface is in a localized crack. Hence, the damage process could be described from micro to macro level. Accompanying fractographic investigations endorse the modelling based on the NDT-techniques.
Special aspects of welded components such as geometrical imperfections, inhomogeneity, strength mismatch and welding residual stresses have to be taken into account in a fracture mechanics analysis since they affect the crack driving force in the component as weil as the fracture resistance of the material. The treatment of components subjected to static loading is based on methods such as the European SINT AP procedure, which has been validated in a nurober of case studies. In the present paper the influence of strength mismatch and residual stresses on the fracture resistance and the assessment of a component are discussed.
The failure behaviour of unidirectional plies tested under off-axis loading is studied. The stress distribution occurring in standard off-axis tests is briefly discussed. The different failure modes, this is, pure fiber breakage, pure inter fiber failure as well as a superposition of both is analysed based on test data and fracture patterns. The large difference of the failure load depending on the failure mode at small off-axis angles is studied by comparison of a short and a long 3° off-axis angle specimen.
The idea to determine the fatigue strength of weldments by means fracture mechanics was originally based on the empirical observation that the major portion of the fatigue life in weldments is frequently spent in crack propagation. The present paper gives a brief overview on the basic principles of fracture mechanics-based determination of fatigue strength and on special features which have to be considered for weldments. Based on this information, the ongoing research project IBESS is introduced and briefly reviewed.
Nondestructive Testing (NDT) and fracture mechanics are two different disciplines in applied engineering science. Both areas are very important for the evaluation of the component integrity. Unfortunately the technical understanding in both disciplines is not identically, what lead to misunderstandings. In the present paper, the basic ideas about fracture mechanics and the input parameters coming from the NDT side are explained, concerning the integrity evaluation of the components. The widely used NDT methods are magnetic particle, dye penetrant, electrical eddy currents, radiography and ultrasonics. But not all of these common NDT methods can deliver parameters satisfy the fracture mechanics requirements. The first two can detect only surface-breaking or immediately sub-surface defects. Eddy current can also find defects in deeper sub-surface layers, while radiography and ultrasonics can also find embedded, remote defects. These three methods have furthermore a high potential for defect sizing and are therefore predestined to provide fracture mechanics input parameters. At the example of steam generator tube inspection the interplay of eddy current and fracture mechanics as related to tube integrity will be explained.
An analytical fracture mechanics model for predicting the finite life fatigue strength of components is presented which Combines a number of well established and newly developed approaches such as Murakami’s and McEvily's approach for describing the transient behaviour of crack closure of short cracks, the analytical (long) crack closure function of Newman, the R6 procedure modified by a method for improving the ligament yielding correction proposed by the authors and other elements. Basic assumption is the preexistence of initial flaws such that the crack initiation or nucleation stage is small and can be neglected. The application of the model is demonstrated for small tension plates of aluminium Al 5380 H321 with artificial initial defects generated by FIB technology, the size of which was fixed on the basis of fractographic investigations on broken, smooth specimens.
The failure of laminates is originated in plies loaded transverse to the fiber direction, e.g. in the 90° ply of a cross ply laminate. The initiation of failure is due to the debonding of individual fibers At some point the interface crack kinks into the matrix and propagates towards the inter-face of the neighbouring fiber. The cracks then continue propagating through the full ply. The interface failure obviously is the dominating process of the failure of plies in high fiber volume fraction composites. Several authors investigated the interfacial crack propagation on model systems. First, Varna and Paris studied the debonding process on a single fiber embedded in pure matrix under transverse ten-sion by fracture mechanical analyses. Correa and Paris performed experimental as well as numerical studies by calculating the mixed mode energy release rate under different loading conditions. These analyses were extended to fibers surrounded by a composite material by the present authors. Among others, Comninou as well as Sun and Jih have shown that the separation into a mode I and mode II energy release rate is not universal but the mixed mode ratio depends on the length of the crack increment. Comninou developed a solution of an interface crack between dissimilar media which reveals the even a small contact zone is found near the crack tip. As a result, the mode I part of the energy release rate vanishes because no opening of the crack takes place. The contact zone, however, is extremely small. If these mathematical phenomena, however, are relevant for physical problems is not verified.