Problem description. It is desired to analyze the cracked body shown using a 3D finite element mesh: Top view. 50 radius. Material properties:

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1 Problem description It is desired to analyze the cracked body shown using a 3D finite element mesh: Top view radius 30 Material properties: 5 2 E = N/mm = 0.29 All dimensions in mm Crack front line 35 radius 30 radius Front view N vertical load applied to top holes Crack front line Bottom holes fixed Cracked body dimensions ADINA R & D, Inc. 17-1

2 We use ADINA-M to create a mesh suitable for fracture mechanics analysis. The arrangements of bodies used in this model are shown in the following figure. This figure shows a section through the model. The faces of the cracked area are shown slightly separated, but this is just to visually show the cracked area. In the model, the faces of the cracked area are initially coincident. B1 B1 B2 B2 B3 B B2, B3 are bodies containing the crack B1 is the body for the rest of the model. Not drawn to scale. Holes in rest of model not shown. Notice that the cracked area is entirely surrounded by bodies B2, B3. The ADINA-M/PS (ADINA-M using the Parasolid geometry kernel) geometry modeler is used in this analysis. (The ADINA-M/OC geometry modeler cannot be used, because some of the body operations used in this problem are not available using ADINA-M/OC.) In the fracture mechanics analysis, we calculate the stress intensity factors K I, K III at various stations along the crack front. Actual crack propagation is not considered. The SVS method of virtual crack extension is used ADINA Primer

3 For the theory used in fracture mechanics, see Chapter 10 of the ADINA Structures Theory and Modeling Guide. In this problem solution, we will demonstrate the following topics that have not been presented in previous problems: Projecting a line onto body faces Linking faces of ADINA-M/PS geometry Defining constraint sets Generating free-form meshes with 27-node hexahedral elements Splitting meshes Creating CRACK-SVS definitions Using cutting planes to examine the mesh and the results Using the fracture mechanics analysis features. Before you begin Please refer to the Icon Locator Tables chapter of the Primer for the locations of all of the AUI icons. Please refer to the Hints chapter of the Primer for useful hints. Note that you must have a version of the AUI that includes the ADINA-M/PS geometry modeler. In addition you need to allocate at least 80 MB of memory to the AUI. This problem cannot be solved with the 900 nodes version of the ADINA System because the model contains more than 900 nodes. Invoking the AUI and choosing the finite element program Invoke the AUI and set the Program Module drop-down list to ADINA Structures. Choose Edit Memory Usage and make sure that the ADINA/AUI memory is at least 80 MB. Defining model control data Problem heading: Choose Control Heading, enter the heading Problem 17: Analysis of a cracked body with ADINA-M/PS and click OK. Overview of geometry definition The SVS method of virtual crack extension allows the mesh to be unstructured (free-form) adjacent to the crack front. This has the advantage that fewer steps need to be used in creating the mesh, as compared to the number of steps needed to create a structured mesh. Before proceeding with the geometry definition, we outline with sketches the steps used. ou may want to refer to these steps when working through this problem. ADINA R & D, Inc. 17-3

4 Step 1) Define geometry without crack. B = body B1 x z y Pipe body created Top holes created Bottom holes created Step 2) Create crack bodies (bodies that will contain the crack). B1 B1 B2 B3 B2 B3 B2 B3 Isometric view of bodies 2 and 3 Section view of bodies 1, 2, 3, bodies 2 and 3 overlap body 1, not to scale Step 3) Subtract crack bodies from the body created in step 1. B1 B1 B2 B3 B2 B ADINA Primer

5 Step 4) Create the crack front line by projecting a line onto faces in the crack bodies. Before projection: Line 101 Projection direction Line 101 B2 B3 B2 F4 F3 B3 B2 F4 F3 B3 Isometric view Section view After projection: B2 F1 F5 F4 F1 B3 B2 F5 F1 F1 F4 B3 Step 5) Create compatible faces on B1, by subtracting B2 from B1 Before subtraction, notice that F17 of B1 is not compatible with F3 of B2 and F3 of B3, also F19 of B1 is not compatible with F6 of B2 and F6 of B3. ADINA R & D, Inc. 17-5

6 B1 B1 F19 F4 F6 B2 F1 F4 F6 B3 F5 F5 F1 F4 B2 F3 F5 F1 F1 F4 B3 F3 F5 F17 Section view of B1, B2, B3 After subtraction, F1 of B1 is compatible with F3 of B2, F2 of B1 is compatible with F6 of B2, etc. B1 B1 F2 F21 F6 F1 F4 F6 F4 B2 B3 F5 F5 F1 F4 B2 F3 F5 F1 F1 F4 B3 F3 F5 F1 F19 Overview of crack definition In this model, we use the mesh split feature to create duplicate nodes on the cracked faces. Step 1) Split the meshes on B2 and B3, to create duplicate nodes on F5 of B2 and F1 of B3. Before mesh split: Mesh on B2 Mesh on B ADINA Primer

7 After mesh split: Duplicate nodes separated in this figure for clarity, in actual mesh, duplicate nodes overlap Step 2) Create the CRACK-SVS definition The crack front line and crack advance stations are shown in the following figure: Crack front line, crack front is closed z Crack advance station 1 = Crack advance station 37 Crack advance station 2 x y Crack front coordinate s Crack advance stations equally spaced every 10 degrees c a b Crack front coordinate system In this case, we want the crack front coordinate direction c to coincide with the tangential direction, as shown. This means that the binormal direction b must point downwards. The radial domains used in the CRACK-SVS definition are shown in the following figure: Radial domain 3, radius 5 mm Radial domain 2 Radial domain 1 ADINA R & D, Inc. 17-7

8 Defining geometry, step 1: Define geometry without crack Pipe: Click the Define Bodies icon, add body 1, set the Type to Pipe, the Outer Radius to 50, the Thickness to 20, the Length to 100, make sure that the Center Position is (0.0, 0.0, 0.0), set the Axis to and click Save. (We do not want to close the dialog box yet.) Creation of holes: To make the first set of holes, we create a cylinder and subtract it from the pipe body. Add body 2, set the Type to Cylinder, the Radius to 15, the Length to 150, the Center Position to (0.0, 0.0, 27.5), make sure that the Axis is and click OK. Now click the Boolean Operator icon, set the Operator Type to Subtract, set the Target Body to 1, enter 2 in the first row of the table and click OK. We make the second set of holes in a similar way. Click the Define Bodies icon, add body 2, set the Type to Cylinder, the Radius to 15, the Length to 150, the Center Position to (0.0, 0.0, -27.5), the Axis to and click OK. Now click the Boolean Operator icon, set the Operator Type to Subtract, set the Target Body to 1, enter 2 in the first row of the table and click OK. When you click the Wire Frame icon, the graphics window should look something like this: 17-8 ADINA Primer

9 Defining geometry, step 2: Create crack bodies (bodies that will contain the crack) Click the Define Bodies icon, add body 2, set the Type to Pipe, the Outer Radius to 40, the Thickness to 10, the Length to 5, set the Center Position is (0.0, 0.0, 2.5), set the Axis to and click Save. Now add body 3, set the Type to Pipe, the Outer Radius to 40, the Thickness to 10, the Length to 5, the Center Position to (0.0, 0.0, -2.5), set the Axis to and click OK. The graphics window should look something like this: All three geometry bodies are shown in the graphics window. Now, in the Model Tree, expand the one entry, highlight 2. GB2 and 3. GB3, then right-click and choose Display. The graphics window should look something like the top figure on the next page. To show all of the geometry bodies again, in the Model Tree, right-click 4. WHOLE_MODEL and choose Display. ADINA R & D, Inc. 17-9

10 Defining geometry, step 3: Subtract crack bodies from the body created in step 1 Click the Boolean Operator icon, set the Operator Type to Subtract, set the Target Body to 1, check the Keep the Subtracting Bodies button, enter 2, 3 in the first two rows of the table and click OK. The graphics window should look something like the top figure on the next page. Now, in the Model Tree, expand the one entry, right-click on 1. GB1 and choose Display. The graphics window should look something like the bottom figure on the next page ADINA Primer

11 ADINA R & D, Inc

12 Defining geometry, step 4: Create the crack front line by projecting a line onto faces in the crack bodies We need to create a geometry line that we can project onto the crack bodies in order to create the crack front line. Click the Define Points icon and notice that less than 100 points are defined. In the first empty row of the table, add point 101 with coordinate (35, 0, 60) and click OK. This point is not displayed because we are still displaying only geometry body 1. In the Model Tree, right-click 4. WHOLE_MODEL and choose Display. Now point 101 is displayed, as shown in the following figure. Geometry point 101 Click the Define Lines icon, add line 1, set the Type to Revolved, the Initial Point to 101, the Angle of Rotation to 360, the Axis to and click OK. The graphics window should look something like the figure on the next page ADINA Primer

13 Geometry line 1 Now click the Body Modifier icon, set the Modifier Type to Project, the Face to 4, the Body to 2, uncheck the 'Delete Lines after Projection' button, enter 1 in the first row of the table and click Save. Now make sure that the Modifier Type is set to Project, set the Face to 3, the Body to 3, check the 'Delete Lines after Projection' button, enter 1 in the first row of the table and click OK. To verify that the crack front line is created, in the Model Tree, right-click 2. GB2 and choose Display. The graphics window should look something like the top figure on the next page. Now, in the Model Tree, right-click 3. GB3 and choose Display. The graphics window should look something like the bottom figure on the next page. ADINA R & D, Inc

14 Edge corresponding to crack front line Edge corresponding to crack front line The faces of bodies 2 and 3 have been split by line 1 in order to form the crack front line ADINA Primer

15 Defining geometry, step 5: Create compatible faces on B1, by subtracting B2 from B1 Click the Boolean Operator icon, set the Operator Type to Subtract, set the Target Body to 1, check the 'Keep the Subtracting Bodies' and the 'Keep the Imprinted Edges Created by the Subtraction' buttons, enter 2 in the first row of the table and click OK. In the Model Tree, right-click 1. GB1 and choose Display. The graphics window should look something like this: Click the Surface/Face Labels icon and use the oom icon and the mouse to enlarge the plot. The graphics window should look something like the figure on the next page. ou should be able to use the Query icon body 1: faces 1, 2, 19, 21. Click the Unzoom All icon Linking adjacent body faces to highlight each of the newly created faces on to return to the previous view. Face links: Choose Geometry Faces Face Link, add face link 1, set the Type to Links for All Faces/Surfaces and click OK. The AUI displays a warning message "Face 1 of body 2 and face 1 of body 3 cannot be linked..." This message is OK because the listed faces are not adjacent to each other. Click OK to close the warning message. Also note that the AUI writes the message 8 face-links are created to the bottom of the Message Window. ADINA R & D, Inc

16 F3 F7 F11 F9 F13 F2 F21 F22 F4 F18 F20 Labels for faces 1 and 19 F14 F17 F1 F5 F19 F6 F8 F15 F10 Specifying the fixed boundaries In order to define the fixed boundaries, we need to know some of the face numbers on body 1. The following figure shows the faces that need to be fixed. z F17 F18 x y F16 F ADINA Primer

17 Click the Apply Fixity icon information and click OK., set the Apply to field to Face/Surface, enter the following Face/Surface Body # Specifying the loads We constrain the faces upon which we apply the forces to points, then we apply the forces to the points. The following figure shows the faces and points: F11 P21 F12 P22 F14 F13 x z y Faces 11 and 12 are constrained to point 21. Faces 13 and 14 are constrained to point 22. ADINA R & D, Inc

18 Constraint equations:. Choose Model Constraints Constraint Equations, define the following constraint sets and click OK. Constraint Set Entity Type Entity # Body # Slave DOF Master Entity Type Point # Master DOF 1 Face Trans Point 21 -Trans 2 Face Trans Point 21 -Trans 3 Face Trans Point 22 -Trans 4 Face Trans Point 22 -Trans (we abbreviate -Translation by -Trans in this table) Loads: Click the Apply Load icon, make sure that the Load Type is Force and click the Define... button to the right of the Load Number field. In the Define Concentrated Force dialog box, add force 1, set the Magnitude to 5E5, the Direction to (0, 0, 1) and click OK. In the Apply Load dialog box, make sure that the Apply to field is set to Point. In the first two rows of the table, set the Point # to 21 and 22 respectively, then click OK to close the dialog box. When you click the Boundary Plot icon and the Load Plot icon, the graphics window should look something like this: PRESCRIBED FORCE B B B B U 1 U 2 U B ADINA Primer

19 Defining the material Click the Manage Materials icon and click the Elastic Isotropic button. In the Define Isotropic Linear Elastic Material dialog box, add material 1, set the oung s Modulus to 2.07E5, the Poisson s ratio to 0.29 and click OK. Click Close to close the Manage Material Definitions dialog box. Defining the element groups Although one element group could have been used in this model, we use two element groups instead, one element group for the crack bodies, and another element group for the rest of the model. Element group definition: Click the Element Groups icon, add group number 1, set the Type to 3-D Solid and click Save. Then add group number 2, make sure that the Type is 3-D Solid and click OK. Subdividing the bodies We will specify a uniform element size in geometry body 1 and a smaller uniform element size in the crack bodies (2 and 3). Click the Subdivide Bodies icon, make sure that the Body # is set to 1, set the Element Edge Length to 8 and click Save. Then set the Body # to 2, set the Element Edge Length to 3, enter 3 in the first row of the table and click OK. Meshing First click the Hidden Surfaces Removed icon so that we don't see the dashed hidden lines in the mesh. Also in the Model Tree, right-click 7. WHOLE_MODEL and choose Display. Click the Mesh Bodies icon, set the Element Group to 1 and set the Nodes per Element to 27. Now click the Advanced tab, set the Int. Angle Deviation to 40, Even Subdivisions on to Every Edge on Linked Faces and Mid-Face Nodes to Mid-point on Diagonal of Quad Face. Set the first two rows of the table to 2, 3 and click OK. ou can ignore and close the Warning dialog box that appears. The graphics window should look something like the top figure on the next page. Click the Mesh Bodies icon, make sure that the Element Group is set to 2 and set the Nodes per Element to 27. Now click the Advanced tab, set the Int. Angle Deviation to 40, Even Subdivisions on to Every Edge on Linked Faces and Mid-Face Nodes to Midpoint on Diagonal of Quad Face. Set the first row of the table to 1 and click OK. The graphics window should look something like the bottom figure on the next page. ADINA R & D, Inc

20 PRESCRIBED FORCE B U 1 U 2 U B B B B B B B B BB B BB B BB B B B B B B B BB BB B B B B PRESCRIBED FORCE B B B B BB BB B B B BB B B B BB B B BB B B BB B B B BBB B BB B B B B C C C C CC C C C C C C C C C C C CC C C C C C C C CC C C C C C C C CC C C C U U U B C C ADINA Primer

21 Crack definition, step 1: Split the meshes on B2 and B3 Problem 17: Analysis of a cracked body with ADINA-M/PS In the Model Tree, right-click 2. EG1 and choose Display. Click the Boundary Plot icon to hide the boundary conditions. Then use the Pick icon and the mouse to enlarge the mesh. The graphics window should look something like this: Now click the Shading icon, the Cull Front Faces icon and the No Mesh Lines icon. The graphics window should look something like the top figure on the next page. No incompatibilities can be seen in the mesh. Now choose Meshing Nodes Split Mesh, set 'Split Interface Defined By' to 'Surfaces/Faces', make sure that 'At Boundary of Interface' is set to 'Split Only Nodes on External Boundary', enter the following information in the table and click OK. Face/Surface Body # Now use the Pick icon and the mouse to rotate the mesh plot until the graphics window looks something like the bottom figure on the next page. ADINA R & D, Inc

22 Faces with duplicate nodes are visible The cracked faces (with duplicate nodes) are visible in the plot ADINA Primer

23 Crack definition, step 2: Create the CRACK-SVS definition Problem 17: Analysis of a cracked body with ADINA-M/PS Fracture control: Choose Model Fracture Fracture Control, check the Fracture Analysis field, set the Dimension to 3-D Crack, set the Method to 'Virtual Crack Extension (SVS)' and click OK. CRACK-SVS definition: Choose Model Fracture 3-D SVS Crack and add Crack Number 1. In the Crack Advance Stations box, set the 'Option' to 'Equally Spaced at Number of Locations' and set the 'Number of Crack Advance Stations' to 37. In the Radial Domains box, set the 'Maximum Outer Radius' to 5 and the 'Number of Domains' to 3. Set the 'Binormal Direction of Crack Front' to 'Down'. In the Closed Crack Front box, set 'Starts At' to 'Node Closest to Given Coordinate' and the Coordinate to (35, 0, 0). Then make sure that 'Side' is set to Top, enter 5, 2 in the first row of the table, then set 'Side' to Bottom, and enter 1, 3 in the first row of the table. Then click OK. When you click the Redraw icon, the graphics window should look something like this: The symbol is plotted for each virtual shift. This symbol is interpreted as shown in the figure on the next page. ADINA R & D, Inc

24 Position of crack advance station on crack front Direction of virtual shift, a direction Domain radius There are 37 crack advance stations and three radial domains, for a total of 111 virtual shifts. ou can use the Query icon to click on each virtual shift symbol, to determine the crack advance station number, radial domain number and virtual shift number for the virtual shift. Generating the data file, running ADINA Structures, loading the porthole file Click the Save icon and save the database to file prob17. Click the Data File/Solution icon, set the file name to prob17, make sure that the Run Solution button is checked and click Save. When ADINA Structures is finished, close all open dialog boxes, set the Program Module drop-down list to Post-Processing (you can discard all changes), click the Open icon and open porthole file prob17. Plotting the deformed mesh We need to magnify the plotted displacements. Click the Scale Displacements icon. The displacement magnification factor appears to be too large for this model, so we will reduce it. Click the Modify Mesh Plot icon and click the Model Depiction button. Set the Magnification Factor to 40 and click OK twice to close both dialog boxes. Now click the Shading icon on the next page.. The graphics window should look something like the figure ADINA Primer

25 DISP MAG Determining the maximum displacement Choose List Extreme Values one, set Variable 1 to (Displacement:-DISPLACEMENT) and click Apply. The AUI reports that the maximum -displacement is E-01 (mm) at node (your node number may be different, but the -displacement should be very close to ours). Click Close to close the dialog box. Plotting the element groups in different colors In the remaining mesh plots, we do not want to view the constraint equations. Choose Display Geometry/Mesh Plot Define Style, set the Constraint Depiction to OFF and click OK. Click the Clear icon, then the Mesh Plot icon. Notice that the constraint equation lines are not displayed. Now click the Cut Surface icon, set the Type to Cutting Plane, the Below the Cutplane field to Display as Usual, the Above the Cutplane field to Do not Display and click OK. Click the Color Element Groups icon the figure on the next page.. The graphics window should look something like ADINA R & D, Inc

26 Click the Color Element Groups icon to turn off the element group colors. Examining the meshing near the crack front line Click the Clear icon, then the Mesh Plot icon. In the Model Tree, expand the one keyword, right click on 2. EG1 and choose Display. Let=s magnify the displacements so that we can see the crack opening under the load. Click the Scale Displacements icon figure on the next page.. The graphics window should look something like the top Let's plot just the elements in element group 1 that are below the crack. Click the Split one icon. In the Split one dialog box, click the... button to the right of the 'With Cutting Plane' field. In the Define Cutsurface Depiction dialog box, set 'Defined by' to -Plane, the Coordinate Value to 0.01 and click OK. In the Split one dialog box, set 'Consider Only Elements in one' to EG1, set the field 'Place Elements Below Cutting Plane into one' to BELOW (you need to type this word, the case doesn't matter), and click OK. In the Model Tree, right click on 2. BELOW and choose Display. Then click the Node Symbols icon and the Scale Displacements icon (to unscale the displacements). The graphics window should look something like the bottom figure on the next page ADINA Primer

27 DISP MAG The thick blue line represents the crack front. ADINA R & D, Inc

28 Now use the oom icon look something like this: to zoom into the graphics window. The graphics window should Observe that the crack advance stations do not coincide with nodes. Also observe that the nodes are not shifted to the quarter-points near the crack front. Graphing the stress intensity factors The following diagram shows the crack front as viewed from above. The crack advance stations and the crack front coordinate are displayed. y x s Crack advance station 2 Crack advance stations 1, 37 Crack advance station ADINA Primer

29 Notice that crack advance stations 1 and 37 are at the same position. Clearly (in degrees) s 360 length of crack front line We can define a resultant that gives the angle for each virtual shift. Choose Definitions Variable Resultant, add Resultant Name ANGLE_ON_CRACK_FRONT, define it as 360*<SVS_CRACK_FRONT_DISTANCE>/<SVS_CRACK_FRONT_LENGTH> and click OK. Now choose Definitions Model Line Virtual Shift, and add Model Line RADIAL_DOMAIN_1. Click the Auto... button, edit the table as follows and click Save (do not close the dialog box yet). Virtual Shift # Crack # Radial Domain # Advance Station # Factor From Step To Now add Model Line RADIAL_DOMAIN_2, click the Auto... button, edit the table as follows and click Save (do not close the dialog box yet). Virtual Shift # Crack # Radial Domain # Advance Station # Factor From Step To Finally add Model Line RADIAL_DOMAIN_3, click the Auto... button, edit the table as follows and click OK. Virtual Shift # Crack # Radial Domain # Advance Station # Factor From Step To ADINA R & D, Inc

30 Now we graph the stress intensity factor K I along the crack front line. Click the Clear icon, choose Graph Response Curve Model Line), make sure that the Model Line Name is set to RADIAL_DOMAIN_1, set the Coordinate to (User Defined: ANGLE_ON_CRACK_FRONT), the Coordinate to (Fracture: K-I) and click Apply. Set the Model Line Name to RADIAL_DOMAIN_2, the Coordinate to (User Defined: ANGLE_ON_CRACK_FRONT), the Coordinate to (Fracture: K-I), the Plot Name to PREVIOUS and click Apply. Finally set the Model Line Name to RADIAL_DOMAIN_3, the Coordinate to (User Defined: ANGLE_ON_CRACK_FRONT), the Coordinate to (Fracture: K-I), the Plot Name to PREVIOUS and click OK. The graphics window should look something like this: LINE GRAPH Line RADIAL_DOMAIN_1 Line RADIAL_DOMAIN_2 Line RADIAL_DOMAIN_ K-I * ANGLE_ON_CRACK_FRONT The results change very little between radial domains 2 and 3. Choose Graph List and scroll to the bottom of the list. The value of K-I for angle E+02 (degrees) should be around E+03 MPa- mm. our results might be slightly different due to free meshing. Let's repeat this procedure to determine the stress intensity factor K III along the crack front line. Click the Clear icon, choose Graph Response Curve Model Line), make sure that the Model Line Name is set to RADIAL_DOMAIN_1, set the Coordinate to (User Defined: ANGLE_ON_CRACK_FRONT), the Coordinate to (Fracture: K-III) and click Apply. Set the Model Line Name to RADIAL_DOMAIN_2, the Coordinate to (User Defined: ANGLE_ON_CRACK_FRONT), the Coordinate to (Fracture: K-III), the Plot ADINA Primer

31 Name to PREVIOUS and click Apply. Finally set the Model Line Name to RADIAL_DOMAIN_3, the Coordinate to (User Defined: ANGLE_ON_CRACK_FRONT), the Coordinate to (Fracture: K-III), the Plot Name to PREVIOUS and click OK. The graphics window should look something like this: LINE GRAPH Line RADIAL_DOMAIN_1 Line RADIAL_DOMAIN_2 Line RADIAL_DOMAIN_3 2. K-III * ANGLE_ON_CRACK_FRONT Again, the results change very little between radial domains 2 and 3. Evidently the crack front is subjected to some out-of-plane shear due to the non-axisymmetry of the loads. Choose Graph List and scroll to the bottom of the list. The value of K-III for angle E+02 (degrees) should be around E+02 MPa- mm. Exiting the AUI: Choose File Exit (you can discard all changes). Notes 1) It is possible to solve this problem using a structured (mapped) mesh adjacent to the crack front. The CRACK-M features of ADINA-M can be used to create a mapped mesh. 2) The accuracy of the solution from a structured mesh, such as that created using the CRACK-M features, can be expected to be higher than the accuracy of the solution from the unstructured mesh used in this problem, considering meshes in which the same numbers of nodes and elements are used. However, it is more difficult to set up a structured mesh, and in practice, a structured mesh might be set up using batch files and the command-line input. ADINA R & D, Inc

32 3) In the meshing for this problem, although 27-node hexahedral elements are specified in the input, a mixture of 27-node hexahedral elements and 10-node tetrahedral elements is generated. 4) For an unstructured mesh, shifting the nodes to the quarter-points can cause the elements to become overdistorted. Therefore the nodes are not shifted to the quarter-points in this CRACK-SVS definition. 5) The stress intensity factor II K can also be graphed, but its value is negligible compared to the other stress intensity factors ADINA Primer

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