Engineering topics
Allen, Phillip A.
Publications and source records attributed to Allen, Phillip A..
Applications of Automation Methods for Nonlinear Fracture Test Analysis
As fracture mechanics material testing evolves, the governing test standards continue to be refined to better reflect the latest understanding of the physics of the fracture processes involved. The traditional format of ASTM fracture testing standards, utilizing equations expressed directly in the text of the standard to assess the experimental result, is self-limiting in the complexity that can be reasonably captured. The use of automated analysis techniques to draw upon a rich, detailed solution database for assessing fracture mechanics tests provides a foundation for a new approach to testing standards that enables routine users to obtain highly reliable assessments of tests involving complex, non-linear fracture behavior. Herein, the case for automating the analysis of tests of surface cracks in tension in the elastic-plastic regime is utilized as an example of how such a database can be generated and implemented for use in the ASTM standards framework. The presented approach forms a bridge between the equation-based fracture testing standards of today and the next generation of standards solving complex problems through analysis automation.
Applications of Automation Methods for Nonlinear Fracture Test Analysis
Using automated and standardized computer tools to calculate the pertinent test result values has several advantages such as: 1. allowing high-fidelity solutions to complex nonlinear phenomena that would be impractical to express in written equation form, 2. eliminating errors associated with the interpretation and programing of analysis procedures from the text of test standards, 3. lessening the need for expertise in the areas of solid mechanics, fracture mechanics, numerical methods, and/or finite element modeling, to achieve sound results, 4. and providing one computer tool and/or one set of solutions for all users for a more "standardized" answer. In summary, this approach allows a non-expert with rudimentary training to get the best practical solution based on the latest understanding with minimum difficulty.Other existing ASTM standards that cover complicated phenomena use standard computer programs: 1. ASTM C1340/C1340M-10- Standard Practice for Estimation of Heat Gain or Loss Through Ceilings Under Attics Containing Radiant Barriers by Use of a Computer Program 2. ASTM F 2815 - Standard Practice for Chemical Permeation through Protective Clothing Materials: Testing Data Analysis by Use of a Computer Program 3. ASTM E2807 - Standard Specification for 3D Imaging Data Exchange, Version 1.0 The verification, validation, and round-robin processes required of a computer tool closely parallel the methods that are used to ensure the solution validity for equations included in test standard. The use of automated analysis tools allows the creation and practical implementation of advanced fracture mechanics test standards that capture the physics of a nonlinear fracture mechanics problem without adding undue burden or expense to the user. The presented approach forms a bridge between the equation-based fracture testing standards of today and the next generation of standards solving complex problems through analysis automation.
Elastic-Plastic J-Integral Solutions or Surface Cracks in Tension Using an Interpolation Methodology. Appendix C -- Finite Element Models Solution Database File, Appendix D -- Benchmark Finite Element Models Solution Database File
No closed form solutions exist for the elastic-plastic J-integral for surface cracks due to the nonlinear, three-dimensional nature of the problem. Traditionally, each surface crack must be analyzed with a unique and time-consuming nonlinear finite element analysis. To overcome this shortcoming, the authors have developed and analyzed an array of 600 3D nonlinear finite element models for surface cracks in flat plates under tension loading. The solution space covers a wide range of crack shapes and depths (shape: 0.2 less than or equal to a/c less than or equal to 1, depth: 0.2 less than or equal to a/B less than or equal to 0.8) and material flow properties (elastic modulus-to-yield ratio: 100 less than or equal to E/ys less than or equal to 1,000, and hardening: 3 less than or equal to n less than or equal to 20). The authors have developed a methodology for interpolating between the goemetric and material property variables that allows the user to reliably evaluate the full elastic-plastic J-integral and force versus crack mouth opening displacement solution; thus, a solution can be obtained very rapidly by users without elastic-plastic fracture mechanics modeling experience. Complete solutions for the 600 models and 25 additional benchmark models are provided in tabular format.
Damage Tolerance Analysis of Space Shuttle External Tank Lug Fillet Welds Using NASGRO
The damage tolerance of the External Tank (ET) lug welds were reassessed because of an increase in the loads due to the removal of the protuberance air load (PAT.,) ramp. The analysis methods included detailed finite element analysis (FEA) of the ET welded lugs and FEA of the lug weld test configuration. The FEA results were used as input to the crack growth analysis code NASGRO to calculate the mission life capability of the ET lug welds and to predict the number of cycles to failure in the lug weld testing. The presentation presents the method of transferring the FEM results to the NASGRO model and gives correlations between FEM and NASGRO stress intensity calculations.
Advanced Damage Tolerance Analysis of International Space Station Pressure Wall Welds
EM20/MSFC has sponsored technology in the area of advanced damage tolerance analysis tools used to analyze the International Space Station (ISS) pressure wall welds. The ISS European modules did not receive non-destructive evaluation (NDE) inspection after proof test. In final assembly configuration, most welds could only be inspected from one side, and some welds were uninspectible. Therefore, advanced damage tolerance analysis was required to determine the critical initial flaw sizes and predicted safe life for the pressure wall welds. EM20 sponsored the development of a new finite element tools using FEA-Crack and WARP3D to solve the problem. This presentation gives a brief overview of the new analytical tools and the analysis results.
Development of a Fatigue Crack Growth Coupon for Highly Plastic Stress Conditions
The analytical approach used to develop a novel fatigue crack growth coupon for highly plastic stress field condition is presented in this paper. The flight hardware investigated is a large separation bolt that has a deep notch, which produces a large plastic zone at the notch root when highly loaded. Four test specimen configurations are analyzed in an attempt to match the elastic-plastic stress field and crack constraint conditions present in the separation bolt. Elastic-plastic finite element analysis is used to compare the stress fields and critical fracture parameters. Of the four test specimens analyzed, the modified double-edge notch tension - 3 (MDENT-3) most closely approximates the stress field, J values, and crack constraint conditions found in the flight hardware. The MDENT-3 is also most insensitive to load misalignment and/or load redistribution during crack growth.
Development of a Fatigue Crack Growth Coupon for Highly Plastic Stress Conditions
This paper presents an analytical approach used to develop a novel fatigue crack growth coupon for a highly plastic 3-D stress field condition. The flight hardware investigated in this paper is a large separation bolt that fractures using pyrotechnics at the appointed time during the flight sequence. The separation bolt has a deep notch that produces a severe stress concentration and a large plastic zone when highly loaded. For this geometry, linear-elastic fracture mechanics (LEFM) techniques are not valid due to the large nonlinear stress field. Unfortunately, industry codes that are generally available for fracture mechanics analysis and fatigue crack growth (e.g. NASGRO (11) are limited to LEFM and are available for only a limited number of geometries. The results of LEFM based codes are questionable when used on geometries with significant plasticity. Therefore elastic-plastic fracture mechanics (EPFM) techniques using the finite element method (FEM) were used to analyze the bolt and test coupons. scale flight hardware is very costly in t e r n of assets, laboratory resources, and schedule. Therefore to alleviate some of these problems, a series of novel test coupons were developed to simulate the elastic-plastic stress field present in the bolt.
Hydrostatic Stress Effect on the Yield Behavior of Inconel 100
Classical metal plasticity theory assumes that hydrostatic stress has negligible effect on the yield and postyield behavior of metals. Recent reexaminations of classical theory have revealed a significant effect of hydrostatic stress on the yield behavior of various geometries. Fatigue tests and nonlinear finite element analyses (FEA) of Inconel 100 (IN100) equal-arm bend specimens and new monotonic tests and nonlinear finite element analyses of IN100 smooth tension, smooth compression, and double-edge notch tension (DENT) test specimens have revealed the effect of internal hydrostatic tensile stresses on yielding. Nonlinear FEA using the von Mises (yielding is independent of hydrostatic stress) and the Drucker-Prager (yielding is linearly dependent on hydrostatic stress) yield functions were performed. A new FEA constitutive model was developed that incorporates a pressure-dependent yield function with combined multilinear kinematic and multilinear isotropic hardening using the ABAQUS user subroutine (UMAT) utility. In all monotonic tensile test cases, the von Mises constitutive model, overestimated the load for a given displacement or strain. Considering the failure displacements or strains for the DENT specimen, the Drucker-Prager FEM s predicted loads that were approximately 3% lower than the von Mises values. For the failure loads, the Drucker Prager FEM s predicted strains that were up to 35% greater than the von Mises values. Both the Drucker-Prager model and the von Mises model performed equally-well in simulating the equal-arm bend fatigue test.
Hydrostatic Stress Effect On the Yield Behavior of Inconel 100
Classical metal plasticity theory assumes that hydrostatic stress has no effect on the yield and postyield behavior of metals. Recent reexaminations of classical theory have revealed a significant effect of hydrostatic stress on the yield behavior of notched geometries. New experiments and nonlinear finite element analyses (FEA) of Inconel 100 (IN 100) equal-arm bend and double-edge notch tension (DENT) test specimens have revealed the effect of internal hydrostatic tensile stresses on yielding. Nonlinear FEA using the von Mises (yielding is independent of hydrostatic stress) and the Drucker-Prager (yielding is linearly dependent on hydrostatic stress) yield functions was performed. In all test cases, the von Mises constitutive model, which is independent of hydrostatic pressure, overestimated the load for a given displacement or strain. Considering the failure displacements or strains, the Drucker-Prager FEMs predicted loads that were 3% to 5% lower than the von Mises values. For the failure loads, the Drucker Prager FEMs predicted strains that were 20% to 35% greater than the von Mises values. The Drucker-Prager yield function seems to more accurately predict the overall specimen response of geometries with significant internal hydrostatic stress influence.
ANSYS Modeling of Hydrostatic Stress Effects
Classical metal plasticity theory assumes that hydrostatic pressure has no effect on the yield and postyield behavior of metals. Plasticity textbooks, from the earliest to the most modem, infer that there is no hydrostatic effect on the yielding of metals, and even modem finite element programs direct the user to assume the same. The object of this study is to use the von Mises and Drucker-Prager failure theory constitutive models in the finite element program ANSYS to see how well they model conditions of varying hydrostatic pressure. Data is presented for notched round bar (NRB) and "L" shaped tensile specimens. Similar results from finite element models in ABAQUS are shown for comparison. It is shown that when dealing with geometries having a high hydrostatic stress influence, constitutive models that have a functional dependence on hydrostatic stress are more accurate in predicting material behavior than those that are independent of hydrostatic stress.