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The purpose of this research was to present a simulation modelling of a crack propagation trajectory in linear elastic material subjected to mixed-mode loadings and investigate the effects of the existence of a hole and geometrical thickness on fatigue crack growth and fatigue life under constant amplitude loading. For various geometry thickness, mixed-mode (I/II) fatigue crack growth studies were carried out to utilize a single edge cracked plate with three holes and compact tension shear specimens with various loading angles. Smart Crack Growth Technology, a new feature in ANSYS, was used in ANSYS Mechanical APDL 19.2 to predict the cracks’ propagation trajectory and their consequent fatigue life associated with evaluating the stress intensity factors. The maximum circumferential stress criterion is implemented as a direction criterion under linear elastic fracture mechanics (LEFM). According to the hole position, the results demonstrate that the fatigue crack grows towards the hole due to the unbalanced stresses on the hole induced crack tip. The results of this simulation are verified in terms of crack growth paths, stress intensity factors, and fatigue life under mixed-mode load conditions, with several crack growth studies published in the literature showing consistent results.

In this study, the primary objective is to analyze fatigue crack propagation in linear elastic fracture mechanics using the SMART crack growth module in the ANSYS Workbench, employing the finite element method. The investigation encompasses several crucial steps, including the computation of stress intensity factors (SIFs), determination of crack paths, and estimation of remaining fatigue life. To thoroughly understand crack behavior under various loading conditions, a wide range of stress ratios, ranging from R = 0.1 to R = 0.9, is considered. The research findings highlight the significant impact of the stress ratio on the equivalent range of SIFs, fatigue life cycles, and distribution of deformation. As the stress ratio increases, there is a consistent reduction in the magnitude of the equivalent range of stress intensity factor. Additionally, a reciprocal relationship is observed between the level of X-directional deformation and the number of cycles to failure. This indicates that components experiencing lower levels of deformation tend to exhibit longer fatigue life cycles, as evidenced by the specimens studied. To verify the findings, the computational results are matched with the crack paths and fatigue life data obtained from both experimental and numerical sources available in the open literature. The extensive comparison carried out reveals a remarkable level of agreement between the computed outcomes and both the experimental and numerical results.

Fatigue crack propagation is a critical phenomenon that affects the structural integrity and lifetime of various engineering components. Over the years, finite element modeling (FEM) has emerged as a powerful tool for studying fatigue crack propagation and predicting crack growth behavior. This study offers a thorough overview of recent advancements in finite element modeling (FEM) of fatigue crack propagation. It highlights cutting-edge techniques, methodologies, and developments, focusing on their strengths and limitations. Key topics include crack initiation and propagation modeling, the fundamentals of finite element modeling, and advanced techniques specifically for fatigue crack propagation. This study discusses the latest developments in FEM, including the Extended Finite Element Method, Cohesive Zone Modeling, Virtual Crack Closure Technique, Adaptive Mesh Refinement, Dual Boundary Element Method, Phase Field Modeling, Multi-Scale Modeling, Probabilistic Approaches, and Moving Mesh Techniques. Challenges in FEM are also addressed, such as computational complexity, material characterization, meshing issues, and model validation. Additionally, the article underscores the successful application of FEM in various industries, including aerospace, automotive, civil engineering, and biomechanics.

Fatigue crack growth modeling is critical for assessing structural integrity in various engineering applications. Researchers and engineers rely on 3D software tools to predict crack propagation accurately. However, choosing the right software can be challenging due to the plethora of available options. This study aimed to systematically compare and evaluate the suitability of seven prominent 3D modeling software packages for fatigue crack growth analysis in specific applications. The selected software tools, namely ABAQUS, FRANC3D, ZENCRACK, LYNX, FEMFAT, COMSOL Multiphysics, and ANSYS, were subjected to a comprehensive analysis to assess their effectiveness in accurately predicting crack propagation. Additionally, this study aimed to highlight the distinctive features and limitations associated with each software package. By conducting this systematic comparison, researchers and engineers can gain valuable insights into the strengths and weaknesses of these software tools, enabling them to make informed decisions when choosing the most appropriate software for their fatigue crack growth analysis needs. Such evaluations contribute to advancing the field by enhancing the understanding and utilization of these 3D modeling software packages, ultimately improving the accuracy and reliability of structural integrity assessments in relevant applications.

The aim of this paper is to simulate the propagation of linear elastic crack in 3D structures using the latest innovation developed using Ansys software, which is the Separating Morphing and Adaptive Remeshing Technology (SMART), in order to enable automatic remeshing during a simulation of fracture behaviors. The ANSYS Mechanical APDL 19.2 (Ansys, Inc., Canonsburg, PA, USA), is used by employing a special mechanism in ANSYS, which is the smart crack growth method, to accurately predict the crack propagation paths and associated stress intensity factors. For accurate prediction of the mixed-mode stress intensity factors (SIFs), the interaction integral technique has been employed. This approach is used for the prediction of the mixed-mode SIFs in the three-point bending beam, which has six different configurations: three configurations with holes, and the other three without holes involving the linear elastic fracture mechanics (LEFM) assumption. The results indicated that the growth of the crack was attracted to the hole and changes its trajectory to reach the hole or floats by the hole and grows when the hole is missing. For verification, the data available in the open literature on experimental crack path trajectories and stress intensity factors were compared with computational study results, and very good agreement was found.

The primary focus of this paper is to investigate the application of ANSYS Workbench 19.2 software’s advanced feature, known as Separating Morphing and Adaptive Remeshing Technology (SMART), in simulating the growth of cracks within structures that incorporate holes. Holes are strategically utilized as crack arrestors in engineering structures to prevent catastrophic failures. This technique redistributes stress concentrations and alters crack propagation paths, enhancing structural integrity and preventing crack propagation. This paper explores the concept of using holes as crack arrestors, highlighting their significance in increasing structural resilience and mitigating the risks associated with crack propagation. The crack growth path is estimated by applying the maximum circumferential stress criterion, while the calculation of the associated stress intensity factors is performed by applying the interaction integral technique. To analyze the impact of holes on the crack growth path and evaluate their effectiveness as crack arrestors, additional specimens with identical external dimensions but without any internal holes were tested. This comparison was conducted to provide a basis for assessing the role of holes in altering crack propagation behavior and their potential as effective crack arrestors. The results of this study demonstrated that the presence of a hole had a significant influence on the crack growth behavior. The crack was observed to be attracted towards the hole, leading to a deviation in its trajectory either towards the hole or deflecting around it. Conversely, in the absence of a hole, the crack propagated without any alteration in its path. To validate these findings, the computed crack growth paths and associated stress intensity factors were compared with experimental and numerical data available in the open literature. The remarkable consistency between the computational study results for crack growth path, stress intensity factors, and von Mises stress distribution, and the corresponding experimental and numerical data, is a testament to the accuracy and reliability of the computational simulations.

As a part of a damage tolerance assessment, the goal of this research is to estimate the two-dimensional crack propagation trajectory and its accompanying stress intensity factors (SIFs) using the adaptive finite element method. The adaptive finite element code was developed using the Visual Fortran language. The advancing-front method is used to construct an adaptive mesh structure, whereas the singularity is represented through construction of quarter-point single elements around the crack tip. To generate an optimal mesh, an adaptive mesh refinement procedure based on the posteriori norm stress error estimator is used. The splitting node strategy is used to model the fracture, and the trajectory follows the successive linear extensions for every crack increment. The stress intensity factors (SIFs) for each crack extension increment are calculated using the displacement extrapolation technique. The direction of crack propagation is determined using the theory of maximum circumferential stress. The present study is carried out for two geometries, namely a rectangular structure with two holes and one central crack, and a cracked plate with four holes. The results demonstrate that, depending on the position of the hole, the crack propagates in the direction of the hole due to the unequal stresses at the crack tip, which are caused by the hole’s influence. The results are consistent with other numerical investigations for predicting crack propagation trajectories and SIFs.

This study presents a comparative analysis of fatigue crack growth (FCG) in four high-performance crystalline metallic alloys: Inconel 718, Ti-6Al-4V, Aluminum 7075-T6, and ASTM A514 Steel. The Finite Element Method was utilized to simulate crack propagation and quantify the individual and synergistic effects of key material properties, including Paris Law constants (C and m), yield strength, and modulus of elasticity, on FCG behavior. The analysis integrates simulation-driven parametric studies to quantify the impact on performance indicators (fatigue life cycles, equivalent stress intensity factors, safety factors, von Mises stress, and strain energy), and provides a quantitative analysis of secondary parameters. The results provide a robust, data-driven framework for material selection in aerospace, industrial, and structural applications where fatigue life is a paramount design consideration. Key findings reveal that Inconel 718 exhibits vastly superior fatigue life which is approximately 15 times greater than the next best-performing material, ASTM A514 Steel. Conversely, Ti-6Al-4V demonstrated the lowest fatigue resistance.

This study presents a unique and comprehensive application of ANSYS Mechanical R19.2’s SMART crack growth feature, leveraging its capabilities to conduct an unprecedented parametric investigation into fatigue crack propagation behavior under a wide range of positive and negative stress ratios, and to provide detailed insights into the influence of hole positioning on crack trajectory. By uniquely employing an unstructured mesh method that significantly reduces computational overhead and automates mesh updates, this research overcomes traditional fracture simulation limitations. The investigation breaks new ground by comprehensively examining an unprecedented range of both positive (R = 0.1 to 0.5) and negative (R = −0.1 to −0.5) stress ratios, revealing previously unexplored relationships in fracture mechanics. Through rigorous and extensive numerical simulations on two distinct specimen configurations, i.e., a notched plate with a strategically positioned hole under fatigue loading and a cracked rectangular plate with dual holes under static loading, this work establishes groundbreaking correlations between stress parameters and fatigue behavior. The research reveals a novel inverse relationship between the equivalent stress intensity factor and stress ratio, alongside a previously uncharacterized inverse correlation between stress ratio and von Mises stress. Notably, a direct, accelerating relationship between stress ratio and fatigue life is demonstrated, where higher R-values non-linearly increase fatigue resistance by mitigating stress concentration, challenging conventional linear approximations. This investigation makes a substantial contribution to fracture mechanics by elucidating the fundamental role of hole positioning in controlling crack propagation paths. The research uniquely demonstrates that depending on precise hole location, cracks will either deviate toward the hole or maintain their original trajectory, a phenomenon attributed to the asymmetric stress distribution at the crack tip induced by the hole’s presence. These novel findings, validated against existing literature, represent a significant advancement in predictive modeling for fatigue life assessment, offering critical new insights for engineering design and maintenance strategies in high-stakes industries.

A comprehensive numerical investigation of Fatigue Crack Growth (FCG) under negative stress ratios (R < 0) was conducted using the Finite Element Method (FEM) and the ANSYS Benchmark 19.2 SMART crack growth module on modified Compact Tension (CT) specimens. This study addresses the critical challenge posed by the compressive portion of cyclic loading, which traditional Linear Elastic Fracture Mechanics (LEFM) models often fail to capture accurately due to the complex interaction of crack closure and reversed plastic zones. The analysis focused on the evolution of the von Mises stress and maximum principal stress distributions at the crack tip across a range of stress ratios, including R = 0.1, −0.1, −0.2, −0.3, −0.4, −0.5, and −1.0. The results demonstrate a significant inverse correlation between fatigue life cycles and the magnitude of the negative stress ratio, consistent with the detrimental effect of increasing tensile stress. Crucially, the numerical simulation successfully captured the non-monotonic behavior of the crack tip stress field, revealing that the compressive load phase substantially alters the effective stress intensity factor range and the crack growth path, which was governed by the Maximum Tangential Stress (MTS) criterion. This research provides a validated computational methodology for accurately predicting FCG life in engineering components subjected to demanding, fully reversed, or compressive–dominant cyclic loading environments.