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Research Papers

Some Recent Advances in Engineering Fracture Modeling for Turbomachinery

[+] Author and Article Information
R. Craig McClung

Mechanical Engineering Division,
Southwest Research Institute,
P. O. Drawer 28510,
San Antonio, TX 78228-0510
e-mail: cmcclung@swri.org

Yi-Der Lee, James C. Sobotka, Jonathan P. Moody, Vikram Bhamidipati, Michael P. Enright

Mechanical Engineering Division,
Southwest Research Institute,
P. O. Drawer 28510,
San Antonio, TX 78228-0510

D. Benjamin Guseman, Colin B. Thomas

Elder Research Inc.,
300 W Main St #301,
Charlottesville, VA 22903

1Corresponding author.

Manuscript received June 26, 2018; final manuscript received July 6, 2018; published online September 19, 2018. Editor: Jerzy T. Sawicki.

J. Eng. Gas Turbines Power 141(2), 021005 (Sep 19, 2018) (9 pages) Paper No: GTP-18-1378; doi: 10.1115/1.4040901 History: Received June 26, 2018; Revised July 06, 2018

Recent advances in practical engineering methods for fracture analysis of turbomachinery components are described. A comprehensive set of weight function (WF) stress intensity factor (SIF) solutions for elliptical and straight cracks under univariant and bivariant stress gradients has been developed and verified. Specialized SIF solutions have been derived for curved through cracks, cracks at chamfered and angled corners, and cracks under displacement control. Automated fracture models are available to construct fatigue crack growth (FCG) life contours and critical initial crack size (CICS) contours for all nodal locations in two-dimensional or three-dimensional (2D or 3D) finite element (FE) models.

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References

Rooke, D. P. , and Cartwright, D. J. , 1976, Compendium of Stress Intensity Factors, HMSO, London.
Tada, H. , Paris, P. C. , and Irwin, G. , 1973, The Stress Analysis of Cracks Handbook, Del Research Corporation, Hellertown, PA.
Enright, M. P. , Lee, Y.-D. , McClung, R. C. L. , Huyse, L. , Leverant, G. R. , Millwater, H. R. , and Fitch, S. K. , 2003, “ Probabilistic Surface Damage Tolerance Assessment of Aircraft Turbine Rotors,” ASME Paper No. GT-2003-38731.
McClung, R. C. , Enright, M. P. , Lee, Y.-D. , Huyse, L. , and Fitch, S. , 2004, “ Efficient Fracture Design for Complex Turbine Engine Components,” ASME Paper No. GT-2004-53323.
Glinka, G. , and Shen, G. , 1991, “ Universal Features of Weight Functions for Cracks in Mode I,” Eng. Fract. Mech., 40(6), pp. 1135–1146. [CrossRef]
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Kiciak, A. , Glinka, G. , and Eman, M. , 1998, “ Weight Functions and Stress Intensity Factors for Corner Quarter-Elliptical Crack in Finite Thickness Plate Subjected to In-Plane Loading,” Eng. Fract. Mech., 60(2), pp. 221–238. [CrossRef]
Orynyak, I. V. , Borodii, M. V. , and Torop, V. M. , 1994, “ Approximate Construction of a Weight Function for Quarter-Elliptical, Semi-Elliptical and Elliptical Cracks Subjected to Normal Stresses,” Eng. Fract. Mech., 40(1), pp. 143–151. [CrossRef]
Orynyak, I. V. , and Borodii, M. V. , 1995, “ Point Weight Function Method Application for Semi-Elliptical Mode I Cracks,” Int. J. Fract., 70(2), pp. 117–124. [CrossRef]
Lee, Y.-D. , McClung, R. C. , and Chell, G. G. , 2008, “ An Efficient Stress Intensity Factor Solution Scheme for Corner Cracks at Holes Under Bivariant Stressing,” Fatigue Fract. Eng. Mater. Struct., 31(11), pp. 1004–1016. [CrossRef]
Fawaz, S. A. , 1999, “ Stress Intensity Factor Solutions for Part-Elliptical Through Cracks,” Eng. Fract. Mech., 63(2), pp. 209–226. [CrossRef]
Lanciotti, A. , and Polese, C. , 2003, “ Fatigue Crack Propagation of Through Cracks in Thin Sheets Under Combined Bending and Tension Stresses,” Fatigue Fract. Eng. Mater. Struct., 26(5), pp. 421–428. [CrossRef]
Huls, R. A. , Grooteman, F. P. , and Veul, R. P. G. , 2013, “ Stress Intensity Factor for a Center Through Crack in a Finite Width Plate Subjected to a Symmetric Remote Displacement Field,” National Aerospace Laboratory NLR, Report No. NLR-CR-2012-222.
Grooteman, F. P. , 2016, “ Stress Intensity Factor Solution for a Quarter Elliptical Corner Crack in a Finite Width Plate Subjected to a Bivariant Remote Displacement Field,” National Aerospace Laboratory NLR, Report No. NLR-CR-2015-202-PT-1.
McClung, R. C. , Lee, Y.-D. , Enright, M. P. , and Liang, W. , 2014, “ New Methods for Automated Fatigue Crack Growth and Reliability Analysis,” ASME J. Eng. Gas Turbines Power, 136(6), p. 062101. [CrossRef]
Enright, M. P. , Moody, J. P. , and Sobotka, J. C. , 2016, “ Optimal Automated Risk Assessment of 3D Gas Turbine Engine Components,” ASME Paper No. GT2016-58091.
Enright, M. P. , McClung, R. C. , Sobotka, J. C. , Moody, J. P. , McFarland, J. , and Lee, Y.-D. , 2018, “ Influences of Non-Destructive Inspection Simulation on Fracture Risk Assessment of Additively Manufactured Turbine Engine Components,” ASME Paper No. GT2018-77058.
McClung, R. C. , Enright, M. P. , Moody, J. P. , Lee, Y.-D. , Sobotka, J. C. , Bhamidipati, V. , and McClure, J. W. , 2017, “ A Comprehensive Framework for Probabilistic Damage Tolerant Design of Aerospace Components,” 35th ICAF Conference and 29th ICAF Symposium (ICAF 2017), Curran Associates, Inc., Red Hook, NY, pp. 1672–1681.
McClung, R. C. , Wawrzynek, P. , Lee, Y.-D. , Carter, B. J. , Moody, J. P. , and Enright, M. P. , 2016, “ An Integrated Software Tool for High Fidelity Probabilistic Assessments of Metallic Aero-Engine Components,” ASME Paper No. GT2016-57877.

Figures

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Fig. 2

Schematic representation of offset embedded crack geometry for bivariant WF SIF solution

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Fig. 1

Schematic representation of offset surface crack geometry for bivariant WF SIF solution

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Fig. 3

Rank ordering of the ratios of WF SIF solutions to FE SIF solutions for bivariant corner crack solution CC09

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Fig. 4

Rank ordering of the ratios of WF SIF solutions to FE SIF solutions for bivariant embedded crack solution EC04

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Fig. 5

Schematic representation of part-elliptical edge through crack geometry for univariant WF SIF solution

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Fig. 6

Schematic representation of chamfered corner crack geometry (right) based on regular corner crack geometry (left)

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Fig. 7

Schematic representation of angled corner crack geometry spanning one chamfer edge

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Fig. 8

Schematic representation of edge cracked plate under remote displacement control

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Fig. 12

Critical initial crack size contours for a 2D axisymmetric finite element model with a designated service life of 5000 cycles

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Fig. 9

Reference solutions for edge-cracked plate subjected to uniform remote displacement loading under type I displacement constraint

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Fig. 10

Fatigue crack growth life contours for a 2D axisymmetric finite element model with an 0.01 in × 0.01 in initial crack at each node in the model

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Fig. 11

Schematic illustration of hybrid inverse scheme for inverse calculation of critical initial crack size

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Fig. 13

Critical initial crack size contours for a 3D finite element model

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