Effect on Mode 1 SIF with Introduction Of Holes Near The Centre Crack

&
Effect of Semi-elliptical Cracks on Stress Concentrated Regions in Pressure Vessel

Amith Anoop Kumar-AM.EN.U4ME18005

Arutselvan CK -AM.EN.U4ME18110
Jenuel John -AM.EN.U4ME18122

Guided by
Dr Arunkumar S

DEPARTMENT OF MECHANICAL ENGINEERING

AMRITA SCHOOL OF ENGINEERING, AMRITAPURI
 FRACTURE & FRACTURE MECHANICS
🔵 Fracture is basically the failure of a material which the breaking of a material into two or more
pieces under the application of the load
🔵 For all practical purposes,modern fracture mechanics was born in 1948 when Irwin fromulated
fracture mechanics using parameters like SIF and energy release rate[1]
🔵 Fracture mechanics is the field of mechanics concerned with the study of the propagation of
cracks in materials[2]
🔵 Fracture mechanics recognizes the role of inherent flaws in structures that effect their
performance and life
🔵 Fracture mechanics is further subdivided into LEFM and EPFM from which we are restricting our
study to LEFM.
🔵 LEFM is used for material conditions which are predominantly linear elastic during the fatigue
process.

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 Modes Of Fracture Failure :
• Modes of fracture refers to the decomposition of crack tip stresses into three loadings.

( Sliding)
(Tearing)

FIG 2: THREE MODES OF FRACTURE

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 Major Results From Reviewed Papers:
S.No Paper Title Results Drawn

1. Crack-Growth Arrest by redirecting crack growth by drilling holes On drilling holes and inserting pins the
and inserting pins cracks converged into the holes . By this
the residual stress was distributed on crack
growth route into pins .

2. Computing SIF and Critical Crack Length of ASTM A26 steel This study proves that SIF value increases
with increase in crack length and material
fails when SIF reaches critical value
3. Analysis of Cracks Starting from a Square Hole in a Rectangular Plate With increase in pressure, all parameters
i.e. maximum Von Mises stress, maximum
deformation, Stress Intensity Factor
increase linearly
4. Stress intensity factor evaluation for crack emanating from Circular-hole The crack propagation trajectories on
using finite element method crack emanating from circular hole of
rectangular plate is propagated straight
forward from both sides of the crack tip

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 Major Results From Reviewed Papers:
S.No Paper Title Results Drawn

5. Analysis of edge crack behaviour of steel sheet based on a shear The notch initial size has a significant
modified GTN damage model impact on the behaviour of notch i.e.
from V to Y .
The cracks length decrease with the
increase of notch width

6. Reduction in the Stress Intensity Factor for Cracks Starting from A Reduction in SIF can be done by drilling
Circular Hole in an Infinite Plate holes at proper locations found by
simulation trails .
7. Computation of stress intensity factor and critical crack length of SIF value increases with increase in crack
ASTM A36 steel using fracture mechanics length and the component failed when the
SIF reaches its critical value
8. Single-edge crack growth in graphene sheets under tension Crack speed decreases with an increase in
the initial crack length

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 Problem Definition :
 Fracture is a common failure mode for system/devices with movable structures. The root cause of
mechanical fracture can be overload, mechanical shock, fatigue, or stress corrosion. Mechanical
fracture of material is caused by disconnection of atomic bonds or molecular bonds.
 The purpose of this project is to propose a new technical method for reducing mode-1 SIF by
drilling holes of different shapes along crack line .

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 Methodology :
• In a rectangular plate of 100mm*50mm we simulated for centre cracks . The crack length 6mm.
• The simulation results of no-hole condition is considered as base case . Then simulations with
holes were done and compared to the base case .
• Three Types of Holes namely circular , square and elliptical holes were used.
• Stress intensity factor simulation results and numerical results were compared and verified. The
mesh size for this configuration were followed for the upcoming models.
• After fixing the load introduced circular , square and elliptical holes at different distances in
different numbers.
• Here holes are introduced axially along the crack tip and symmetrically above the crack tip.
• The simulation results were tabulated and further interpretation were drawn.

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 Geometry With Centre Crack :

FIG 3 : Rectangular plate with Centre Crack

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 Normalized SIF : Analytical and Ansys

CENTRE CRACK

Normalised SIF

0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26 0.28 0.3

a/W

FIG 4: Comparison of Normalized SIF for Centre Crack

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 Analytical Formulae Used :
•Stress intensity factor (SIF) K1(mode 1) is the function of geometry , size and shape of the crack and
type of loading . The SI unit of SIF is MPa. m^(-1/2) . (All values mentioned in this ppt have the same
unit)
•For different loading and geometry configurations , a SI modification factor Y can be incorporated .

For Centre-Crack under Tension ,

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 Mesh Conditions :

• Here we have meshed our rectangular plate using a quad dominant meshing.
• Quad elements are better than tri elements, so we have limited tri element % to less than 1%.
• We initially ran a mesh a dependency test and found out an ideal mesh size for this configuration
is of size 0.35mm.
• We could achieve nearly a 100 element quality with the mesh.
• For centre crack model , total of 122880 nodes with 41648 elements are meshed .

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 Discretized Finite Element Model :

FIG 5: FE model and Equivalent Stress distribution of Centre Crack

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 CENTRE CRACK :
Here We can see circular holes in vicinity of crack tip of centre crack both
(i) Circular Hole: axial and vertical orientation and its corresponding Stress distribution

FIG 27 :Centre crack with circular holes along axial direction of crack line

FIG 28 : Centre crack with circular holes along vertical direction to crack line

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 •Generally Normalized SIF value increases with
increasing diameter for the first few distances.
• After a distance of 10 mm Normalized SIF values
are in a close range for different diameters.
•After 10 mm hole diameter don't have much
influence on SIF.

FIG 29: Plot of results for circular holes axially along the crack tip

•Here we compare the case of 2mm circular

holes with different number of holes.SIF
increases with in number of holes.
• Moving away from the crack tip SIF
decreases and converging happens.

FIG 30 :Plot of results for different number of circular holes

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 •Normalized SIF value decreases with increasing diameter
throughout the graph.
•For 1 and 2 mm holes between crack centre hole centre has
less influence on Normalized SIF.
• For 3,4 mm distance between crack centre hole centre
have significance on Normalized SIF value.

FIG 31 : Plot of results for circular holes vertically

along the crack tip

•Here we compare the case of 2mm circular holes

above the line of crack with different number of holes.
•Normalized SIF decreases with increase in number of
holes. Moving away from the crack Normalized SIF
starts to decrease.

FIG 32 :Plot of results for different number of circular holes

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(ii) Square Hole: Here We can see square holes in vicinity of crack tip of centre crack both
axial and vertical orientation and its corresponding Stress distribution

FIG 33 :Centre crack with square holes along axial direction of crack line

FIG 34 : Centre crack with square holes along vertical direction to crack line
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 •When diameter increases correspondingly Normalized
SIF decreases smoothly..
•Lowest Normalized SIF is for one 1 mm hole at 15 mm
distance(1.014532).

FIG 35: Plot of results for square holes axially along the crack tip

•Here we compare the case of 2mm square holes

with different number of holes.
•Moving away from the crack tip Normalized
SIF value decreases and converges most at a
distance of 10 mm.

FIG 36 :Plot of results for different number of square holes

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 •SIF value decreases with increasing hole diameter.
Moving far from the crack center Normalized SIF value
varies a bit .
•After a distance of 6 mm Normalized SIF has started to
converge. Lowest Normalized SIF value of 0.87 is for
three 4mm holes at a distance of 6 mm.

FIG 37 : Plot of results for square holes vertically

along the crack tip

•Here we compare the case of 2mm square holes

above the line of crack with different number of
holes.
•Normalized SIF is almost in a straight line for
different number of holes.

FIG 38 :Plot of results for different number of square holes

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(iii) Elliptical Hole: Here We can see elliptical holes in vicinity of crack tip of centre crack
both axial and vertical orientation and its corresponding Stress
distribution

FIG 39 :Centre crack with elliptical holes along axial direction of crack line

FIG 40 : Centre crack with elliptical holes along vertical direction to crack line
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 •In case of elliptical holes in CENTRE crack
the Normalized SIF steadily converges with
increasing distance from the crack tip .

FIG 41: Plot of results for elliptical holes axially along the crack tip

•With increasing number of holes

the Normalized SIF initially has
some variation but converges with
increasing distance .
•The lowest Normalized SIF is
0.686 at a distance of 6 mm .

FIG 42 :Plot of results for different number of square holes

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 •With increasing diameter the
Normalized SIF follows a steady
reducing trend with lowest value 0.588
for major dia 5mmand minor dia 4mm .

FIG 43 : Plot of results for square holes vertically

along the crack tip

•With an increase in the number of

holes the Normalized SIF tends to
converge over increasing distance .

FIG 44 :Plot of results for different number of square holes

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Conclusion:
The problem of a 2D plate with centre and centre crack subjected to axial loading on the mode I SIF are
investigated numerically in this work. The numerical model is validated using analytical equations. The
SIF in case of centre crack is around 72.Based on the finite element analysis, following conclusions can be
drawn:
 i.Holes along the axis
•When introducing holes along the line of crack, SIF increases with increase in hole diameter . Moving the
hole far from the crack tip SIF reduces.
•In the case of centre cracks
•circular holes: Lowest SIF value of 31.12 for two 1 mm holes at a distance of 13mm.
square holes: Lowest SIF value of 31.14 for one 1 mm hole at distance of 15 mm .
elliptical hole : Lowest SIF of 20.12 for major diameter of 2mm and minor diameter of 1mm holes at
distance of 10 mm.

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 ii.Holes above the crack tip
•For 1,2 mm holes distance from crack doesn't have much influence on SIF.
•For 3,4 mm holes distance from crack have significance on SIF value, when moving far from the
crack SIF decreases.
•In case of Centre Crack
circular holes: Lowest SIF value of 22.54 for four 4 mm holes at 4 mm.
square holes: Lowest SIF value of 26.732 for three 4mm hole at 6 mm.
elliptical hole: Lowest SIF value of 17.86 for major dia 5mm minor dia 4mm holes at 6mm.

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 Effect of Semi elliptical Cracks on Stress Concentrated Regions in
Pressure Vessel

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 PRESSURE VESSEL
• Pressure vessels are closed containers that store fluids at low or high pressure with
a pressure difference between inside and outside of the container. They are used in
a variety of industries like
• Petroleum refining
• Chemical
• Power
• Food & beverage
• Pharmaceutical

FIGURE 1:PRESSURE VESSELS

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 TYPES OF PRESSURE VESSELS 
• There are three main types of pressure vessels in general
• Horizontal Pressure Vessels
• Vertical Pressure Vessels
• Spherical Pressure vessels .
• However there are some special types of Vessels like Regeneration Tower, Reactors but these
names are given according to their use only.

FIGURE 2:TYPES OF PRESSURE VESSELS

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 Major Results From Reviewed Papers:
S. No. Paper Title Results drawn

1 Effect of Crack Inclination and Residual Nature of residual stress significantly affects the life of the vessel. A
Stress on the Stress Intensity Factor of tensile residual stress reduced the failure pressure and hence the SIF
Semi-elliptical Crack in a Pressure Vessel

2 Stress intensity factors of semi-elliptical A crack located at the nozzle–cylinder body intersection, which is
surface cracks in pressure vessels by the highest stress concentration area of the pressure vessel, is less
global-local finite element methodology critical for large a/tc and small a/c ratios, as compared to the same
crack located away from this discontinuity area
3 Analysis of cracked cylindrical pressure Stress intensity factor value increased with the increasing length of
vessel by using experimental approach crack

4 Analysis of stress intensity factor and SIF in deepest point had greater value rather than the stress intensity
crack propagation for alloy X-750 in corner points for two reasons first; the resistance of the material
pressure vessel with a blunting crack against the crack propagation was stronger in the deepest point.
Second, analysis was done for static loading in LEFM

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 S. Paper Title Results drawn
No.
5 Fracture analysis for reactor pressure vessel refined closed-form solutions or finite element analyses should
nozzle corner cracks be used if postulated flaw sizes smaller than 1/4t are considered,
or if other than circular flaw shapes are considered

6 Evaluation of stress intensity factor for semi SIF results of crack located in areas away from geometrical
elliptical and quarter elliptical crack in pressure discontinuity are less critical than crack located at discontinuity
vessels using finite element methodology area
As a/c ratio goes beyond 0.5 the maximum SIF location on
crack front shifted from deep point to surface point

7 Design optimization of horizontal pressure vessel Use of torispherical head results in minimal stress for the same
material and load ,Locating the inlet and outlet nozzles at the
centre of the shell results in less stress ,The supports need to
sufficiently farther from the centre of the shell

8 Design of metallic pressure vessels – a fracture fracture based design shall be carried out for materials that are
mechanics based approach fracture prone to prevent the premature failure during loading

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 Von Mises Stress & Total deformation for Different Materials
Material Von Mises Stress (Mpa) Total Deformation(mm)
Structural Steel 308 0.4326
ASTM A36 308.35 0.412
Stainless Steel 308 0.44626
Aluminium Alloy 307.27 1.2017
Titanium Alloy 306.09 0.87539

Based on the following comparison and considering other factors such as cost,availability,usability ASTM A 36 is chosen
as the required material

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 PROBLEM DEFINITION

🔵 The estimation of SIF on pressure vessel by introducing multiple semi elliptical cracks at stress
concentration zones of the vessel
🔵 Here a 3d numerical simulation on pressure vessel is carried out in ANSYS Workbench

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 SIMULATION

MODELLING OF PRESSURE VESSEL:

• The horizontal pressure vessel with hemispherical head being analyzed in this work is shown. The vessel
• has a length of 1000 mm, thickness of 15 mm and radius 150 mm, which is typical of a small industrial
pressure
vessel [1]. The basic components of the pressure vessel are marked in above figure

GEOMETRY

FIGURE 3:PRESSURE VESSEL

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 MESH DEPENDENCY TEST
• Here we started off with grid dependency test to find out suitable mesh size
for our pressure vessel. Here we have concluded the ideal mesh size is 10
mm
320

310

300

Von Mise Stress, MPa 290

280

270

260

250
9971 10783 12517 16185 19792 23186 33998 44417 51795 63107

No. of Elements

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 FINITE ELEMENT MODEL

FIGURE 4:MESHED MODEL

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 Failure Pressure Estimation

pressure vs von mises stress

600

500
Von Mises Stress, MPa

400

300

200

100

0
1 2 3 4 5 6 7 8 9 10

Pressure, MPa

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 BOUNDARY CONDITION
• The main boundary conditions used here are internal pressure and fixed
supports

FIGURE 5:BOUNDARY CONDITIONS

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 Validation of pressure vessel
16.00

12.00

Stress, MPa
8.00

Theoritical Stress
4.00
Ansys Stress

0.00
0.2000 0.2500 0.3000 0.3500 0.4000 0.4500 0.5000 0.5500 0.6000

a/b

As per ASME-Viii-Div.3-2019-Pressure Vessel

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 Stress Concentrated Regions

REGION 1

REGION 2

REGION 3

FIGURE 6:REGIONS CHOSEN FOR SIMULATION

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 Variation of SIF for internal and external cracks

250

200 External cracks Internal cracks

150
K1,[MPa]

100

50

0
2 4 6 8 10 12 14

a/b

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 Region 1-Top Nozzle

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 Region 2- Front Nozzle

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Region 3- Base Region

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 Variation of SIF ratio by increasing number of cracks
160

140

120

100
K1/K2

80
Bottom Region
Top Nozzle
Front Nozzle
60

40

20

0
1 2 3 4

No. of Cracks

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 Variation of SIF ratio by increasing crack dimensions
90

80

70

60

50
K1/K2

40

30

20

10

0
2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8

a/b

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 Variation of SIF ratio according to temperature

40

35

30

25

20
K1/K2

15

10

0
100 200 300 400 500 600 700 800 900 1000

-5

Temperature(°C)

Top Nozzle Base Region Front Nozzle

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 Introduction of residual stress
8

Pressure, MPa
4

Residual Stress Base Vessel

The stresses that remain in the body upon the removal of the external forces or moments are termed as residual
stresses. This may be induced due to misfits within the different sections of the assembly or material. The most
common reasons for misfits are steep thermal gradients, phase transformations and non-uniform plastic deformation

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 Conclusion
• Assessing both internal and external surfaces of a pressure vessel we could
conclude internal region is more threat for crack propagation, This is due to the fact
that the internal crack faces are directly subjected to pressure loading
• By increasing number of cracks we tend to observe there is a sudden increases
when multiple cracks are introduced but thereafter the value tends to be constant
• Increasing temperature tends to see a decrease in SIF ratio though we see a general
increase in mode II SIF
• Varying the a/b ratio of the crack we see a higher SIF ratio in case of base regions
and comparatively lesser in nozzle regions
• Residual stresses endanger the safety of the pressure vessel, and hence reduce its
design life. From this, it may be concluded that the pressure vessel fails at a lower
internal pressure if tensile residual stresses are present in the component.

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 REFERENCES
[1] Effect of Crack Inclination and Residual Stress on the Stress Intensity Factor of Semi-elliptical Crack in a
Pressure Vessel
[2] SIF of semi elliptical surface cracks in pressure vessel by finite element methodology
[3] Adeyefa, O., & Oluwole, O. Finite element analysis of von-mises stress distribution in a spherical shell of
liquified natural gas (LNG) pressure vessels
[4] Analysis of stress intensity factor and crack propagation for Alloy X-750 –E Mahdavi, M Amidpour
[5] Design Optimization of horizontal Pressure vessel- S Arunkumar ,N.Karthik, P.R Eshwara Moorthy
[6] Sun, Q., Zan, D., Chen, J., & Pan, H. (2015). Analysis of edge crack behavior of steel sheet in multi-pass cold rolling based
on a shear modified GTN damage model. Theoretical and applied fracture mechanics, 80, 259-266.
[7]Souiyah, M., Alshoaibi, A., Muchtar, A., & Ariffin, A. K. (2008). Stress intensity factor evaluation for crack emanating from
circular-hole using finite element method. International review of mechanical engineering, 2(4), 545-549.
[8]Mr. A. A. Kshirsagar, Prof. P. R. Kulkarni, 2014, Reduction in the Stress Intesity Factior for Cracks Starting from A Circular
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[9] Makabe, Chobin, Kaito Naka, and Md Shafiul Ferdous. "Method of arresting crack growth for application at a narrow
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[11] Elements of fracture mechanics- Prashant Kumar
[12] https://www.youtube.com/watch?v=IscPV-lq-kk

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 [13]Miloud Souiyah, Abdulnaser Alshoaibi., “Stress intensity factor Evaluation for crack Emanating from circular hole
using Finite element method”, International review of mechanical engineering.
[14] (2008) 25- 50. [2] Xiangqiao Yan and Baoliang Liu, “Hole Crack Problems in Infinite Plate Subjected to Uniform
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1997;19(4):283–91.

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 THANK YOU

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