10th International Conference on Structural Engineering and Construction Management (ICSECM)

th th
12 – 14 December 2019 l Earl’s Regency Hotel l Kandy l Sri Lanka
ISBN-978-955-589-274-2
ICSECM2019-134
NUMERICAL MODELING ON RE-CRACKING BEHAVIOUR OF STRENGTHENED
CRACK STOP HOLES IN STEEL STRUCTURES.

S. Abeygunasekera1 *, J. C. P. H. Gamage2 and S. Fawzia3

1
University of Moratuwa, Katubedda, Moratuwa, Sri Lanka.
2
University of Moratuwa, Katubedda, Moratuwa, Sri Lanka.
3
Queensland University of Technology, Australia.
* Correspondence E-mail: abeygunasekarasampath@gmail.com, TP: +94712227790

Abstract: This study aims to analyze the alternative tech-niques to improve the service
performance of crack stop holes (CSH). This paper compares the performance of five different
CSH improved techniques. Among these techniques Carbon Fiber Reinforced Polymer (CFRP)
strengthening technique is an initial approach to investigate the feasibility on strengthens CSH.
The J-integral theory was utilized to calculate the cyclic J-integral values of each method while
the Power law was applied to estimate the required number of cycles for the crack initiation. A
significant improvement in delaying crack initiation of CSH was analyze using ABAQUS and
CFRP technique yields the maximum performance.

Keywords: Crack stop hole(CSH), J-integral, cyclic J integral, CFRP. Fracture mechanics

1. Introduction propagation of the cracks. Research studies have

A crack stop hole technique has been verified as
enhancing the fatigue service life of a structure [1]
[2]. The crack stop hole technique is simple [3], and
non-expensive, thus it is widely applied in
maintenance purposes of metal structures [4]. This
technique has become widespread in the Aerospace
industry. The process of CSH includes fabricating
the drill hole at the crack tip, to transfer the crack
into a notch which results in reducing the stress
concentration effects on the structure.However, in
many instances fatigue damage often occurs at the
crack stop hole due to the structural discontinuity.
Hence, it is continuously subjected to stress
concentrations. This action is caused for re-
initiation of cracks. Tanaka and Mura have
proposed that crack initiation originates from slip
bands, without accounting the effect of cyclic
hardening [5]. Similarly, Bozek et al. have
suggested a probabilistic simulation technique for
particle cracking in a specimen [6]. In addition,
Fine and Bhat, [7]; Mura and Nakasone, [8]; Xie et
al., [9] have emphasized that an energy barrier
method would be able to overcome crack initiation
due to fatigue.The two main approaches used to
predict fatigue life in the current context are
namely, the S-N curve approach and the fracture
mechanics approach,
which are utilized in this study. Theory of fracture
mechanics is based on the initiation and
described various types of crack stop hole
strengthening techniques. This investigation
simulated five different CSH strengthen techniques
using finite element analysis under elastic-plastic
fracture mechanics (EPFM) phenomena. They are
bolted stop-hole, pinned-stop hole, cold expanded
stop hole, ancillary holes added stop hole and
CFRP strengthen CSH. The cyclic J-integral
method with Power law were utilized for predicting
the required number of cycles for crack initiation at
CSH and also to compare the results dominant with
an un-strengthened CSH.All these strengthen
techniques have contributed to change the stress
near the crack stop hole which controls the re-
cracking behavior of the crack stop hole.
The main aim of this investigation is numerical
analysis of re-cracking behavior of CSH and to
compare the performance of different strengthening
methods to introduce a simple and cost-effective
technique for further delay re-cracking of CSH. As,
most conventional repair options are considered
complicated, expensive, difficult to apply narrow
locations and marginally effective. Results of
similar research studies have confirmed that CFRP
shows excellent fatigue resistivity, as CFRP
materials are lightweight, high in strength, has
excellent corrosion resistance, and easy to use.
Field applications have also proven significant
strength gain with CFRP materials. Therefore, this
investigation pays attention in evaluating the

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th th
12 – 14 December 2019 l Earl’s Regency Hotel l Kandy l Sri Lanka
ISBN-978-955-589-274-2
ICSECM2019-134
potential to utilize CFRP strengthening CSH as a
solution for issues related to re-cracking. In
addition, understanding of parametric influences
such as effect of size of CSH, location of the CSH
with respect to loading point and the member
thickness effects for re-cracking is also considered
in this study.
2. Methodology
The Finite element method (FEM) is a dominant
technique in structural analyses. The main function
in the FEM is physically subdividing the structural
element into small structural components, as these
physical components can be mathematically
modelled in simple geometry. The responses of
elements have several degrees of freedom. Thus,
the values of unknown parameters in the set of
nodal points could be estimated using FEM under
the defined boundary conditions.
1.2.1 FE mesh and Boundary conditions
The FE mesh played a vital role in the contour
integral analysis method. A special mesh pattern
was introduced around the CSH as shown in Figure
1(a) and Figure 1(b). A Rosette pattern was formed
at the crack tip region and a coarser mesh was used
for the remaining area as shown in Figure 1(b). It
was assumed that the elements lie within the
domain of the contour integral technique.

1(a) 1(b)
Figure 1(a): Complete mesh
Figure 1(b): FE mesh around CSH

Fixed boundary conditions were assigned for both
edges. Furthermore, loading rate at the mid-plane
was kept constant at a fixed rate of 0.2 mm/min
throughout the analysis using loading options and
ASTM standards was followed [10]. A specimen
was placed under stress through the direction of the
thickness, while the load applied in perpendicular to
the plane which stress adapted to the analysis
process.

Figure 2: A schematic view of the model specimen

1.3 Method of analysis

Each specimen module was loaded with a LCF
mode using the direct cyclic option. A 8 mm radius
loading nose was used for loads applied and mid-
vertical span was limited to 5 mm. Furthermore, a
fatigue load was applied to the specimens at the
mid-plane with 5 Hz frequency and 0.05 stress ratio
as shown in Figure 3. The static general loading
method was applied from 0 – 0.02 Sec and the
direct cyclic loading method was applied from 0.02
to 0.2 Sec. Then, while maintaining the fatigue load
under the 2 kN constant amplitude with 5 Hz
frequency and 0.05 stress ratio. Also, the required
number of cycles for crack initiation (Ni) was
obtained by using the results of analytical methods
and the developed Power law equation [11].

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th th
12 – 14 December 2019 l Earl’s Regency Hotel l Kandy l Sri Lanka
ISBN-978-955-589-274-2
ICSECM2019-134

Figure 3: 3D object with 240 mm span length under the 3 points cyclic flexure load

The Power law can be used to evaluate the number element simulation using the contour integral
of cycles to crack growth as shown in Equation 1. technique. The contour integral model and the
The maximum and minimum values of J-integral elastic-plastic zone around the CSH are shown in
were obtained from analytical results of finite Figure 4(a) and Figure 4(b).

4 (a) 4 (b)
Figure 4(a):Contour Integral Model
Figure 2(b):Distribution of stress at CSH

For the purposes of comparing, the magnitude of
load, loading frequency and stress ratio were kept at
a constant level throughout the simulations. The
diameter of the crack stop hole at the crack tip was
changed from 8 mm to 24 mm range with 4 mm
increments. Cyclic J- integral values were taken by
using the Equation 02 while the Power law was
utilized to estimate the number of cycles needed to
initiates cracks up to 1 mm length. The Young's
modules and poisons ratio were considered as 200
MPa and 0.3, respectively. The procedure was
repeated for five different strengthening methods
listed below.

3. Theoretical Background parameter utilized with elastic-plastic fracture

3.1The J-integraltechnique
James Rice in 1968 introduced the path-
independent contour integral analysis technique for
crack analysis [12]. He explained that the J-integral
method is usually connected with elastic-plastic
fracture mechanics (EPFM). The cyclic J-integral
(ΔJ-integral) could be considered as a crack tip
mechanics. The cyclic J integral (ΔJ-integral) is
determined as an analytical approximation of
numerical methods. The cyclic elastic plastic crack
driving force is utilized at the short fatigue crack
propagation stage. The J-integral technique could
also be viewed as an energy parameter as well as a
stress intensity parameter for the non-linear
materials.

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th th
12 – 14 December 2019 l Earl’s Regency Hotel l Kandy l Sri Lanka
ISBN-978-955-589-274-2
ICSECM2019-134
√ …………………………………….....(1)

Where ΔJ is the cyclic J- integral value, Jmin is the
minimum value available at FEA results and J max is
the maximum value available at the same FEA
evaluation
3.2 The Power law
Prediction of crack growth is vital for structural
components during their service life, since such
predictions assist in deciding the calculation of the
remaining service life of the structural components
or whole structures. In addition, it could be
supported to determine inspection intervals for
maintenance and repair purposes. Therefore, more
accurate and reliable numerical approaches are
da/dN =9.858x10 (Δ J) ..................................................................... (2)
-4 0.479
needed to estimate crack propagation behaviour of
structures. On the other hand, such a method should
be simple; however, fulfilling both requirements is
not an easy task, as numerous variables
significantly influence the crack initiation process.
Fracture mechanics theory is a well-established and
commonly applied method to predict the crack
propagation. In fact, an elastic-plastic fracture
mechanics approach is more compatible to evaluate
more complex and nonlinear context. Since the
cyclic J-integral technique is based on the fracture
mechanics Dowling and Begley[13] have proposed
and implemented the J-integral technique[19]
considering the relations of crack growth rate,
da/dN, and cyclic J-integral, ΔJ.

4. Numerical Modelling

In this study five different techniques were selected

to strengthen the crack stop hole. They are bolted,
pinned, CFRP strengthening, cold expanded and
ancillary holes CSH. Each strengthening method
was individually evaluated and the results were
compared with each other strengthened CSH.
During the process of analysis all other parameters
were kept at a constant level. The main variable
was the strengthened method of CSH, which is
explained above. Boundary conditions, properties
of materials and loading rates were also kept at a
constant level throughout the analysis process.
4.1 The Bolted CSH
In this method the tip of the existing crack was
removed by drilling a hole. A tensile load was
applied to the crack stop hole as shown in Figure
05. In general open and close mechanism is
required to propagate the fatigue cracks. When the
CSH subjects to tension the bolt connects to CSH
shares the tensile stress. This process delays the re-
cracking behaviour till the connected bolt is safe
from fatigue failure.
Figure 03: Bolted stop hole (Schematic diagram)
The bolt tension loads also contribute to reduce the
effectiveness of the stress range of the compression
regime. The result of the bolt tension leads to a
delay in the crack growth. The efficiency of this
process depends on the bolt tension and method of
anchorage.The tightening of the nut results in the
tension loads applies on the CSH. Nevertheless, a
special attention should be made on corrosion
protection since the specimen material and the bolt
material may possess a different electromotive
force which results in accelerated rate of corrosion.
Some investigations have confirmed that the bolted
stop hole technique has high potential in delaying
re-cracking.

6(a) 6 (b)

Figure 4(a): bottom plane view of stress contour of blted hole

Figure 6(b): Stress distribution pattern at bolted stop hole

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12 – 14 December 2019 l Earl’s Regency Hotel l Kandy l Sri Lanka
ISBN-978-955-589-274-2
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since observers may feel visually uncomfortable
4.2 The Pinned CSH
observing a series of holes on the structures.
In this technique a pin was inserted into the hole as Furthermore, pin treatments were supported to
shown in Figure 07. With the same properties to prevent the activities of birds and other animals in
minimize effects due to fluctuation of the interior of the hollow structural elements as an
environmental temperature and corrosion effects. added advantage.
However, non-metallic materials such as wood or a
rubber pin also could be introduced as an
alternative. The diameter of the pin was selected as
4 % higher than CSH diameter and length of the pin
and the thickness of the member were considered
equal. This technique was based on the introduction
of residual compressive stresses around crack stop
holes. Compressive stresses occur around the CSH
when inserting the pin. This residual compressive
stresses load to delay in crack initiation.
Furthermore, the pinned technique changes the
direction of the crack growth. This method could be
considered as a positive visual indication technique, Figure 5: A pinned CSH

8(a) 8(b)

Figure 8(a): stress contours of tensile plane (Plane view Bottom)

Figure 8(b): Stress distribution at pinned stop hole

during this investigation. A single layer of CFRP

4.3 CFRP strengthened CSH
attachment was analysed in this study. Thus, the
A layer of CFRP was attached to the tensile face as CFRP composite repair technique could be
shown in Figure 09. The CFRP strengthen method introduced as a worthy strengthening technique
could be considered as an improvement technique than any conventional improved method. However,
of the CSH. The CFRP layer was attached at the this technique is difficult to utilize in narrow
bottom of the specimen in this method, because locations. A limited number of research studies
tension loads effect the bottom of the specimen and related to CSH strengthening with CFRP are
it has a high tendency to crack initiation rather than available in literature. F. Lin et al confirmed that
the upper part of the specimen. A crack stop hole externally bonded CFRP strips, greatly reduced the
combined with CFRP lamination helps to reduce strain concentration of a drilled hole[14].
the stress at the edge of the hole. Dimensions of the
CFRP layer were selected as 100 mm length and 40
mm width while the thickness of CFRP layer was
considered as 0.167 mm according to the data sheet.
Young’s module and poisons ratio of the material
was 240 GPa and 0.28, respectively. The interaction
mode of the ABAQUS was utilized for attaching
the CFRP layer to the crack hole steel plate. The Figure 09: Schematic view of the CFRP
steel plates were considered as the master surface strengthened CSH
and a CFRP layer was attached as a slave surface

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12 – 14 December 2019 l Earl’s Regency Hotel l Kandy l Sri Lanka
ISBN-978-955-589-274-2
ICSECM2019-134

10 (a) 10 (b)

Figure 10(a): Visualization of the bottom view under 3 points flexural cyclic load with CFRP strengthened
CSH.

Figure 10 (b):Stress distribution at bolted stop hole

4.4 Cold expanded CSH

In the cold expanded stop hole method, a sleeve
was inserted into the hole as shown in Figure 11.
The stress distribution around the CSH is shown in
Figure 12(a) and the stress zone also described in
the Figure12 (b). In this method a metal sleeve or
tapered mandrel was inserted to the crack stop hole.
The outer diameter of the sleeve was slightly higher
than the diameter of the CSH and its thickness was
equal to the thickness of the specimen (5 mm). The
result created a compressive residual stresses
around the crack stop hole as the cyclic residual
stress contributes immensely in initiating cracks.
The cold expansion technique reduces the stress
concentration at the crack stop hole. Thus,
permanent compressive stresses are made
surrounding the crack stop hole and the result is
mitigating a crack initiation. In addition, cold work
around a crack stop hole produces residual stresses,
therefore both circumferential and radial directions
around the crack stop hole are important during and
after the cold working process. Generally Cold-
expansion imposes circumferential tensile stresses
and radial compressive stresses around the crack
stop hole. Strain hardening also contributes to
enhanced tensile and yield strengths of the material
around the hole. Therefore, it improves the
effectiveness of the crack-stop hole. Several
experimental investigations have been attempted in
this study area. The inner diameter of the sleeve and
sleeve materials are major parameters in this
technique. However, in this technique a uniform
radial expansion of the crack stop hole should be
ensured. Therefore, the same material was used for
making a sleeve. On the other hand, if there is a
different expansion co-efficient, it may create
unwanted issues due to fluctuation of
environmental temperature. In addition, if different
materials are selected for sleeves, due to changes in
properties of materials, corrosion effects may
accelerate at the crack stop hole. Application of the
cold expansion technology includes repairing of
fighters and commercial aircraft Investigations
conducted by the Landy et al, N. Chandawanich et
al and Champoux et al confirmed the effectiveness
of compressive residual stresses in enhancing
fatigue life under conditions of cyclic loading[15].
Stefanescu et al experimentally confirmed the
change of cold expansion residual stresses
effectively under static compressive loads.

Figure 11: Cold expanded hole (Fatigue

Technology 2011)

12(a) 12(b)

Figure 12(a): Visualization of the bottom view under 3 points flexural cyclic load with a cold expanded CSH.
Figure 12(b): Stress distribution at cold expanded stop hole

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ISBN-978-955-589-274-2
ICSECM2019-134
4.5 Ancillary holes added CSH technique depends on stress concentration and the
Two or more small holes were placed around the diameter of ancillary holes. A short distance
CSH in this method and such holes are named as between the crack stop hole and the ancillary holes,
ancillary holes. Generally, additional holes are lowers the stress concentration at the CSH edge. A
placed near crack stop holes. By placing an considerable amount of stress concentration was
ancillary hole, the stress concentration pattern reduced by the size of ancillary holes which was
changes as shown in Figure 14(a) and Figure 14(b). considered large. However, the diameter of the
These techniques have positive and negative ancillary holes being larger than the crack stop
effects, due to low stress concentration at the crack holes is impracticable. Therefore, the overall
stop holes. Ancillary holes are supported to reduce effectiveness of this technology depends on the
stress concentration at the edges of the crack stop location, diameter of the hole and the number of
hole. The effectiveness of an overall arrangement of holes. Furthermore, drilling techniques and speed of
the holes contributes to retard crack initiation at the drilling, also has an influence on the result due to
CSH. Thus, the overall effectiveness of this changes in residual stress.

Figure 13: Schematic view of the ancillary holes Added CSH

6(a) 14(b)

Figure 7(a): Visualization of the bottom view under 3 points flexural cyclic load with an ancillary CSH.

Figure 14(b): Stress distribution with ancillary holes

5. Results and Discussion
This investigation focuses on a non-linear finite
element analysis at the crack stop hole under 3 -
point cyclic flexural loads. The model geometry,
material properties, boundary conditions and the
finite element mesh were described in earlier. All
models were solved with LCF under cyclic loads.
According to the results from the analytical
technique, the required number of cycles for crack
initiation changed in different stress levels due to
the increase in the crack stop hole diameter with its
constant cross section. The stress distribution
pattern when the three-point flexural cyclic load
was applied on the bolted stress is shown in Figure
06(b) according to the model results. It shows a
symmetrical and consists of a clear distribution
pattern around the CSH. When the three points
cyclic flexural load is applied on pinned CSH, the
stress distribution pattern is shown in Figure 08(b).
It shows a symmetrical stress distribution pattern
around the CSH. But the elastic plastic zone is not
clearly visible.
When the three points cyclic flexural load is applied
on CFRP strengthen CSH, the stress distribution
pattern is shown in Figure 10(b). The stress
variation around the CSH is not clearly visible
because elastic plastic zone is controlled by the
CFRP layer. This is the main reason for delay crack
initiation at the CSH compared to other strengthens
techniques which are discussed in this study. When
the three points cyclic flexural loads are applied to
the cold expanded stop hole, the stress distribution
pattern is shown in Figure 12(b). There is no clear
stress distribution variation around the CSH. It

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could be observed that all stress is concentrated at the simulation. Therefore, there is a delay in crack
the sleeve. Therefore, the elastic plastic zone was initiation.
not clearly visible around the CSH. This is the main
reason for a delayed crack initiation at the cold
expanded hole. Five different techniques were numerically
analyzed in this study and results are shown in
When the three points cyclic flexural load was Table 01. These analytical results were not only
applied to the ancillary holes added crack stop hole, based on the proposed technique, it depended on
the stress distribution pattern is shown in Figure the diameter of the crack stop hole, the location of
14(b). Stresses were distributed around the CSH as the hole, the aspect ratio, the stress ratio, the
well as the ancillary holes, therefore the stress loading frequency and the magnitudes of the loads.
concentration is drastically reduced. The elastic
plastic zone was not clear in the results analysis of

Table 01: Results Compare with each techniques

CSH number of cycles for crack initiation
diameter Bolted Pinne CFRP Cold CSH with
(mm) CSH CSH Strengthen CSH ancillary
CSH holes
8 5000 3191 5900 3226 1312
12 5317 6394 7362 3318 5627
16 4531 4381 6693 4308 3682
20 3114 3250 3023 3268 4002
24 3540 4840 4500 7052 5677

However, the results of each technique exhibited theoretical stress concentration factor for a plate
common behavior with hole diameter it is shown in with a hole under bending load shows a sinusoidal
Figure 15.Investigations conducted by the stress pattern.
Kormay&Disnig, Ack et at has reported that the

Figure 15: Number of cycles for crack initiation with different CSH strengthened techniques with respect to
hole diameter.

Conclusions crack initiation for CSH with different techniques

were estimated by using J-integral technique.
In this study, CSH was numerically analyzed using
Results of the Power law were compared. The
the Power law. The required number of cycles for
following conclusions were obtained:

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ISBN-978-955-589-274-2
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1) Small or large crack stop hole diameters
are not a significant gain with all the
improved techniques
2) Different improved techniques
responded in different ways with hole
diameters of the CSH.
3) A medium size crack stop hole exhibited
the most effective results with the
considered technique.
4) According to this investigation, a 12 mm
CSH diameter was reported as a
maximum performing hole diameter.
5) the bolted crack stop hole has shown the
maximum performance with a lower
range of CSH diameter.
6) Pinned stop hole method shows the
maximum performance in the medium
range of crack stop hole diameter
7) CFRP strengthening CSH has exhibited
significant delaying of crack initiation
with respectively all other strengthened
techniques.
8) This technique is performed with small
and medium size CSH diameters.
9) However, a larger CSH did not exhibit a
significant enhancement with CFRP
material,
10) The ancillary holes added technique did
not report any significant crack initiation
delaying with most of CSH diameters
except the 20 mm.
11) The results of selected techniques were
reported as 12 mm CSH diameter, which
showed excellent performance with a
majority of selected techniques.
Acknowledgements
The authors gratefully acknowledge the support of
the IT laboratory staff of the Department of Civil
Engineering at the University of Moratuwa for their
support during FEA.
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