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ME 721 Design Lab

Report Experiment No: 5
Determination of Plane Strain fracture Toughness of Metallic
material as
per ASTM
E399

1. Objective: To determine the plane strain fracture toughness 𝐾𝑖𝑐 of Aluminum.

2. Introduction: The determination of plane strain fracture toughness is a critical aspect

in evaluating the structural integrity of metallic materials. This introduction explores the
significance of ASTM E399, a widely used standard test method, in accurately assessing a
material's resistance to crack propagation under plane strain conditions, essential for ensuring
safe and reliable engineering applications.

3. Theory and Background:

(A) The difference between toughness and Fracture toughness:

​ Toughness:

Toughness is a general term that refers to a material's ability to absorb energy and deform
plastically before fracturing. It encompasses various mechanisms, such as plastic deformation,
microstructural changes, and crack propagation. A material with high toughness can absorb a
significant amount of energy before failing. Toughness is often measured by the area under the
stress-strain curve in a tensile test, which reflects the energy absorbed during deformation and
fracture.

​ Fracture Toughness:

Fracture toughness is a specific aspect of toughness that focuses on a material's resistance to

crack propagation and its ability to withstand the presence of pre-existing flaws or cracks. It is
particularly important when dealing with materials and structures containing inherent defects or
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cracks. Fracture toughness takes into account the critical stress intensity factor (𝐾𝑖𝑐), which

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quantifies the stress level at the tip of a crack needed to initiate crack propagation. Higher fracture
toughness indicates a greater ability to resist crack growth and sudden fracture.

(B) The difference between plane stress condition and plane strain condition:

​ Plane Strain Condition: In a plane strain condition, a material is subjected to loads that
cause deformation in one plane, but the material is prevented from expanding or
contracting in the direction perpendicular to that plane. This means that any changes in
thickness are negligible. Plane strain conditions often apply to thick structures.

​ Plane stress Condition: In a plane stress condition, a material is subjected to loads that
result in stresses acting within a specific plane, while the stresses in the perpendicular
direction are assumed to be negligible. This means that the material is free to expand or
contract in the direction perpendicular to the plane of stress. Plane stress conditions
commonly occur in thin structures like sheets and plates.

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 (C) Why are we interested in plane strain fracture toughness and not in plane stress
fracture toughness?

​ Plane Strain Conditions are More Realistic: In many practical engineering situations,

materials are subjected to three-dimensional stress states that are closer to plane strain
conditions than to plane stress conditions. Plane strain conditions more accurately
represent the complex stress distributions around a crack tip, especially in thick or large
components.

​ Conservative Design: When designing structures or components, engineers need to

ensure that they are safe under various loading conditions. Using the plane strain fracture
toughness value ensures a more conservative design, as it accounts for the worst-case
scenario in terms of crack propagation.

(D) Mode of Fractures:

​ Mode I – Opening mode: a tensile stress normal to the plane of the crack,

​ Mode II – Sliding mode: a shear stress acting parallel to the plane of the crack and

perpendicular to the crack front, and

​ Mode III – Tearing mode: a shear stress acting parallel to the plane of the crack and

parallel to the crack front.

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 Specimen Provided: ASTM E399, Material: Aluminum.

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Fracture toughness is an indication of the amount of stress required to propagate a pre-existing
flaw. Solid bodies containing cracks can be characterized by defining a state of stress near the
tip. Since the stress values near a crack tip are always remarkably high (and infinity at the tip)
the strength of material approach of failure prediction is not valid. Material failure is predicted
by comparing the stress intensity factor with a critical stress intensity factor. The fracture
toughness can be represented by:

𝐾𝑖𝑐 = 𝑌 𝜎 √(𝜋𝑎)

Where, Y=dimensionless geometry factor; 𝜎 = Overall stress at failure; a= crack length

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The value of strain fracture toughness can be found experimentally under some constraints laid out
by ASTM E399. The determination of plane strain fracture toughness 𝐾𝑖𝑐 can be done by:
1. Single edge notch bend or 3 points bending.
2. Compact Tension (CT)

The figure shows the dimensions ‘W,’ ‘a’ and ‘B.’

The figure of compact tension test specimen is shown above. To ensure plane strain failure and
accurate 𝐾𝑖𝑐 measurement the following constraints must be satisfied.

​ 𝑊
≤𝐵≤𝑊
4 2
𝑎
​ 0.45 ≤ ≤ 0.55 = yield strength of material
𝑊

​ 𝑎, 𝐵 ≥ 2.5 ( 𝐾𝑐 ), where 𝜎

𝑦𝑠
𝜎𝑦𝑠 𝑎
𝑃⋅𝑓( )
𝑊
The value of 𝐾𝑐 can be found out using the 𝐵√𝑊
formula:

𝐾𝑐 =

Where,

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 2
𝑎 𝑎 𝑎 𝑎 3 𝑎 4
𝑎 (2+( ))

𝑊
𝑓()= 𝑎 2
3 [0.886 + 4.64 ) − 13.32 ( ) + 14.72 ( ) − 5.60 ( ) ]
𝑊 (1−( 𝑊 𝑊 𝑊
𝑊
)) (
𝑊

If all the three constraints are satisfied, then the value obtained is 𝐾𝑖𝑐 or plane strain
fracture toughness.

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4. Observations:
● Specimen Dimensions:
Thickness, B= 12.78mm; Width, W=62.55mm and a=23.00mm

5. Calculation:
Checking first condition:
𝑊
= 62.55 = 15.6375𝑚𝑚
4 4

𝑊 62.55
2= 2 = 31.275𝑚𝑚
Thus, the first condition is not satisfied, and the value of B is slightly less than what required.
Satisfying the second condition, we must make a notch using hacksaw to satisfy the second condition.
𝑎 23
= ( 62.55 ) = 0.3677 𝑎
(𝑊 ) = [0.45,0.55],
( ) 𝑎𝑐𝑡𝑢𝑎𝑙 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑
𝑊 which is less
than what
required as

therefore we must make slight notch of length a’ such that the condition is satisfied, we have two
values of a’ one for 0.45 and other for 0.55.

= 28.1475 − 23 = 5.1475𝑚𝑚 .
Now, for (𝑎𝑚𝑖𝑛) = 0.45 ⋅ 62.55 = 28.1475𝑚𝑚 , 𝐶𝑢𝑡

𝑊
𝑚𝑖𝑛 = 34.4025 − 23 = 11.4025𝑚𝑚.

And for (𝑎𝑚𝑎𝑥 ) = 0.55 ⋅ 62.55 =

34.4025𝑚𝑚, 𝐶𝑢𝑡

𝑊 𝑚𝑎𝑥

So, the length of the cut ranges from 5.1475mm to 11.4025mm but we will try to keep it close to
the minimum value i.e., 5.1475mm.

The actual cut length is: 5.88mm.

𝑛𝑒𝑤 = (23+5.88)
62.55
= 0.461.
Thus, 𝑎

𝑎
(𝑊 ) = (23+5.88) = 0.461.
𝑛𝑒𝑤,𝑎𝑐𝑡𝑢𝑎𝑙
Now, the actual value of 62.55

So, the second condition is now satisfied.

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Checking the third condition:
i.e., yield stress for Aluminum = 276MPa
,𝜎
𝑎, 𝐵 ≥ 2.5 ( 𝐾𝑐 ) here the value
of 𝜎
𝜎𝑦𝑠 𝑦𝑠 𝑦𝑠

We have,

𝑓 ( 𝑎) can be calculated as
Factor 𝑊 follows:
2 3
4
𝑎
(2 + ( ))

𝑎 𝑊 𝑎 𝑎
𝑓( )= + 14.72 ( ) − 5.60 ( )]
𝑎
𝑎
[0.886 + 4.64
(
) − 13.32 (
)

3 𝑊 𝑊 𝑊 𝑊
𝑊
𝑎
(1 − ( ))2
𝑊

𝑎 )=(𝑎 ) = 0.461 in the

On putting (𝑊 𝑛𝑒𝑤,𝑎𝑐𝑡𝑢𝑎𝑙
𝑊 above equation we
get,

𝑎 (2 + (0.461))
𝑓( )= [0.886 + 4.64(0.461) − 13.32(0.461)2 + 14.72(0.461)3 − 5.60(0.461)4]

𝑊 3
(1 − (0.461))2

𝑎 (2.461)
⇒ 𝑓 (𝑊) = (0.3957) [0.886 + 4.64(0.461) − 13.32(0.2125) + 14.72(0.0979) − 5.60(0.0451)]

) = 6.219[0.886 + 2.139 − 2.8305 + 1.441 −

⇒ 𝑓(𝑎
𝑊 0.25256]

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 𝑎
⇒ 𝑓 (𝑊) = 6.219 ⋅ 1.38294

𝑎
⇒ 𝑓 (𝑊) = 8.60

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As we can see from the above plot the peak value of load from the plot is 9911.7 N. Hence, we
consider 95% of the peak value for our calculation purpose.

Therefore, 𝑃 = 0.95 ⋅ 9911.7 ⇒ 𝑃 = 9416.11 𝑁

Calculating the fracture toughness:
𝑎
𝑃⋅𝑓( )
𝑊
We have, 𝐾𝑐 = 𝐵√𝑊

⇒ 𝐾𝑐 = 25.33𝑀𝑃𝑎√𝑚
⇒ 𝐾𝑐 = 9416.11⋅8.60 12.78√62.55

Now, checking constraint specified by the given equation: 𝑎, 𝐵 ≥ 2.5 ( 𝐾𝑐 )

𝜎𝑦𝑠

25.33 ⇒ 𝑎, 𝐵 ≥ 0.02105 ⇒ 𝑎, 𝐵 ≥ 21.05𝑚𝑚

2

⇒ 𝑎, 𝐵 ≥ 2.5 ( 276 )

But B is less than 21.05mm.

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6. Conclusion: Since both condition 1st and condition 3rd are not satisfied
therefore the calculated value of 𝐾𝑐 is not the plane strain fracture toughness.
𝜎𝑦𝑠
= (276×106) = 0.0040058
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𝐸 68.9×10

From the table given below, we can find out the recommended value of ‘a’ and ‘B’:

Considering the value to be close to 0.005: The recommended value of ‘a’ and ‘B’ = 75mm.

7. Result: The compact test specimen does not comply with the required constraints as
per ASTM E399 and hence the calculated value of 𝐾𝑐 is not the plane strain fracture
toughness of aluminum.

Calculated value of 𝐾𝑐 = 25.33𝑀𝑃𝑎√𝑚.

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