Finite Element Study of

Structural Discontinuities
 Presentation Objectives

Discuss background of structural

discontinuities
Introduce the finite element method
Explain how to generate a finite element
model
Review previous work
Present new work
Discuss possibilities for future work
Answer questions
 What is a Structural
Discontinuity?
A break or gap within a structural
component that alters its behavior
under load
 Examples of Structural
Discontinuities
Holes: Often used to lighten an
aerospace structure or to rivet
components together

Cracks: Usually a result of material

imperfections or areas of high
stress
 Concerns

Uniform loading of a square plate results in

a uniform stress distribution
 Concerns

Holes alter the

stress distribution
and induce stress
concentrations.

Study of Mesh Refinement

EM 360 Fall 2002
 Concerns

Stress concentrations at crack tips

Crack propagation
 Possible Consequences

Stress fields around discontinuities can

interact with each other and cause
failure.

Cessna 402C Mishap Investigation, 1999

 Solution Method

Structural discontinuity problems are

often very difficult to solve analytically,
sometimes impossible.

Our method is to use ABAQUS, a finite

element program.
 The Finite Element Method
(FEM)
General technique
for constructing
approximate
solutions to
boundary value
problems

Study of Mesh Refinement

EM 360 Fall 2002
 How to Generate a Finite
Element Model
An input file must be written
containing the following two parts:

Model Data: This portion defines the

geometry of the model and
material properties.

History Data: This portion defines how the

model will be loaded and what
values should be outputted.
 Some Important Factors to
Consider
Boundary
Conditions

Load Type and

Directions

Mesh Refinement
Study of Mesh Refinement
EM 360, Fall 2002
Some Important Factors to
Consider : Mesh Refinement

Petersons Stress Concentration Factors, 1997

11 Elements
1 Second
K=4.342
s max
K= ____
s

Finite Element Study of Structural Discontinuities, 2003

Some Important Factors to
Consider : Mesh Refinement
67 Elements
1 second
K=4.41

Finite Element Study of Structural Discontinuities, 2003

Some Important Factors to
Consider : Mesh Refinement
211 Elements
1 second
K=4.47

Finite Element Study of Structural Discontinuities, 2003

Some Important Factors to
Consider : Mesh Refinement
823 Elements
2 seconds
K=4.512

Finite Element Study of Structural Discontinuities, 2003

Some Important Factors to
Consider : Mesh Refinement
Approx. 3000 Elements
4 seconds
K=4.517

Finite Element Study of Structural Discontinuities, 2003

Some Important Factors to
Consider : Mesh Refinement
Approx. 19000 Elements
21 seconds
K=4.520

Finite Element Study of Structural Discontinuities, 2003

Mesh Convergence Curve
4.54

4.52

4.5

4.48

4.46

4.44
Ktg

4.42

4.4

4.38

4.36

4.34

4.32
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000

Number of Elements

Mesh Convergence

Finite Element Study of Structural Discontinuities, 2003

 Computation Time
25

20
Computation Time (sec)

15

10

0
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
Number of Elements

Effect of Number of Elements on Compuation Time

Finite Element Study of Structural Discontinuities, 2003

 Mesh Convergence

Refining a coarse finite element mesh

will result in a more accurate solution
at the cost of computation time.
 Caveat and Approach

Just because a solution is obtained does not

necessarily mean it is correct. Therefore, it
is important to study the results and
compare your solution with a known,
correct solution.
 Previous Work

Model 1

Petersons Stress Concentration Factors, 1997

Finite Element Study of Structural Discontinuities, 2003

 Previous Work

Model 1 (continued)
5

4.5

4
Ktg = smax /s
3.5

3
Ktg

2.5

1.5

ABAQUS
1

0.5
Peterson

0
0 0.1 0.2 0.3 0.4 0.5 0.6

d/H

Stress Concentration Factor (Model 1)

Finite Element Study of Structural Discontinuities, 2003
 Previous Work

Model 2

Petersons Stress Concentration Factors, 1997

Finite Element Study of Structural Discontinuities, 2003

 Previous Work

Model 2 (continued)
3.5

Ktg = smax /s1

2.5

2
Ktg

1.5

ABAQUS
0.5
Peterson

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

d/l
Stress Concentration Factor (Model 3)
Finite Element Study of Structural Discontinuities, 2003
 New Work

Reduction of stress concentrations

from edges of holes

Finite element modeling of cracks

Reduction of crack stress intensity

factor
 Reducing Stress
Concentrations from Holes
Method:
Add another hole to alleviate the stress
concentration.

Constant: Radius of original hole = 2 in

Tensile Load = 1 psi in horizontal
direction

Variables: R = radius of added hole

L = distance between
centers of holes
 Reducing Stress
Concentrations from Holes

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes
Conclusion:

Adding holes in a plane perpendicular

to the loading direction does not
reduce the stress concentration factor.
 Reducing Stress
Concentrations from Holes

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes

3.1

2.9

2.7

2.5
SCF

2.3

2.1

1.9

1.7

1.5
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
R (in)
Variation of Stress Concentration Factor with Second Hole Radius
(L = 4 in)

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes

3.2

2.8
SCF

2.6

2.4

2.2

2
0 0.5 1 1.5 2 2.5
R (in)

Variation of Stress Concentration Factor with Second Hole Radius

(L = 5 in)

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes

2.9

2.7

2.5

2.3
SFC

2.1

1.9

1.7

1.5
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
R (in)

Variation of Stress Concentration Factor with Second Hole Radius

(L = 7.50 in)

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes

2.6

2.55
Optimal SFC

2.5

2.45

2.4

2.35
0 1 2 3 4 5 6 7 8
L (in)

Effect of Hole Spacing on Stress Concentration Factor

Finite Element Study of Structural Discontinuities, 2003

 Reducing Stress
Concentrations from Holes
Conclusion:

Adding holes in a plane parallel to the

loading direction does reduce the
stress concentration factor.
 Finite Element Analysis of
Cracks
Crack configuration models:

Tada The Stress Analysis of

Cracks Handbook

Model 1 Model 2 Model 3

Finite Element Analysis of
Cracks

Crack Model 1 (Center Cracked Plate)

Finite Element Analysis of
Cracks

Crack Model 2 (Edge Cracked Plate)

Finite Element Analysis of
Cracks

Crack Model 3
Finite Element Analysis of
Cracks

Tada, The Stress Analysis of Cracks Handbook

Crack Model 3
 Finite Element Analysis of
Crack Repair
Crack repair models:

Finite Element Study of Structural Discontinuities, 2003

Finite Element Analysis of
Cracks

Center Cracked Plate with Stop Holes

Finite Element Analysis of
Cracks

Center Cracked Plate with an Array of Holes Near the Crack Tip
Finite Element Analysis of
Cracks

Patch Repair of Center Cracked Plate

Finite Element Analysis of
Cracks

Arrester Repair of Center Cracked Plate

 Finite Element Analysis of
Cracks
2.9

2.8

2.7

2.6
K (psi-in 0.5 )

2.5

2.4

2.3

2.2

2.1

2
0 1 2 3 4 5 6 7
L (in)

Variation in Stress Intensity Factor with Arrester Strip Distance

 Summary of Work
Completed This Semester
Used the FEM to determine how holes
and cracks affect stress distributions.

Devised a method to alleviate stress

concentrations around holes.

Investigated crack repair methods.

Possibilities for Future Work

Finite element modeling of structural

discontinuities under cyclic loading

Finite element modeling of structural

discontinuities in more complex structures

Adaptation of scripting feature in ABAQUS