Probabilistic modeling and simulation of multiple surface crack propagation and coalescence

Highlights

• Competing failure modes of multiple surface cracks and interior cracks are studied.

• A probabilistic procedure for modeling multiple surface crack propagation and coalescence is proposed.

• Multiple surface cracking considering crack coalescence is simulated and verified.

• The probability when a critical crack appears by crack coalescence is derived.

Abstract

In the low cycle fatigue (LCF) regime, fatigue failure of metallic materials with high strength and less impurities generally dominates by multiple surface crack propagation and coalescence, in which its final failure shows a stochastic nature on crack initiation, propagation and coalescence under cyclic loadings. According to this, the competing failure modes of multiple surface cracks and interior cracks are studied through coupling numerical simulations with fracture mechanics methods. In particular, a probabilistic procedure for modeling multiple surface crack propagation and coalescence is established by incorporating Monte Carlo simulation with experimental evidences, including surface crack density and crack length distributions measured from LCF replica tests of 30NiCrMoV12 steel. In addition, it calculates the probability of coalescence of neighboring cracks with allowance for their interactions and local plastic deformation at the crack tips. Finally, it estimates the remaining usage lives of specimens from initial state to critical cracks by propagation and coalescence of dispersed cracks.