Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

M.Tech. Design Engineering
Digital Learning Handout

Summary
Course Title Fracture Mechanics
Course No(s) DE ZG514
Credit Units 5
Credit Model (32 Hours of Class-room Instruction + 32 Hours of Case-
studies/Tutorials/Laboratories + 64 Hours of Student
Preparation)
Content Authors Sharad Srivastava
Version No. 2
Date 20-7-2019

Course Objectives

No

CO1 Fracture mechanics is based on implicit assumption that there exists a crack in the
structural component. The crack may be inside the material or at the subsurface. To
understand the Types of failure, Types of fracture, Modes of fracture, Fracture
criteria, Energy release rate

CO2 To understand the Stress intensity factor (SIF), Linear elastic fracture mechanics,
Environmentally assisted cracking (EAC), Weibill fracture statistics, Plane stress
and plane strain, Elastic plastic analysis through J-integral,

CO3 To understand the Crack tip opening displacement, R-curve, Test methods, Fatigue
failure, Mixed mode crack initiation and growth, Crack detection through NDT.

Text Book(s)

T1 Prashant Kumar, Elements of Fracture Mechanics, Tata McGraw-Hill Publishing

Company Ltd., New Delhi, 2009.

Reference Book(s) & other resources

 R1 T. L. Anderson, Fracture Mechanics: Fundamentals and Applications, 3rd Edition,
CRC Press
R2 E. E. Gdouto, Fracture Mechanics: An Introduction, 2nd Edition, Springer.

R3 D. Broek, Elementary Engineering Fracture Mechanics, 4th Edition, Springer

Content Structure
1. Background
1.1. Kinds of Failure
1.2. Historical aspects
1.3. Brittle and Ductile Fracture
1.4. Modes of Fracture Failure
1.5. How Potent is crack
1.6. Damage tolerance
2. Energy Release Rate
2.1. Griffith's Dilemma
2.2. Surface Energy
2.3. Griffith's Realization
2.4. Griffith's analysis
2.5. Energy Release Rate
2.5.1 Definition
2.5.2 Mathematical Formulation
2.5.3 Change in compliance approach
2.5.4 Change in strain energy approach
2.6. Energy Release Rate of DCB Specimen
2.7. An elastic deformation at crack-tip
2.8. Crack Resistance
2.9. Stable and Unstable crack growth
2.10. R-curve for brittle cracks
2.11. Critical Energy Release Rate
3. Stress Intensity Factor
3.1. Introduction
3.1.1. Why should Investigations be closer to crack tip
3.1.2. Linear Elastic Fracture Mechanics (LEFM)
3.2. Stress and displacement fields in Isotropic Elastic Material
3.3. Stress Intensity Factor
3.4. Mathematical Analysis
3.4.1. Field Equations
3.4.2. Concept of Complex Variables
3.5. Westergaard's Approach
 3.5.1. Mode-I (Opening Mode)
3.5.2 Mode-II (Sliding Mode)
3.5.3. Mode-III (Tearing Mode)
4. SIF of complex cases
4.1. Applications of Westergaard's Approach
4.1.1. Wedge loads on cracked surfaces
4.1.2. Collinear cracks in an infinitely long strip
4.2. Principle of Superposition
4.2.1. Internal pressure on cracked faces
4.2.2. Wedge load at the surface of a crack face
4.3. Crack in a plate of finite dimensions
4.4. Edge cracks
4.5. Embedded Cracks
4.5.1. Elliptical Crack
4.5.2. Semi- Elliptical Crack
4.5.3. Quarter or corner cracks
4.6. Relationship between GI and KI
4.7. Critical Stress Intensity Factor
5 An elastic Deformation at the crack tip
5.1. Approximate shape and size of the plastic Zone
5.1.1. Plastic Zone shape for Plane stress
5.1.2. Plastic Zone shape for Plane strain
5.2. Effective crack length
5.2.1 Approximate approach
5.2.2. The Irwin Plastic Zone correction
5.2.3. Dugdale approach
5.3. Effect of Plate Thickness
6. J-Integral
6.1. Definition
6.2. Path Independence
6.3. Stress-strain relation
6.4. Discussions on J-integral
6.4.1. Designer's Point of view
6.4.2. Experiments to determine the critical J-integral
7. Crack tip opening Displacement
7.1. Relation between CTOD, GI and KI
7.2. Equivalence between CTOD and J
8. Test Methods
8.1. KIC test techniques
8.2. Test methods to determine JIC, Test methods to determine GIC and GIIC
8.3. Determination of critical CTOD
9. Fatigue Failure and Environment assisted fracture
9.1. Fatigue failure
 9.1.1. S-N Curve
9.1.2. Crack initiation and Propagation
9.1.3. Effect of an overload
9.1.4. Crack Closure
9.1.5. Variable Amplitude Fatigue Load
9.2. Environment assisted fracture
9.2.1 Micro mechanisms
9.2.2. Major factors influencing Environment assisted fracture
9.2.3. Liquid metal embrittlement
10. Crack detection through NDT
10.1 Liquid Penetrant inspection
10.1.1. Procedure
10.1.2. Crack observation
10.2. Ultrasonic Testing
10.3. Radiographic Imaging
10.3.1. Contrast through absorption rate
10.3.2. Fogging
10.3.3. Penumbra effect
10.4. Magnetic Particle Inspection
10.4.1 Principle
10.4.2. Flaw Orientation
10.4.3. Demagnetization

Learning Outcomes: Students will be able to

LO1 Acquire the principles of stress and strain at crack tip

LO2 Recognize stable and unstable crack growth

LO3 Describe various ways of experimentally measuring crack growth

LO4 Discuss the effect of environment on crack growth

LO5 Put to use some NDT methods to detect crack

Experiential Learning Components:

1. Lab: Onramp, Virtual lab (Franc3D)

2. Case study: None
3. Work integrated Learning Exercise: None
4. Design work/Field work: None

Part B: Learning Plan

 Contact Hour 1 and 2

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 1 Basic knowledge of mechanics TB, Lecture notes

of materials, stress, strain,
yielding criterion, fatigue,
creep etc.

During TB- Chapter 1 Background TB, Internet resources

CH

Post CH TB- Chapter 1 Case studies of failure of TB, Internet resources

components

Contact Hour 3 and 4

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 2 Read about Stress at a point, TB, Lecture notes
stress concentration at the
vicinity of the crack tip

During TB- Chapter 2 Energy release rate TB, Internet resources

CH

Post CH TB- Chapter 2 Revise Dilemma of Griffith, TB, Internet resources

Surface energy, Griffith’s
realization

Contact Hour 5 and 6

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 2 Revise differentiation, TB, Lecture notes

integration, deflection of beams
etc

During TB- Chapter 2 Griffith’s analysis, TB, Internet resources

CH Mathematical formulation,
Critical energy release rate

Post CH TB- Chapter 2 Try mathematical formulation TB, Internet resources

to find the energy release rate of
different type of specimens. to
understand the concept of
critical crack
 Contact Hour 7 and 8

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 3 Basic understanding of stress- TB, Internet resources

strain-displacement relation.
plane stress and plane strain
problems, Mohr's circle

During TB- Chapter 3 Stress Intensity Factor TB, Internet resources

CH

Post CH TB- Chapter 3 Calculation of stress-strain TB, Internet resources

fields at crack tip

Contact Hour 9 and 10

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 3 Revise complex variables TB, Internet resources

During TB- Chapter 3 Linear elastic fracture TB, Internet resources

CH mechanics (LEFM), Mode I

Post CH TB- Chapter 3 Understand the Mode I Failure TB, Internet resources
Problems

Contact Hour 11 and 12

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 3 Study about Mode I, Mode II, TB, Internet resources, reference
Mode III Failure books

During TB- Chapter 3 Mode II, Mode III Problems TB, Internet resources, , reference
CH books

Post CH TB- Chapter 3 Revise the difference between TB, Internet resources, , reference
Mode I, Mode II, Mode III books
failures

Contact Hour 13 and 14

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 4 Background of mathematical TB, Internet resources, , reference

analysis books

During TB- Chapter 4 SIF of complex cases, TB, Internet resources, , reference
CH Application of the principle of books
 superposition, Crack in a plate
of finite dimensions, Edge
cracks, Embedded cracks e.t.c,
Relationship between GI and KI
Critical Stress Intensity Factor

Post CH TB- Chapter 4 Application of westergaard TB, Internet resources, , reference

approach to different problems books

Contact Hour 15 and 16

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 5 Review about concept of TB, Internet resources, , reference
plastic deformation, plane books
stress, plane strain, ductile
materials

During TB- Chapter 5 An elastic Deformation at the TB, Internet resources, , reference
CH crack tip, Approximate shape books
and size of the plastic Zone,
different approaches to calculate
the Effective crack length

Post CH TB- Chapter 5 Learn to calculate plastic zone TB, Internet resources, , reference
shape and size around the books
crack tip and also to predict the
effective crack length

Contact Hour 17 and 18

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 6 Stress-strain curve for elastic- TB, Lecture Notes/reference books
plastic deformation

During TB- Chapter 6 Definition, Path Independence, TB, Lecture Notes/reference books
CH stress-strain relation

Post CH TB- Chapter 6 Compare the stress-strain TB, Lecture Notes/reference books
relation of LEFM and EPFM

Contact Hour 19 and 20

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 6 Recall Ramberg-Osgood TB, Lecture Notes/reference books

 relation to model non-linear
elastic material

During TB- Chapter 6 Designer's point of view on J- TB, Lecture Notes/reference books
CH integral, Experiments to
determine critical J-integral

Post CH TB- Chapter 6 Numerical to predict the TB, Lecture Notes/reference books
maximum stress to be applied
without causing the crack
growth

Contact Hour 21 and 22

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 7 Revise Concept of energy TB, Lecture Notes/reference books
release rate, stress intensity
factor, J integral

During TB- Chapter 7 Crack tip opening TB, Lecture Notes/reference books
CH Displacement
Relation between CTOD, GI
and KI, Relation between
CTOD and J

Post CH TB- Chapter 7 Application of CTOD TB, Lecture Notes/reference books

approach to compare
toughness of materials

Contact Hour 23 and 24

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 8 Recall toughness of material, TB, Lecture Notes/reference books
methods to measure toughness

During TB- Chapter 8 Test Methods to calculate KIC, TB, Lecture Notes/reference books
CH JIC, Critical CTOD

Post CH TB- Chapter 8 To identify which test method TB, Lecture Notes/reference books
is appropriate for the given
material

Contact Hour 25 and 26

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 9 Recall concept of fatigue TB, Lecture Notes/reference books
During TB- Chapter 9 S-N Curve,. Crack initiation TB, Lecture Notes/reference books
CH and Propagation, Effect of an
overload, Crack Closure,
Variable Amplitude Fatigue
Load

Post CH TB- Chapter 9 Practice Problems to TB, Lecture Notes/reference books

Calculate propagation life up t
failure of component

Contact Hour 27 and 28

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 9 Concept of corrosion, TB, Lecture Notes/reference books

corrosion mechanisms

During TB- Chapter 9 Environment assisted fracture TB, Lecture Notes/reference books
CH

Post CH TB- Chapter 9 Try to Find out case studies TB, Lecture Notes/reference books
where both fatigue load and
environmental factors
contribute to crack growth

Contact Hour 29 and 30

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 10 Study about advantages of TB, Lecture Notes/reference books
NDT techniques

During TB- Chapter 10 Crack detection through TB, Lecture Notes/reference books
CH NDT

Post CH TB- Chapter 10 Case studies of measuring TB, Lecture Notes/reference books
crack through ultrasonic
technique

Contact Hour 31 and 32

Type Content Ref. Topic Title Study/HW Resource Reference

Pre CH TB- Chapter 10 Basic principles of TB, Lecture Notes/reference books

radiographic testing technique
 and MPI technique

During TB- Chapter 10 Crack detection through TB, Lecture Notes/reference books
CH NDT

Post CH TB- Chapter 10 Case studies of measuring TB, Lecture Notes/reference books
crack through radiographic
testing technique and MPI
technique

Assignments
Each student is given an individual assignment on any of the topics discussed in the class
 Assignments are take-home and deadline-driven (typically of 2 weeks
duration) announced post Mid-semester examination
 Students to spend at least 16 hours of work in study, research, discussion and
preparation of the report and presentation.
 As part of deliverables, the student is expected to prepare a report and make a
short-presentation in the class

Project Activity/ Experiential Lab:

Sr No Lab Details/ Project Details Access

01 Franc3D On-ramp Through online portal
02 Virtual Lab: Franc3D Simulink software: – 16 hours of Through online portal
practice – Graded for 20%

Evaluation Scheme
Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session

Evaluation Name Type (Open Weight Duration Day, Date,

Component (Quiz, Lab, Project, Mid- book, Session, Time
term exam, End semester Closed
exam, etc.) book,
Online, etc.)
Theory- Quiz/Assignment Online 10% 2 Weeks September 10-
20, 2020
Lab Assignment Online 16 % October 20-30,
EC - 1 2020
Lab Quiz Online 04% November 10-
20, 2020
EC - 2 Mid-Semester Test Closed Book 30% 2 hours Friday,
09/10/2020
(FN)
10 AM - 12
 Noon
Comprehensive Exam Open Book 40% 3 hours Friday,
27/11/2020
EC - 3 (FN)
9 AM – 12
Noon

Closed Book: No reference material of any kind will be permitted inside the exam hall.
Open Book: Use of any printed / written reference material (books and notebooks) will be
permitted inside the exam hall. Loose sheets Photocopies and Laser printouts of any material
will not be permitted. Computers of any kind will not be allowed inside the exam hall. Use of
calculators will be allowed in all exams. No exchange of any material will be allowed.

Note:
It shall be the responsibility of the individual student to be regular in maintaining the self-
study schedule as given in the course handout attend the online/on demand lectures as per
details that would be put up in the BITS eLearn (Taxila) website elearn.bits-pilani.ac.in
and take all the prescribed components of the evaluation such as Assignments/Quizzes Mid
Semester and End Semester Examination according to the Evaluation Scheme given in the
respective Course Handout. If the student is unable to appear for the Regular Examination
due to genuine exigencies the student must refer to the procedure for applying for Make-up
Examination which will be available through the Important Information link on the eLearn
website on the date of the Regular Examination. The Make-up Tests/Exams will be
conducted only at selected exam centres on the dates to be announced later.

(P.T.O)
 FRACTURE MECHANICS – Simulation LAB
1. Scope of the lab
To support the theory learned in fracture mechanics course with the aid of simulation
tool to understand the nature of crack propagation and remaining life prediction on
components/structures which makes confidence in students to approach the real-world
problems.
2. Objectives of Lab
Developing skill set to perform the crack propagation analysis on various
components/structures to determine critical crack length and to predict the remaining
life.
3. Learning Outcome of the lab
 To incorporate crack at critical location.
 To perform crack growth analysis.
 To predict critical crack length and fatigue life.
4. List of simulation experiments: Software Tool used: Franc3D

Tutoria Tutorial Name Quiz Assignment Chapter

l Marks Marks Number
Number
1. Plate with surface crack 4.5
2. Plate with holes 4.5
Crack propagation from notch
3. 4.4
specimen
4. Three-point bending specimen 4.4
5. Leak detection in pipe bend 4.5
4 16
Propagation of weld root crack on
6. 4.4
T-joint
Crack propagation in gear
7. 4.5
assembly
Crack propagation in bracket
8. 4.5
assembly
5. Evaluation Scheme
Evaluation Name Type Weight Duration
Component

EC - 1 Lab Quiz Online 4% 2 hrs

Assignment (12) Online 16% 2 hrs

Note: After completion of every practice tutorial problem, take a snapshot and include the
same in the final assignment PPT lastly. Quiz questions will be based on the practice tutorial
problems and results.

Instruction Schedule

Lab Class Instructions Online TBA 2 Hrs

work Delivery

Evaluation Scheme

Evaluation Name Type Marks Dates Lab Exam Date Duration

Component

Quiz based Online 04

on virtual
lab

Assignment Online 16 Regular                      TBA

based on TBA
EC - I virtual lab
(12 for Makeup                      TBA
assignment TBA
and 4 for
practice
screenshots)

Note: After completion of every practice tutorial problem, take a snapshot and include the
same in the final assignment PPT lastly. Quiz questions will be based on the practice tutorial
problems and results.

Lab-in-Charge