2D and 3D finite element analysis of crack growth under compressive residual stress field

In the present study, plasticity induced crack closure (PICC) concept and three dimensional (3D) finite element method (FEM) were used to study the effect of compressive residual stress field on the fatigue crack growth from a hole. Furthermore, a new methodology on the basis of a correction factor was presented to increase the PICC precision. The result obtained was compared to two dimensional (2D) FEM, superposition method and Liu’s experimental data. To simulate the elasto-plastic behavior of the material, isotropic hardening was assumed and the Von-Mises yield criterion was implemented. A 3D mesh was built using eight-node hexahedral elements and one half of the specimen was modeled. The simulation results were fairly well correlated with experimental data. Furthermore, the 3D elasto-plastic FEM predicted a slightly smaller fatigue life than a 2D plane stress FEM. Applying the modified PICC method reduces the 3D FEM fatigue life prediction errors.

► The effect residual stress on the fatigue crack growth from a hole was studied. ► Plasticity induced crack closure (PICC) concept and 3D FEM were used. ► A new methodology was presented to increase the PICC precision. ► Simulation results were compared with superposition method and experimental data.