Analysis of stress intensity factor in a cracked structure

Abstract

This research evaluates the Stress Intensity Factor (SIF) in cracked structures and investigates how variations in crack dimensions and loading conditions influence fracture behavior. The study addresses the historical limitations of classical engineering by explicitly considering the presence of flaws often described as the "silent destroyers" of materials to ensure structural safety and reliability. Numerical simulations were performed using the Finite Element Method (FEM) within the ABAQUS environment. A 2D stainless steel plate was modeled with specialized mesh refinement at the crack tip to capture the singular stress field, and KI values were extracted using the J-integral method. The simulation yielded a KI value of 19.98 for the baseline model. Parametric studies revealed that increasing the crack length or external pressure significantly elevates the KI/KIc ratio moving the component closer to the threshold of unstable, catastrophic propagation. This work confirms that virtual prototyping is a strategic asset for structural integrity assessment and damage-tolerance analysis. By quantifying the mathematical stress singularity at the crack tip, the methodology provides a robust framework for safer engineering designs. Ultimately, the research proves that numerical modeling accurately predicts failure boundaries, ensuring the reliability of critical components in industrial applications.