Using the local approach to evaluate scaling effects in ductile fracture

This paper uses a local model to predict ductile fracture in geometrically similar structures of different sizes containing either sharp cracks or blunt stress concentrators. Simple theoretical considerations suggest that when fracture occurs by quasi-isotropic void growth, fracture initiation at blunt notches follows replica scaling, whereas fracture initiation at sharp cracks does not. Simulations with a local fracture model of fracture events in (1) fatigue precracked compact specimens and (2) three-point-bend bars containing blunt notches confirm these conclusions. However, a comparison of simulations with actual experimental results with HY-130 steel specimens leads to mixed conclusions. Predicted and observed behaviors for fracture at sharp cracks agree well, but the discrepancy is considerable for fracture initiating at blunt notches loaded in bending. Significant sealing effects are observed in the experiments for the conditions of fracture initiation at blunt notches. Fractographic analysis reveals that the reason for this discrepancy is a difference in the micromechanisms controlling fracture at sharp cracks as opposed to blunt notches. At sharp cracks, quasi-isotropic void growth dominates, whereas fracture initiates at blunt notches by a shear localization process and the nucleation, growth, and coalescence of voids in a mixed shear and tensile deformation field. The transition from one mode to the other may be governed by the hardening rate and, if so, is material dependent. Therefore, when using local fracture models for predicting fracture under generalized geometric and loading conditions, care must be taken; that the micromechanisms of ductile fracture invoked in the actual material match those assumed by the local fracture model. If this correspondence is verified, local fracture models can be used to predict fracture conditions and associated scaling effects for situations not amenable to treatment by classical elasto-plastic fracture mechanics. However, new or expanded models that can treat ductile fracture in localized shear zones should be developed to realize the full potential of these local fracture methodologies.