Improved Design Package for Fracture Mechanics Analysis

ABSTRACT: To address the needs of the U.S. Air Force to improve existing software design packages so that they account better for short crack growth regime, Sentient proposes to incorporate its its DigitalClone-Component(DCC) modeling technology into these packages for short crack growth regime. The use of fracture mechanics to characterize the growth of fatigue cracks in metals is well established in the design of structures. However, initiation of failure generally occurs by nucleation and propagation of critical micro-cracks with sizes ranging from several to a few hundred micrometers. Crack growth doesn"t follow the conventional linear elastic fracture mechanics (LEFM) approach. Therefore, to obtain a reliable life prediction model, a physics-based model is needed to analyze the fatigue crack nucleation and short crack growth. During Phase I, Sentient will use their DCC model for analysis of damage initiation and short crack growth regime. This model accounts for the effect of microstructure on the fatigue crack creation and early growth, and also predicts the fatigue life of the structure where conventional LEFM approach doesn"t work. In Phase II, an improved DCC model will be implemented in a validated design package used in the aerospace industry, through collaboration with aerospace companies. BENEFIT: Sentient"s DigitalClone-Component DCC) technology will allow the aerospace OEMs and other industries to design their structures and components more efficiently and perform more accurate performance and life analysis. This specially is more significant when they use new materials in their design. This will significantly reduce the uncertainty, errors and conservatism in design of new components and structures, thereby improving design process, increasing performance, reliability and durability, and reducing cost of operation. The physical nature and computational strength of the improved design tool will help testing more geometries, materials and design concept resulting in better final products. Sentient"s DCC enhanced modeling capabilities for fracture mechanics analysis will be used throughout the military and commercial aerospace as well as in automotive industries.