BAMF running as an AFGROW plug-in (courtesy Mr. Josh Hodges/Hill Engineering, LLC)

On July 17, 2019 a joint webinar on the latest developments in FEA-based 3D crack growth simulation, titled “3D Crack Growth Simulation: Advancements & Applications”, was provided by ESRD’s Brent Lancaster, LexTech’s James Harter and Hill Engineering’s Joshua Hodges.

In this webinar, we detailed the latest technological advancements for accurate simulation of three-dimensional crack growth in metallic structures, with and without residual stresses, via coupled finite element analysis (FEA) and fatigue life computations. Additionally, the webinar expanded further on the DaDT analysis best practices presented in ESRD’s June 2017 webinar, titled “Durability and Damage Tolerance (DaDT) Analysis Best Practices“, and highlighted the importance of mitigating the errors of approximation associated with stress intensity factors (SIF’s) and if applicable, engineered residual stresses (e.g. cold-working).

Webinar attendees from a wide range of industries were treated to a demo of Hill Engineering’s Broad Application for Modeling Failure (BAMF) Sim App, which provides a robust integration between StressCheck’s high-fidelity DaDT/fracture solutions and AFGROW’s crack growth life prediction capabilities. The BAMF demonstration showed how to set up a parametric model for DaDT analysis via StressCheck and then, with limited user intervention, integrate with AFGROW and StressCheck via their respective COM API’s to perform an on-demand 3D crack growth simulation. It was very impressive demo, indeed!

View Webinar Recording

Click the button below to view the 3 part, 65-minute webinar recording (scroll to the bottom of the webinar landing page to find the videos):

View Webinar Slides

Click the button below to view the webinar slides (PowerPoint Show):

Additional Resources

During the webinar, we identified several relevant DaDT and/or crack growth simulation resources that may be of interest:

• “Analytical Modelling of Fatigue Crack Behaviour Under Representative Spectrum Loading in the F/A-18 A/B Y508 Wing Root Shear Tie”, Dr. Kevin Walker (DST Group)
• “Crack Aspect Ratio Investigation, Analytical Methods Subcommittee: Round Robin for Cx Holes”, Mr. Robert Pilarczyk (Hill Engineering, LLC)
• “Benchmarking Problems in Fatigue Crack Growth Analyses”, Mr. Robert Pilarczyk (Hill Engineering, LLC)
• “Numerical Simulation Series: Fracture Mechanics Parameters”, Dr. Ricardo Actis (ESRD)
• “Improving Global-Local Simulation Workflows for High-Fidelity Stress and Damage Tolerance Analysis”, Mr. Eric Buettmann & Mr. Gordon Lehman (ESRD)
• “Computation of SIFs for Cracks in Cold-Worked Holes”, Dr. Ricardo Actis & Mr. Matt Watkins (ESRD), Dr. Scott Prost-Domasky (AP/ES) and Mr. Joshua Hodges (USAF)
• “Crack Propagation Analysis Tool for 3D Crack Simulation: A Simulation App Case Study”, Mr. Matt Watkins (ESRD)
• The Contour Method for Measuring Residual Stresses (Hill Engineering, LLC)

Acknowledgments

As always, many thanks to our attendees for their interest and feedback! And, of course, thanks to LexTech and Hill Engineering for their time and contributions. We hope to collaborate on another webinar in the future!

ESRD Co-Presents at ERSI Workshop 2019

Interactive K-solver crack propagation (CPAT) in StressCheck used for the prediction of fatigue growth rates.

ESRD’s Dr. Ricardo Actis attended and co-presented with technology partner Analytical Processes/Engineered Solutions (AP/ES) at the Engineered Residual Stress Implementation (ERSI) Workshop 2019 in Clearfield, UT.  This annual workshop is focused on the development of a damage tolerance methodologies for fatigue crack growth through deep Engineered Residual Stress (ERS) fields.

Sponsored by the US Air Force’s A-10 Airframe Structural Integrity Program (ASIP), the goal of this workshop is to develop a roadmap for the implementation of the beneficial effect of engineered residual stresses within the United States Air Force (USAF) Damage Tolerance Analysis (DTA) fatigue crack growth and lifing programs.

At ERSI Workshop 2019, Dr. Thomas Mills (AP/ES) and Dr. Ricardo Actis (ESRD) co-presented “Fatigue Life Modeling at CX and Interference Holes”.  The presentation summary is as follows:

• Crack closure experimental observations and modeling.
  • Continuation of previous year’s work.
• Residual stress redistribution at interference filled holes.
  • Task evolved from USAF goals dictated at ERSI.
  • Goal is to better understand interference fit fasteners and their interaction with residual stresses from cold-working (CX).

A PDF of the presentation may be downloaded at the following link:

ESRD Sponsors the WashU Racing Team

Congratulations to the Washington University in St. Louis Racing Team on a successful season! It was a pleasure to sponsor the team as they improved their global standings in multiple events, and increased their team to over 50 members. Below is a signed image of the racing team members, as well as a letter of appreciation sent to the racing team sponsors:

The 2019 Washington University Racing Team.

Washington University Racing Team Letter to Sponsors.

We are pleased to have a positive impact on our local engineering community, and look forward to our continued sponsorship of the team!

Corner crack at the edge of the hole inserted after cold-working. Contour show the progression of crack opening as the external load is increased from 0 to 27 ksi. First noticeable crack opening appears around 19 ksi.

ESRD’s Dr. Ricardo Actis attended and presented with technology partner Analytical Processes/Engineered Solutions (AP/ES) at the Engineered Residual Stress Implementation (ERSI) Workshop 2018 in Clearfield, UT.  This annual workshop is focused on the development of a damage tolerance methodologies for fatigue crack growth through deep Engineered Residual Stress (ERS) fields.

Sponsored by the US Air Force’s A-10 Airframe Structural Integrity Program (ASIP), the goal of this workshop is to develop a roadmap for the implementation of the beneficial effect of engineered residual stresses within the United States Air Force (USAF) Damage Tolerance Analysis (DTA) fatigue crack growth and lifing programs.

At ERSI Workshop 2018, Dr. Ricardo Actis (ESRD) and Dr. Thomas Mills, Dr. Scott Prost-Domasky, and Mr. Craig Brooks (AP/ES) presented “RS Crack Closure: Experimental Observations and Modeling”, the PDF of which can be downloaded below:

The ERSI Workshop 2018 attendees are shown below:

Attendees to the Third ERSI Workshop.

ESRD, Inc. continues to work closely with AP/ES and the USAF to develop and implement accurate solutions for challenging Durability and Damage Tolerant applications.