Fracture Analysis

Fracture Analysis is at the core of what our FEA consulting engineers do at our Singapore FEA consultancy office in BroadTech Engineering. It has many useful engineering applications, such as fatigue analysis, buckling analysis, and gear failure analysis (IL: Gear Failure Analysis)

Fracture Analysis


Common FEA Simulation Solver used for Fracture Analysis 

A market-leading component of Siemens PLM Software Umbrella, Femap FEM Modeling Software Tools Offers a Highly independent backbone to a number of other well-known and industry-respected CAD and CAE solver products.
Once the FEA Numerical model is Finished preprocessed as part of the FEA Consultancy Project, it Should be prepared and Transmit to the solver for FEA Pipe Stress analysis. Here, we show the top Most Technical Confrontations Often associated with this Workflow. Respondents were Demanded to Choose the top three.
Based on the type of Numerical CAE analysis and Modeling Needed, Various solvers be Required. For example, CFD (computational fluid dynamics) and FEA structural analysis each have their own Unique FEA solver.
On average, Engineering Computational Structural Dynamics Businesses Particularly Structural Engineering Companies report using 3.3 Various solvers. For each solver, the FEA simulation model Might Require Small adjustments based on the type of FEA Analysis Simulation (example Non-linear FEA, Dynamic FEA, FEA Thermal Analysis) done as part of the FEA Consulting Services Performed. The model Might also Require to be Greatly simplified with a different approach or the mesh size or shape Might Necessitate being adjusted. If preprocessing tools and FEA Software lack the Abilities Required to optimize the FEA model for the Expected FEM Simulation analysis, you have to either skip the Ansys Finite Element Analysis or use Various Softwares, the latter of which Increases Simulation Solve time and complexity to the Workflow.

Types of Fracture Simulation Analysis We can do:

  1. Linear & Non-Linear Fracture Analysis
  2. Structural Fracture Analysis
  3. Bio-Mechanical Fracture Analysis


Siemens PLM Software’s Solution

Solid Edge Simulation is the Main Software Constituent component that is Targeted on bringing FEA Finite Element Thermal Analysis Much Quicker to the Product design workflow Operation and is intended to make FEA Thermal Structural Analysis Simulation more accessible and easier to Utilize by both occasional users and Seasoned Professionals while maintaining the Full Data integrity of both the 3D CAD model and the FEA Simulation analysis Results.

Femap NX Nastran FE Model Updating

Femap NX Nastran FE Model Updating software is an advanced correlation tool designed to automatically update FE models to match real-life test data. The Gear Failure Analysis tool is Totally integrated with Femap NX Nastran structure modules, making the updating Workflow More Effective, intuitive, and productive. 
SMBs and Structural Design Consultants can now take complete advantage of what Siemens PLM Software Tools have Gained from serving these large manufacturing Organizations. Siemens PLM Software has a comprehensive PLM Engineering solution to the engineering Challenges facing SMB manufacturers that helps them become more Cost competitive, Operationally Streamline and profitable.

FEA Analysis Software Module benefits

  1. Use FEA Software to Quicky evaluate and improve the dynamic behavior of rotating systems before physical prototyping Creation and production Schedule commit in a fully integrated CAE Work Process
  2. Through commercial FEA Services, it helps to Evaluate and develop optimal in-service Engineering design modifications to Boost production process Operational throughput of rotating equipment systems 
  3. Boost the productivity of your FEA Vibration Consultancy by performing model Update in a Similar Engineering environment used for Numerical model creation and FEA analysis
  4. The FEM Modeling Software helps to Improve accuracy and increase General Trust in your Numerical FE model Created
  5. Provide Fast sensitivity-based Methodology for performing Faster, more Reliable Failure Analysis Services

Parametric Design Optimization

Simcenter Femap NX Nastran Provides parameter and topology optimization FEA Software solutions. The topology optimization algorithm nds an optimal geometric Geometry to Withstand Force Loading or sfy Specific responses or Physical manufacturing constraints.
The resulting Geometry Geometry obtained from the Finite Element Thermal Analysis is Very Frequently described as “organic” and they can be Quickly manufactured to Geometrically fit well with Complex additive manufacturing methods.
The Complex algorithms of Simcenter Femap NX Nastran Assist the use of FEA Contact Analysis in Finding and Scanning the Engineering design space and finding the right combination of Input param­eters that will Gain optimal performance.
Common Selectable Input parameters include shell thickness Dimension, composite Material ply thickness,  composite ply Relative Direction, material Physical properties, and spring Physical stiffness.




Featured Fracture Analysis Case Studies

Fracture Analysis

Fracture Analysis of FGM and Conventional Materials

Environment: Abaqus 6.12.
Method used: Our FEA consultant used the Contour integral and extended finite element method.
Conclusion: Stress intensity factor and j integrals were evaluated during the FEA analysis.

Fracture based Fatigue Analysis

Objective: To study the crack length vs the number of load cycles using FEA simulation.
Method: Xfem based low cycle fatigue analysis was carried out in an aluminum 6061 specimen. Paris law is used, which demands the material constants to be applied as input. These values were obtained from the literature.
Conclusion: The finite element analysis study was performed successfully using the FEA simulation software.

Fracture Simulation Analysis of Rubberized Concrete 

Simulation objective: Fracture analysis of rubberized concrete
1. Using Acoustic Emission (AE) to monitor and locate the cracking during the fracture process of common concrete and rubberized concrete;
2. FEM Modeling the fracture of both materials using vibration fatigue analysis
Rubberized concrete has a better ductility than common concrete. AE hit count growth during the fracture process has a similar trend to that of energy dissipation from FEM analysis.



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Featured Fracture Analysis Case Studies

Development of a computational algorithm for FEA simulation of fracture propagation in the rock
1. FEA Simulation Objective:
Development of a computational algorithm for the simulation of fracture propagation in the rock
2. FEA Simulation Methodology and Approach:
Numerical code based on eXtended Finite Method (XFEM) is developed for the simulation of the fracture propagation in the rock. The fracture propagation results are validated with the existing literature.
  • FE analysis type: Non- linear static analysis
  • Coding platform: Visual studio
  • Coding language: Fortron (Stress-strain calculation). C++ (Fracture propagation)
3. Outcome & Conclusion
Propagation path of the pre-existing crack is calculated

3D printed Auxetic structures for protection against impact events

1. FEA Simulation objective::
Auxetic structures are tailored meta materials by design, which posses novel negative Poisson’s ratio characteristic, owing to their ability to contract/expand under compression/tension loading conditions.  Due to this unique characteristic,  they show huge potential in the field of protective structure, for their ability to resist external compressive loadings under ballistic events.  The objective of this research is to come up with an ideal auxetic design using FEA approach for protection against projectile  and drop weight impact (high speed compression).
2. FEA Simulation Methodology and Approach:
The protective performance of Honeycomb sandwich panels (HSP) is compared and contrasted against Auxetic Sandwich panels (Triangle core, Re entrant core, and Straight core).  The total mass of the sandwich panels are kept constant for valid comparison.  The performance of the panels when subjected to a cylindrical projectile impact, with a velocity of 30m/s is investigated using ABAQUS/Explicit.  The performance is benchmarked against the stress transferred to the top of the protected structure and the total reaction force transmitted to the protected structure.
Under highly dynamic conditions, it is imperative to consider the strain rate effects of the materials into account.  Hence, the full Johnson and Cook model accounts for the various factors during a projectile impact or blast, such as the materials wide range of strain, rate dependency, temperature and pressures. The Johnson cook parameters for Steel grade AISI 4030 steel, reported in previous literatures are taken into account.
3. Project Conclusion & Outcomes:
Auxetic sandwich panels with chiral core containing wavy ligaments have found to reduce the peak force transferred to the protected structure by 75%.  The stress transferred under such loading conditions was also found to be reduced by 60%.  Current ongoing work involves validating the simulations by rapid prototyping of the optimized geometry obtained from the FEA approach, using additive manufacturing.

Fracture mechanics FEA Simulation: 

Found that fracture ductility was strongly dependent on stress triaxiality for specimens’ printed using stereo lithography.
Software used: Abaqus
Material modeling: Developed a user material subroutine (VUMAT) to incorporate constitutive material model of arterial wall (anisotropic hyper elastic with 4 fiber families) in commercial FE code, Abaqus, using Fortran

Fracture analysis of pincer crane in Esfahan’s Mobarakeh Steel Complex.

They had a catastrophic failure in the pincer crane and they wanted to know what was the source of fracture. We analysed all components of the crane from static point of view but everything was fine. Then, we checked the components against the brittle fracture (by FEM analysis)  and performed some experimental experiments on the material.  Finally we figured out that the ductility of St52 was not sufficient and the problem was due to poor material selection.

Multiphysics numerical analysis of soil and tissues subjected to blast loads.

In this write-up, Our FEA Consultant would like to mention two of the most challenging or important projects Our FEA Consultant was involved in.
During my time in Colorado in the US, Our FEA Consultant worked with researchers in ARL (Army Research Laboratory) on a project funded by USAMRMC (United States Army Materials Research and Materials Command) to perform multiphysics numerical analysis of soil and tissues subjected to blast loads.
Soils and biological tissues (skin and brain) are multiphasic with their pores often saturated with water and multiple physics has to be accounted into the model to characterize the behavior accurately. Also, during a blast, the material undergoes high rate loading conditions and so high performance, stable explicit codes had to be developed with care. Soils analysis can be performed on commercial software like ABAQUS and LS-DYNA but they have several limitations. No commercial software could carry out a coupled finite element analyses at a detail required by researchers in ARL to design helmets and protective gear. Our FEA Consultant was hired to identify limitations of commercial software packages like ABAQUS and LSDYNA and also extend the capabilities of their open source FEM software. Also, skin and brain tissue material models are not readily available and Our FEA Consultant had to write user subroutines like UMAT and UANISOHYPER-INV (Anisotropic Hyperelasticity) on ABAQUS.
Our FEA Consultant successfully completed the project after a lot of research in mechanics and mathematical modelling by developing a stable three field finite element model. This experience nurtured my technical skills and broadened my intellectual horizon and is something Our FEA Consultant am really proud of.

FEA Simulation on photonic crystals is to investigate the propagation


1. FEA Simulation Objective:
Objective of simulation on photonic crystals is to investigate the propagation thourgh the photonic crystal fiber.
2. FEA Simulation Methodology and Approach:
Methodoly is using the Matlab software by typing programming language to simulate the subject and also using the matrix calculation.
3. Outcome & Conclusion
Outcome is the method of inducing circular polarization using coreless photonic crystal fiber (CO-PCF). The mode distribution of the fundamental mode for left and right rotation is numerically simulated.


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