Enhancing Fatigue Life Prediction Accuracy: A Parametric Study of Stress Ratios and Hole Position Using SMART Crack Growth Technology
This study presents a unique and comprehensive application of ANSYS Mechanical R19.2’s SMART crack growth feature, leveraging its capabilities to conduct an unprecedented parametric investigation into fatigue crack propagation behavior under a wide range of positive and negative stress ratios, and t...
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MDPI AG
2025-06-01
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| author | Yahya Ali Fageehi Abdulnaser M. Alshoaibi |
| author_facet | Yahya Ali Fageehi Abdulnaser M. Alshoaibi |
| author_sort | Yahya Ali Fageehi |
| collection | DOAJ |
| description | This study presents a unique and comprehensive application of ANSYS Mechanical R19.2’s SMART crack growth feature, leveraging its capabilities to conduct an unprecedented parametric investigation into fatigue crack propagation behavior under a wide range of positive and negative stress ratios, and to provide detailed insights into the influence of hole positioning on crack trajectory. By uniquely employing an unstructured mesh method that significantly reduces computational overhead and automates mesh updates, this research overcomes traditional fracture simulation limitations. The investigation breaks new ground by comprehensively examining an unprecedented range of both positive (R = 0.1 to 0.5) and negative (R = −0.1 to −0.5) stress ratios, revealing previously unexplored relationships in fracture mechanics. Through rigorous and extensive numerical simulations on two distinct specimen configurations, i.e., a notched plate with a strategically positioned hole under fatigue loading and a cracked rectangular plate with dual holes under static loading, this work establishes groundbreaking correlations between stress parameters and fatigue behavior. The research reveals a novel inverse relationship between the equivalent stress intensity factor and stress ratio, alongside a previously uncharacterized inverse correlation between stress ratio and von Mises stress. Notably, a direct, accelerating relationship between stress ratio and fatigue life is demonstrated, where higher R-values non-linearly increase fatigue resistance by mitigating stress concentration, challenging conventional linear approximations. This investigation makes a substantial contribution to fracture mechanics by elucidating the fundamental role of hole positioning in controlling crack propagation paths. The research uniquely demonstrates that depending on precise hole location, cracks will either deviate toward the hole or maintain their original trajectory, a phenomenon attributed to the asymmetric stress distribution at the crack tip induced by the hole’s presence. These novel findings, validated against existing literature, represent a significant advancement in predictive modeling for fatigue life assessment, offering critical new insights for engineering design and maintenance strategies in high-stakes industries. |
| format | Article |
| id | doaj-art-27289a96a1ce4d609fdd5cad9bf6a51a |
| institution | DOAJ |
| issn | 2073-4352 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Crystals |
| spelling | doaj-art-27289a96a1ce4d609fdd5cad9bf6a51a2025-08-20T02:45:55ZengMDPI AGCrystals2073-43522025-06-0115759610.3390/cryst15070596Enhancing Fatigue Life Prediction Accuracy: A Parametric Study of Stress Ratios and Hole Position Using SMART Crack Growth TechnologyYahya Ali Fageehi0Abdulnaser M. Alshoaibi1Department of Mechanical Engineering, College of Engineering and Computer Sciences, Jazan University, Jazan 45142, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering and Computer Sciences, Jazan University, Jazan 45142, Saudi ArabiaThis study presents a unique and comprehensive application of ANSYS Mechanical R19.2’s SMART crack growth feature, leveraging its capabilities to conduct an unprecedented parametric investigation into fatigue crack propagation behavior under a wide range of positive and negative stress ratios, and to provide detailed insights into the influence of hole positioning on crack trajectory. By uniquely employing an unstructured mesh method that significantly reduces computational overhead and automates mesh updates, this research overcomes traditional fracture simulation limitations. The investigation breaks new ground by comprehensively examining an unprecedented range of both positive (R = 0.1 to 0.5) and negative (R = −0.1 to −0.5) stress ratios, revealing previously unexplored relationships in fracture mechanics. Through rigorous and extensive numerical simulations on two distinct specimen configurations, i.e., a notched plate with a strategically positioned hole under fatigue loading and a cracked rectangular plate with dual holes under static loading, this work establishes groundbreaking correlations between stress parameters and fatigue behavior. The research reveals a novel inverse relationship between the equivalent stress intensity factor and stress ratio, alongside a previously uncharacterized inverse correlation between stress ratio and von Mises stress. Notably, a direct, accelerating relationship between stress ratio and fatigue life is demonstrated, where higher R-values non-linearly increase fatigue resistance by mitigating stress concentration, challenging conventional linear approximations. This investigation makes a substantial contribution to fracture mechanics by elucidating the fundamental role of hole positioning in controlling crack propagation paths. The research uniquely demonstrates that depending on precise hole location, cracks will either deviate toward the hole or maintain their original trajectory, a phenomenon attributed to the asymmetric stress distribution at the crack tip induced by the hole’s presence. These novel findings, validated against existing literature, represent a significant advancement in predictive modeling for fatigue life assessment, offering critical new insights for engineering design and maintenance strategies in high-stakes industries.https://www.mdpi.com/2073-4352/15/7/596finite element analysisfatigue-induced fracturepositive and negative stress ratiovon Mises stressequivalent stress intensity factorfatigue life |
| spellingShingle | Yahya Ali Fageehi Abdulnaser M. Alshoaibi Enhancing Fatigue Life Prediction Accuracy: A Parametric Study of Stress Ratios and Hole Position Using SMART Crack Growth Technology Crystals finite element analysis fatigue-induced fracture positive and negative stress ratio von Mises stress equivalent stress intensity factor fatigue life |
| title | Enhancing Fatigue Life Prediction Accuracy: A Parametric Study of Stress Ratios and Hole Position Using SMART Crack Growth Technology |
| title_full | Enhancing Fatigue Life Prediction Accuracy: A Parametric Study of Stress Ratios and Hole Position Using SMART Crack Growth Technology |
| title_fullStr | Enhancing Fatigue Life Prediction Accuracy: A Parametric Study of Stress Ratios and Hole Position Using SMART Crack Growth Technology |
| title_full_unstemmed | Enhancing Fatigue Life Prediction Accuracy: A Parametric Study of Stress Ratios and Hole Position Using SMART Crack Growth Technology |
| title_short | Enhancing Fatigue Life Prediction Accuracy: A Parametric Study of Stress Ratios and Hole Position Using SMART Crack Growth Technology |
| title_sort | enhancing fatigue life prediction accuracy a parametric study of stress ratios and hole position using smart crack growth technology |
| topic | finite element analysis fatigue-induced fracture positive and negative stress ratio von Mises stress equivalent stress intensity factor fatigue life |
| url | https://www.mdpi.com/2073-4352/15/7/596 |
| work_keys_str_mv | AT yahyaalifageehi enhancingfatiguelifepredictionaccuracyaparametricstudyofstressratiosandholepositionusingsmartcrackgrowthtechnology AT abdulnasermalshoaibi enhancingfatiguelifepredictionaccuracyaparametricstudyofstressratiosandholepositionusingsmartcrackgrowthtechnology |