X-FEM for Abaqus (XFA) Toolkit for Automated Crack Onset and Growth Simulation: New Development, Validation, and Demonstration

A software tool for automated crack onset and growth simulation based on the eXtended Finite Element Method (X-FEM) is developed. This XFA tool for the first time is able to simulate arbitrary crack growth or composite delamination without remeshing. The automated tool is integrated with Abaqus/Standard and Abaqus/CAE via the customization interfaces. It seamlessly works with the Commercial, Off-The-Shelf (COTS) Abaqus suite. Its unique features include: 1) CAE-based insertion of 3D multiple cracks with arbitrary shape of crack front that is independent of an existing mesh; 2) simulation of crack growth inside or between solid elements; 3) simulation of non self-similar crack growth along an arbitrary path or a user-specified interface; 4) extraction of G/K parameters via the modified VCCT, cohesive method, or CTOD; and 5) CAE-based data processing and visualization. The G/K predictions agree very well with published results using the conventional, double-node model and domain integration method. The toolkit can be used for the following simulation needs: 1) crack propagation, fatigue life prediction, multiple crack interaction, and sensitivity analysis and design optimization; 2) 2D or 3D solid model in quasi-static, monotonic or fatigue loading; 3) metallic fracture or composite delamination;4) elastic The usability of the toolkit is illustrated through a series of industrial problems.