3D crack propagation study of a railway component using XFEM method

This work develops a methodology to study the crack propagation through ABAQUS simulation. This simulation study uses the service condition of the mechanical component and the complex geometry of a manufacturing defect obtained by microtomography. It was concluded that the XFEM method is an essential tool in predicting crack propagation of a railway component. Furthermore, the type of criteria used in the XFEM method allowed the analysis of the propensity of the manufacturing defect to initiate crack propagation. The C3D4 elements were essential in realising the crack propagation simulation, considering a manufacturing defect. Having the pore's complex geometry was crucial to developing the methodology presented in this study. The static analysis results indicated that the maximum stress concentration value in the pore is in a zone that can be identified as a hot spot. In addition, the pore showed a higher concentration of Von-Mises stresses than in the static simulation performed without a pore and of the material's ultimate strength. In conclusion, the methodology presented in this work shows that developing a more realistic simulation study is possible. For a complete structural integrity study, the mechanical design simulation studies must include some complex geometries of intrinsic manufacturing defects.