Abstract
The effect of crack shape, size and its distribution on the stress magnification of Aluminum alloy AA2024-T3 tensile test specimen was studied using Finite Element Analysis (FEA) approach. A defect free neat reference sample of the alloy was developed as per ASTM-E8 standard using ANSYS Multiphysics. Circular and rectangular cracks of 0.1 inch to 0.3 inch diameter for circular cracks and 0.1 inch to 0.3 inch wide rectangle having same area as their circular counterparts were incorporated in the reference sample to study influence of crack morphology on stress magnification, while three 0.1 inch circular cracks were distributed diagonally on the reference specimen to study the influence of crack distribution, with separate simulations for each specimen. Each specimen was subjected to a fixed support and a tensile load on opposite end was applied to stress the material to Ultimate tensile strength. 24%, 13% and 26% increase in stress magnification was observed for 0.1 inch, 0.2inch and 0.3-inch rectangular cracks of same area as their circular crack counterparts while 21% reduction in stress magnification was observed by distributing same number of cracks from concentrated to diagonal distribution.
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