FEACrack Home:

When FEACrack is first opened you are presented with the "Home" window. In this window there are 3 fields that can be used. When
you open a stored file that has completed generating a mesh, the first screen displayed will be the mesh that has been created.

Choose the unit system for your model. Enter an optional analysis name, and enter optional notes about your model.

Units = kip - in - ksi (there are 6 to choose from)

Analysis Name = crack at the toe of the fillet weld connecting the nozzle and shell
(this information is for your reference)
Notes = (blank) (additional details i.e. type of analysis being run, or client information, etc)

You can save the model now, or at anytime while entering data; you will also be reminded to save the model when generating the
mesh.

Once you have completed the fields of your choice click Continue. Note: links to move back and forth through the windows are on
each form, and are also located on the tool bar. There are also icons on the left navigation bar to move to each step form.
FEACrack Geometry:

Select the geometry from the pull down menu on the Configuration tab. There are 15 choices in the geometry library including a user
defined geometry.

Structural Shape = Nozzle on Shell (There may be one more additional option that can also be selected based on the structural shape,
i.e. Weld or Nozzle Type, or none)
Nozzle Type = Set on nozzle without pad (alternative option may be available on the geometry)

Save your file and move to the next step form by clicking the right arrow of the Crack icon in the left navigation bar.
FEACrack™ Configuration:

On the configuration tab select the crack location and the mesh symmetry. The number of crack location and symmetry choices will
vary for each geometry choice.

External Axial Flaw is selected

The Model is Half Symmetric (Right Half)
FEACrack Crack Dimensions:

On the Dimensions tab select the crack shape from the pull down menu, and choose either single or multiple crack sizes to evaluate.
The Range of Crack Sizes choice gives a spread sheet for the user to enter multiple crack dimensions. A mesh will be generated for
each set of crack dimensions. The number of options will again vary for each geometry choice.

Crack Shape = Surface Crack

Evaluate = Single Crack Size
Crack Type = Elliptical
Crack Length (2c) = 3.5 in
Crack Depth (a) = 0.45 in
FEACrack Geometry Dimensions:

Continue entering Dimensions now for the geometry selected. These options will vary depending on the geometry choice. For the
example provided there are 3 tabs, Nozzle, Positive X Side, and Negative X Side. Complete the fields on each tab. Since the
geometry symmetry chosen for this nozzle example is the right half side of the model, the Negative X shell length is zero. The left
side of the nozzle is not present in the right half symmetric model.

Nozzle: Positive X Side:

Nozzle Length (L_N) = 8 in Inside Radius (IR_C) = 8 in
Nozzle Interior Diamater (ID_N) = 4 in Shell Thickness (T_C) = 1.05 in
Nozzle Thickness (T_N) = 0.95 in 1/2 Shell Length (L_C) = 16 in
Height of Weld (H_W) = 0.8 in
Width of Weld (W_W) = 0.8 in Negative X Side:
1/2 Shell Length (L_C) = 0 in
FEACrack Boundary Conditions:

In the boundary conditions window the user enters information about the loading and constraints for the model. On the General tab
enter the number of load steps. Usually an elastic analysis will have one load step. If the geometry can contain internal pressure, the
Pressure tab is available to enter the internal pressure, if any. On the Constraints tab pull-down menus are available for each location
on the model.

Boundary condition locations will vary for each geometry choice. For this right half symmetric nozzle example, constraints such as
fixed displacements, forces, and stresses can be applied to the top of the nozzle or the right end of the shell.

General: Condition Pressure:

Number of Time Steps = 1 Equation Based Crack Face Pressure Maximum Internal Pressure = 5 ksi
Loading
Option Boxes select or not Tabular Crack Face Pressure Loading
Apply a Temperature Boundary

Constraints:
Select both the Nozzle and Positive X Side constraints. For each the Displacements and Rotations can be customized or used the
default settings.
FEACrack™ Material Model Type:

Click on the Material Properties button on the navigation bar to open the Material Data window. The number of material regions in
the model varies for each geometry. The nozzle has three material regions; the shell, nozzle, and fillet weld. The user can enter
different material values for these regions. Match the material choice to the analysis type; for this example with a single load step
select the elastic behavior.

Assume Elastic Behavior (example selected)

Use Deformation Plasticity
Use Incremental Plasticity
FEACrack™ Material Properties:

In the Material window the material values may be selected from the pull-down menu or entered by the user. If the Use Defaults
option is selected, choose a material from the pull-down menu; many common alloys are available. If the User Specified option is
selected, the text boxes are available to enter the material values like Young's modulus of elasticity and Poisson's ratio. No
temperature loading was applied in the boundary conditions window for this example, so no thermal properties need to be entered in
the material form.

Shell Material = A508 Cl2 & Cl3 Forg

Nozzle Material = A508 Cl2 & Cl3 Forg
Weld Material = ES Weld & HAZ; LA, HHA, 3% NACl
User Specified (selected, information remains the same for each Material section)
Young's Modulus = 30000 ksi
Poisson's Ratio = 0.3
Stress Free Reference Temperature = 0
Coefficient of Thermal Expansion = 0

When all the information has been entered click "OK" for each material section.
FEACrack™ Build Mesh:

Next, click on the "Build Mesh" icon. You will be prompted automatically to save the file before building the mesh. The program
will now use the information provided to generate the 3D crack mesh. The Wait message window will appear while the mesh is
building. Any errors in the input data will be displayed at this time and allow changes to be made before choosing Build Mesh again.

The mesh generation can take several minutes or longer depending on the input parameters and the capabilities of the computer being
used.

Once the model has been built use the many View Options to rotate the model in any directions, zoom in or out, or select a predefined
view setting (View Type) to examine the mesh details.
FEACrack™ Run FEA:

IMPORTANT: Demo users are required to download the full set of files to run this analysis (the FEA input file is needed). Full Use
owners can build the mesh and input file to run the analysis, or use the results files provided in the download.

To select the FEA input files for analysis click on the Run FEA button in the navigation window; the Finite Element Analysis file
dialog window will appear. Locate the correct folder in the left window. Use the file type filter from the pull down menu to select the
desired type of input file. Highlight the desired file or files in the middle window and click the right arrow to add the input file(s) to
the analysis list in the right window. When all the input files have been selected and added to the list in the right window click the
Run Input Files button. Each analysis will be run one after the other automatically. For this example select the
nozzle_right_half_wrp.inp file and run the analysis.

The time to run each finite element analysis depends on the mesh size (more time needed for more nodes and elements) and the
capabilities of the computer being used.

NOTE: A Fatigue Analysis can also be run by full-use owners where the crack mesh is automatically updated as the crack grows.
This type of analysis is not available with the demo.
FEACrack™ FEA Results:

When the analysis is finished, click on the FEA Results icon to open the File Selection dialog window. Again, select the correct folder
in the left window, and select the result(s) file in the center window. Use the right arrow to add the *_wrp.out result file to the list in
the right window. One or more results files can be post-processed together to compare the effect of changing parameters on the crack
results. The file type filter can be selected from the pull down menu (different file extensions for each FEA program). Then click on
the Refresh Results button; the selected result files will be loaded for viewing.
FEACrack™ FEA Results:

Full Result Image :

The deformed shape of the mesh can be viewed with a stress or strain result superimposed as a color contour. The displacement scale
is set by typing a multiplier number in the Displacement Scale text box; try 100 or 1000, etc. A stress result can be selected from the
pull down menu. Click the Crack Results button in the navigation bar to get x-y plots of the J-integral, stress intensity K, etc.
FEACrack™ FEA Results:

Cut Result Image:

Allow user to cut sections of mesh out (view is after cut)

FEACrack™ FEA Results:

2D Result Plot:

Allow user to view 2D plots of selected node or element result values.