Raster Approach to Modelling the Failure of Arbitrarily Inclined Interfaces with Structured Meshes

This paper presents an approach to evaluate the failure of arbitrarily inclined interfaces using FE models with structured spatial discretization, providing accurate prediction of crack propagation along paths known a priori that are not constrained to the element boundaries. The combination of algorithms for the generation of structured discretization of representative polycrystalline microstructures with novel cohesive element formulations allow modelling the failure of complex topologies along rasterised boundaries, with noticeably higher computational efficiency and comparable accuracy. Two formulations of raster cohesive elements are presented, adopting either elastic-brittle or Tvergaard–Hutchinson traction separation laws. The formulations proposed are first validated comparing the failure of the interface within bi-crystal structures discretised using hexahedral elements either within a structured mesh (i.e. with rasterised boundaries) or an unstructured mesh (i.e. with planar boundary). Subsequently, the effectiveness of the formulations is demonstrated comparing the inter-granular crack propagation within complex polycrystalline microstructures. The behaviour of the novel cohesive element formulation in structured meshes consisting of regular hexahedral elements is in excellent agreement with the deformation and failure of classic cohesive element formulations placed along the planar boundaries of unstructured meshes consisting of tetrahedral elements. The higher computational cost of the raster cohesive elements is more than compensated by the increase in computational efficiency of structured meshes when compared to unstructured meshes, leading to a reduction of the simulation time of up to over 200 times for the simulations presented in the paper, thus allowing the simulation of large domains.