Study on Stress Intensity Factor of the Pit-Crack Model for Portal Crane Girders

In shipbuilding gantry cranes in long-term service in the coastal humid salt-spray environment, the main beam is affected in many places by corrosion fatigue-formed corrosion pits, affecting the structural strength of the main beam. This paper focuses on the impact of corrosion-generated pits under the conditions of crack nucleation. Corrosion fatigue crack nucleation is a local damage evolution process and the stress intensity factor criterion is one of the critical conditions to discern whether a crack sprouts at the corrosion pit. This paper establishes a corrosion pit-crack model based on the overall finite element model of the portal crane, and uses ANSYS software to simulate the stress intensity factor under complex boundary conditions. The results show that the different sizes and depth-to-diameter ratio of the pits greatly affect the value of the stress intensity factor and the stress concentration phenomenon may be the main factor causing the emergence of cracks; the change in the size of the pits on the stress intensity factor is not obvious, but with the increase in the depth-to-diameter ratio of the pits, the stress intensity factor of the pit-crack model is significantly increased. According to the hypothesis of semi-ellipsoidal pitting, the relationship between the stress intensity factor and the stress concentration factor at the pit is proposed, and its calculation results are within 5% error compared with the finite element method, and it is found that the effect of the etch pit on the stress intensity factor is positively correlated with the stress concentration factor; with the increase in the etch pit depth–diameter ratio, the crack budding location changes with the change in the stress concentration location, and the crack is more likely to be generated from the shoulder of the etch pit when the depth–diameter ratio of etch pit exceeds 1.