PSI - Issue 83

Teresa Morgado et al. / Procedia Structural Integrity 83 (2026) 286–294

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Fig. 5. 3D analysis with contact: a) SIF percentual error versus crack length; b) J-Integral percentual error versus crack length

The 3D fatigue study was conducted using the contact forces model, and the convergence study was performed (Figure 6). From Figure 6, it can be observed that values of a crit and N decrease significantly, reaching a convergence value from test 5 onward. The convergence test had a considerable impact on the study.

Fig. 6. Mesh Converge test results of three-dimensional fatigue analysis with contact.

From the error fatigue study, the a crit percentual error presents a value range from 3.35% to 9.08% (Table 3). It is worth noting that the results from the A and C Data Sets are excellent (remaining below 5%), and the results from the B Data Set are very good (remaining below 10%). Table 3. Results of a crit percentual error

a critNum [mm]

a critRef [mm]

Error a crit [%]

Data Set

A B C

4.18 4.30 4.24

2 4 6

3.35 9.08 4.07

4. Conclusions In conclusion, the finite element analysis using the Contour Integral Method is applicable to parts produced by additive manufacturing; however, special attention should be given to the expected direction of crack propagation. Using the Contour Integral Method with the condition of load with contacts, Mesh Convergence studies had a greater influence on static and fatigue analysis. It is confirmed that it is very important to perform a mesh convergence study, regardless of the analysis being conducted, to avoid mesh related errors. The 3D finite element simulation with contact