Fatigue cracking is the most common failure mode that endangers the safety and service life of parts. Initial manufacturing flaws are a critical factor affecting the growth of fatigue cracks. Currently, mixed-mode crack growth research frequently applies a simplistic two-dimensional finite element model, which cannot adequately represent the crack growth mechanism. An improved finite element method is proposed in this paper to overcome this drawback. Fatigue fracture propagation investigations on 25CrNiMo compact tensile specimens are conducted in this study, and the crack propagation rate is calculated using the Paris formula. Moreover, the special element modeling method and second-order Runge-Kutta integration method are utilized to perform finite element calculations on the 3D model. The results are highly consistent with the experimental test results. The propagation mechanism of cracks with varied initial inclination angles is explored depending on the finite element method. The relationship between the stress intensity measures KI, KII, and KIII is discovered to be competitive. The results have significant application value for the crack growth path prediction and crack life in parts with initial flaws.
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