I am working to simulate very thin aluminum layer (t = 0.3 mm) with central crack subjected to multi axial fatigue by abaqus (standard) software as shown in the figure below and according to the following procedure:

1. create two parts (aluminum layer and crack) (3D model)

2. add partitions on aluminum part.

3. properties (Elastic + Damage initiation and damage evolution)

4. assemble the above two parts.

5. specify steps and the required outputs. (with low cyclic fatigue)

6. interaction (Special - crack - create - XFEM crack - specify crack domain - crack location)

7.loading and boundary conditions

8. meshing (assign mesh control (Hex-structured) and element type C3D8

but at job implement appear this error "the following XFEM crack are failing to correctly generate. the error condition are listed with the crack names: Crack-1 - Failed to locate crack tip"

• when doing the above model "without partitions" this error disappears and the job is done.
• when I try to change the aluminum layer thickness to 0.6 mm with using partitions this error disappears and the job is carried out well and completely.

I think the problem is concern on thickness and partition with XFEM crack

0.3 mm thickness with partitions (error)

0.3 mm thickness without partitions (ok)

0.6 mm thickness with partitions (ok)